Process Design Research Articles

Energy-efficient optimization design of bio-butanol fermentation broth purification process

To address the downstream processing challenges of the IBE (isopropanol-butanol-ethanol) system and obtain biobutanol products with a mass fraction of 0.9999, as well as obtain a mass fraction of 0.99975 for the IE (isopropanol-Ethanol) mixture product as a gasoline additive, this study proposes a four-column distillation process termed "Dehydration-Butanol-Extractive Four Column Distillation" (DBE-4CD). With the heat load as the optimization target, the DBE-4CD process was optimized to determine the optimal operating parameters. Based on the optimized process and considering the energy-saving potential of the dividing wall column, an “Azeotropic Dividing Wall-Extractive Three Column Distillation” (ADE-3CD) process was subsequently proposed to further enhance energy efficiency and reduce consumption. Compared to both conventional literature process and the DBE-4CD process, the total load of the ADE-3CD process decreased to 7433.5 kW, representing reductions of 20.35% and 10.11%, respectively. Additionally, the mass recovery rates of butanol and the IE mixture reached 99.90% and 99.64%, respectively, exceeding those of the conventional literature process, which were 99.11% and 99.18%.

Hexafluoroisopropanol-based deep eutectic solvents for efficient aqueous two-phase extraction of flavonoids from Flos Sophorae Immaturus

Aqueous two-phase systems (ATPSs) based on deep eutectic solvents (DESs) are green extraction and separation media and have demonstrated remarkable potential for extracting bioactive substances from natural matrices. However, thus far, flavonoid extraction using DES-based ATPSs has rarely been reported. In this study, the state-of-the-art technique using DES-based ATPSs was employed for developing an effective method for extracting flavonoids from Flos Sophorae Immaturus (FSI). DESs prepared with hexafluoroisopropanol (HFIP) and five quaternary ammonium salts, N111xCl (x = 1, 4, 8, 12, and 16), were used as the hydrogen bond donor and hydrogen bond acceptors, respectively, for constructing ATPSs with K2HPO4 as a salting-out agent and utilized for extracting flavonoids from FSI. Fourier-transform infrared, 1H nuclear magnetic resonance, 1H–1H nuclear Overhauser effect spectroscopy analyses, and density functional theory calculations were implemented to demonstrate the successful preparation of DESs. The DES containing dodecyltrimethylammonium chloride and HFIP with a molar ratio of 1:2 was screened as the optimal DES, showing a higher extraction efficiency and yield of flavonoids compared to those of other DESs and the traditional solvent ethanol. Subsequently, various experimental parameters (amount of DES, salt concentration, liquid-to-solid ratio, extraction temperature, and ultrasonic time) for the extraction process were studied comprehensively and optimized using response surface methodology. The yield of flavonoids from FSI was 21.05 % under optimal extraction conditions (amount of DES = 2 g, salt concentration = 0.21 g/mL, liquid-to-solid ratio = 81 mL/g, and extraction temperature = 60 ℃), which is close to the predicted value of 20.82 %. Extraction mechanisms underlying the performance of DES-based ATPSs during the extraction of bioactive substances are yet to be fully understood. Therefore, molecular dynamics (MD) simulations were employed with rutin as the target compound to probe the extraction mechanism under DES-based ATPS conditions, and the results revealed that hydrogen-bonded frameworks are pivotal for the extraction process. Moreover, the existence of K2HPO4 was found to promote not only the increase in hydrogen bonding networks and π–π stacking interactions within rutin molecules but also the increase in solvent flexibility, facilitating the extraction process. The present work offers a promising approach for flavonoid extraction using DES-based ATPSs. Interpreting the extraction mechanism at the molecular level by adopting the MD simulation technique provides new insights that enable a deeper understanding and aid in the design of the extraction process for bioactive substances under DES-based ATPS circumstances.

Forming limit analysis of magnesium alloy sheet metal forming process at elevated temperatures

Abstract Magnesium alloys are valued by industry for their lightweight structures. Magnesium alloy are mainly produced by warm forming because the sheet formability is poor at room temperature. The mechanical properties of magnesium alloy AZ31, such as stress-strain curves and damage values at different elevated temperatures, were obtained by this study using a computerized screw universal testing machine. Freudenthal fracture criteria were used to obtain the forming limit at distinct temperatures. The forming limit analysis proceeded during the sheet metal forming process at various elevated temperature. The fracture’s forming load, stroke, and position were determined for different working temperatures of the sheet metal forming process for AZ31, using a finite element simulation combined with the ductile fracture criteria. Finally, the predicted values were compared with the experimental results during the sheet metal forming process. The simulation results agreed with the experimental values for the fracture forming load, stroke, and position of the sheet metal forming process. The feasibility of the present method was confirmed to predict forming limit during the sheet metal forming process for different elevated temperatures. A finite element analysis for forming limit prediction would be beneficial to the design of sheet metal processes for AZ31 magnesium alloys.

Jet Array Design for the Physical Tempering Process of Ultrathin Glass

Jet Array Design for the Physical Tempering Process of Ultrathin Glass

Carbon-neutral design of ammonia synthesis process using oxy-fuel combustion-based carbon capture: Carbon-techno-economic comparison

This study proposes a novel blue ammonia synthesis process by applying oxy-fuel combustion to simplify the CO2 capture process. Generally, ammonia production requires N2 as the primary feedstock, prompting the deployment of an air separation unit (ASU) to supply N2. However, the ASU also produces O2 as a byproduct, which remains unused in conventional air combustion processes. Therefore, this study introduces oxy-fuel combustion that harnesses surplus O2, thereby overcoming the limitations of amine-based CO2 capture units in the conventional process. In the proposed process, high-purity CO2 is separated through simple water condensation. This eliminates the significant thermal energy consumption required for amine solution regeneration and avoids the additional cost of distillation columns. Instead, only an increase in the ASU scale is required to supply the oxygen necessary for combustion. A comprehensive carbon-techno-economic analysis compares the proposed oxy-fuel combustion-based process with a conventional air combustion-based process involving amine-based CO2 capture. Remarkably, the proposed system achieved a 61% reduction in CO2 emissions compared with the conventional system and demonstrated the highest return on investment at 19.5%. These findings suggest that oxy-fuel combustion significantly enhances the potential of blue ammonia as a low-carbon energy carrier.

Analysis of droplet motion in cavity zone of rotating packed bed

Droplet motion in outer cavity zone of rotating packed bed is a complex phenomenon that requires analysis of liquid and gas flow to clarify influences of factors such as rotation speed, liquid flow rate, or gas flow rate. In this study, hydrodynamics is described using laser Doppler velocimetry and high-resolution visualization for droplet motion characterization. The results reveal that droplet motion initially depends on the peripheral velocity of the packing, while further from the packing, it loses kinetic energy mainly due to the drag force caused by the surrounding gas. Two-way coupling is investigated as both phases interact with each other. Rankine vortex theory is applied to simulate gas flow in the outer cavity zone. A model, based on Newton’s second law, is developed to predict droplet dynamics, including impingement velocity, trajectory length, and total residence time. Validation of the model shows that it can predict the liquid velocity in the outer cavity zone accurately. Upon impingement of droplets on the casing, part of the liquid rebounds as secondary droplets into the cavity, where they circulate with the gas flow. Overall, this study provides insights into droplet dynamics in the rotating packed bed and offers a basis for optimizing process efficiency and design in various applications, including chemical processing and environmental engineering.

Course gamification: Applying the KANO model to gather student perceptions

Design for Six Sigma (DFSS) is a critical component of the Six Sigma methodology, focusing on product, process, and service design. DFSS is proactive, focusing on design rather than existing processes. Its wide application in various sectors, from manufacturing to service industries, has proven its effectiveness. Despite this, its adoption in education remains limited. This research explores the application of DFSS in education, particularly in redesigning a course through gamification to enhance student engagement. This study addresses this gap by illustrating how DFSS principles can enhance education, mainly through gamification. Gamification, incorporating game elements into learning, holds promise for engaging students and improving learning outcomes. Using the DMADV framework, the study defines project objectives, gathers the voice of the customer using the Kano model, analyzes survey data, designs gamification elements, and verifies their effectiveness through student feedback. Results indicate several attractive elements identified through the Kano model, such as smartphone integration and clear rules. Implementation challenges, particularly in a Jeopardy-style review session, are identified and addressed using DFSS tools such as failure mode and effects analysis. Subsequent surveys capture student feedback and suggest improvements, highlighting the iterative nature of DFSS. The study underscores the potential of DFSS in educational redesign, particularly through gamification, to enhance student engagement and learning outcomes. While focused on a specific course, the methodology's generalizability and applicability to diverse educational contexts warrant further exploration for broader implementation.

Особенности построения системы экологического менеджмента организации с учетом вновь введенных национальных стандартов ГОСТ Р ИСО 14006—2022 и ГОСТ Р МЭК 62430—2023

The information on legislative documents of the Russian Federation regulating the activities of companies in the sphere of environmental management, considering environmental standards in design, has been provided. The relevance and feasibility of application of the system-structural process approach at the stage of development and implementation of the environmental management system, considering the environmental standards in design based on the standards GOST R ISO 14006—2022 and GOST R IEC 62430—2023, have been substantiated. The use of the process approach to the environmental management system development considering environmental standards in design based on the systems approach using the well-known PDCA principle has been methodologically substantiated; the basic issues of its applicability have been considered. A matrix of processes and subprocesses is compiled in accordance with the sections of GOST R ISO 14006 and the process typology as provided by ISO/TC 176/SC 2/N 544R3 (company’s management processes; processes of measurement, analysis, and improvement; key processes of resource management); the processes are ranked by their level. A model of the environmental management system has been developed considering environmental standards in design based on the process approach, Structured Analysis and Design Technique (SADT), and IDEF0 functional modeling methodology. The main context diagram of the environmental management system considering environmental standards in design in IDEF0 notation is developed. The decomposition of processes and subprocesses of the second and third levels has been completed; all their functional connections are described. The provided process modeling methodology allows reaching positive effect as to minimization of costs and time of the development of the environmental management system model, considering environmental standards in design. It has been demonstrated that the process approach applied to design of the system model of environmental management system considering environmental standards in design enables structuring the composition of processes, precise determining of input and output parameters of processes, participants of processes, resources, and ensuring process control and adjustment.

Timber family houses: Potential for digitization and automation

Abstract Wooden constructions have a rich historical background globally. Due to their attributes, modern timber buildings present opportunities for energy efficiency and environmental conservation, thus aiding in mitigating the ecological footprint of the construction sector. This paper aims to compare the diverse methodologies employed in timber construction between the US and Europe and subsequently evaluate the potential for digital transformation and automation within the operations of RD Rýmařov, Czechia’s largest producer of single-family timber residences. The unique aspect of this company is the whole process (design, prefabrication, assembly) is fully controlled by the company itself. This study synthesizes insights from the ongoing research project Automation4Timber, currently in its concluding phase. The methods section delineates the process enhancement initiatives carried out by RD Rýmařov, encompassing preparatory, production, and assembly phases, each comprising various components. All instituted alterations facilitating digitalization and automation are elucidated in the Results section. The subsequent discussion and conclusion sections encapsulate the experiential insights gained from the implementation process, highlighting key aspects and potential challenges. This paper adds value by presenting a tangible case study of a manufacturing enterprise.

Application of mechanical crack defect detection based on thermal energy parameter simulation and sensing images in product process design

Application of mechanical crack defect detection based on thermal energy parameter simulation and sensing images in product process design

Unleashing the potential of castor oil as extraction solvent of carotenoids from tomatoes

Adding carotenoids to cosmetic formulations aligns with the industry’s growing ethos of producing safer, more sustainable, and nature-inspired products. While synthetic compounds still have their place in cosmetics, the shift towards natural ingredients such as carotenoids reflects a more significant commitment across the industry to satisfy consumer preferences and contribute to a greener future. Castor oil is a well-known natural oil used in several cosmetic formulations because it reduces moisture loss and enhances skin hydration. However, it’s only added to cosmetics simultaneously with all the other components, including natural extracts. Thus, this work goes behind literature and classic downstream approaches. A simplification of cosmetics formulations is intended by using castor oil directly as the extraction solvent of natural bioactive compounds, such as carotenoids from tomatoes. A comparison of its extraction performance with conventional extraction solvents was made, and all the process operating conditions were optimized (SLR = 0.06 gbiomass.mLsolvent-1, percentage of castor oil = 50 % (v/v), and time of extraction = 90 min) to achieve a maximum recovery of 3.2 ± 0.2 mgCar.gbiomass-1. Additionally, its capacity as a preservative of carotenoids degradation was also tested against a conventional solvent to enhance natural pigments’ shelf life showcasing increased stability (especially at 75 °C), a current problem of their application in industry. The environmental performance of the process proposed was analyzed based on the carbon footprint, with electricity consumption identified as the most significant contributor. This impact could be greatly reduced by utilizing photovoltaic energy. Lastly, a conceptual process design has been proposed to envision its practical application in an industrial setting.

Citric acid functionalized chitosan hydrogel beads for enhanced Cr(VI) removal: Experimental assessment and COMSOL modelling of adsorption in a fixed-bed system

Chitosan hydrogel beads (CHB) and cross-linked CHB functionalized with tricarboxylic citric acid (CA-GLA-CHB) were synthesized and used for the removal of Cr(VI) from aqueous solutions in batch and dynamic adsorption systems. Applicability of COMSOL Multiphysics software as a tool for predictive modelling of column dynamics using a minimum set of experimental parameters was tested and compared with experimental results. Batch experiments demonstrated that CA-GLA-CHB showed almost 20% higher adsorption capacity and wider operational pH range compared to non-functionalized CHB. In a dynamic system, CA-GLA-CHB was used as column packing material and the column dynamics was investigated at different conditions. The breakthrough and exhaustion time of the column increased with an increase in bed height and a decrease in feed flow rate and initial Cr(VI) concentration. Computational modeling by COMSOL software with implemented Advection-Dispersion-Reaction (ADR) equation was used to simulate breakthrough curves for the applied dynamic system in order to validate the possibility of its application for process design in the scaled-up fixed-bed column systems for wastewater treatment. The simulated breakthrough curves of Cr(VI) adsorption matched well with the experimental, thus proving that COMSOL Multiphysics software can be used for scaling-up fixed-bed column systems packed with low-cost and effective CA-GLA-CHB bioadsorbent.

Thread plate posture analysis for screw rolling adjustment design

Abstract This research focuses on process design of the adjustment of movable thread plate and fixed thread plate in the screw rolling machine during production. By observing some key dimensions of the threaded screw, one can determine the movement amount and the rotation direction of the adjustment screw bars mechanism of the fixed thread plate that required for the specified size of this type of screw. One establishes a relationship from the adjustment of the screw bars mechanism to the fixed thread plate posture. It can be seen that the formed screw size deviations will lead the machine operator to adopt one of the proposed process to achieve the posture adjustment of the fixed thread plate. While the screw specification deviations do not conform to the standard ones, the operator just need to find out the error type of the formed screw and measures its specification to follow one of the proposed formulas, then the wrong thread plate posture can be modified to the correct posture under operator’s adjustment. The method addressed in this research can not only reduce the operational difficulty of screw thread rolling machine but also can reduce the trial-and-error processes in traditional operation methods.

Facilitative preparation of graphene/cellulose aerogels with tunable microwave absorption properties for ultra-lightweight applications

Graphene aerogels, as a novel type of carbon-based composite material, have shown great potential in the field of wave absorption due to its characteristics of high conductivity, adjustable structure and good corrosion resistance. It is of great significance to precisely control the dielectric properties of graphene aerogel composites by effectively adjusting their microstructures through the preparing process design, ultimately leading to improve their wave-absorbing performances. In this study, two kinds of graphene/cellulose aerogel composites with three-dimensional porous structures, were successfully prepared using graphene and short staple cellulose as raw materials via the freeze-drying method based on the dissolution-regeneration strategy. A comparative analysis was conducted to examine the differences of microstructures, dielectric properties and corresponding electromagnetic wave absorption performances, which reveals that the graphene/cellulose aerogel composites with graphene nanosheets incorporated into the cellulose matrix realize superior absorbing performances. The graphene/cellulose aerogel composite with a 32 wt% graphene addition realizes effective electromagnetic wave absorbing (reflection loss less than −10 dB) in the whole X-band (8–12.4 GHz) in a relatively large thickness range (3.9–4.7 mm). The densities of the proposed aerogel are no more than 0.02 g/cm3, demonstrating great potential for excellent lightweight microwave absorbing materials. The multiscale electromagnetic wave absorption mechanism is summarized, which would provide an important reference for designing ultra-lightweight absorbing materials with perfect absorption in wideband.

Comprehensive techno-economic and environmental assessment for 2,3-butanediol production from bread waste

Bread waste (BW) is a common food waste in Europe and North America and has enormous potential as a biorefinery substrate for the sustainable synthesis of various platform chemicals. Our previous work made use of BW for the fermentative production of 2,3–butanediol (BDO). The present work evaluated the economic prospects and environmental consequences associated with the overall processes, handling 100 metric tons BW per day. The comprehensive process design using Aspen Plus and integrated techno-economic and environmental assessment was carried out for two different BW hydrolysis scenarios: acid and enzyme hydrolysis, followed by fermentation and extraction-based downstream BDO separation. The optimal heat exchanger network was designed using pinch analysis, which improved the energy efficiency of the process significantly, with about 10 % savings of BDO production costs. Despite this improvement, the BDO derived from BW was exorbitant (4.2–6.9 $/kg) compared to the market price (3.23 $/kg) due to relatively higher capital investment for the current plant capacity. Further, the process inventory was modelled in SimaPro v9.1.0 to estimate the environmental consequences of these production processes for impact categories, such as global warming (2.63 – 3.19 kg CO2 eq.), marine eutrophication (3.55 × 10-4 – 4.01 × 10-4 kg N eq.), terrestrial ecotoxicity (6.44 – 7.88 kg 1,4 − DCB), etc. Sensitivity and uncertainty analyses were also conducted to establish the reliability of the results. It was found that the enzyme hydrolysis was associated with lower environmental impacts than acid hydrolysis. This comprehensive study can be used as a guideline for developing sustainable BW-based biorefinery in the future.

Hydraulic Design Concept of 6.60MLD Water Treatment Plant

Abstract: The design and construction of a 6.6 million liters per day (MLD) water treatment plant (WTP) in Belpada Village, Odisha, aim to meet the increasing water demand while ensuring public health through effective water treatment processes. The plant, which sources raw water from the Tel River, follows a well-structured treatment process that includes aeration, sedimentation, filtration, and disinfection. This journal outlines the hydraulic design, treatment schemes, and structural components of the WTP. Design calculations, based on CPHEEO standards, are also discussed, focusing on the hydraulic detention times, surface loading, filtration rates, and sludge management techniques.The design of water treatment plants (WTPs) plays a crucial role in delivering safe drinking water, especially in areas with high population density and industrial growth. The 6.6 MLD WTP designed for Belpada Village in Balangir District draws water from Tel River and utilizes a cascade aeration system for the removal of contaminants. This paper discusses the hydraulic and process design, focusing on flow rates, detention times, and surface loading parameters that meet the Central Public Health and Environmental Engineering Organization (CPHEEO) standards.

Развитие теории и принципов планирования многономенклатурных технологических процессов механообработки и сборки

Instructional guidelines for planning a multiproduct manufacturing activity (MA) for machining and assembly aimed at solving currently existing problems of machining industries process design, i.e. subjectivity of making design decisions, insufficient automation, and inability of the observing of current production situation are presented. The objective reasons for the need to improve approaches to the development of MA are the long cycle of the process design period, the low quality of the processes operation, and the impossibility to adjust MA at the implementation stage. The main structural elements of multiproduct manufacturing activity planning are described. Based on a systematic approach, all stages of work on technological support of production systems are combined, making possible to use the information arrays of data on the real state of the production system and operational information on production tasks in a short time frame. The results of theoretical work provide for the process of making MA as a system that combines the design and implementation of technology, taking into account the impact of changes in the production situation. In the process of approbation and use of the presented methodological approaches, significant areas of research were identified, smoothing away difficulties connected with the performance targets, enabling the development path of the system. Among them: the interaction with the design preparation of production; detailing data on the initial workpieces in connection with the choice of the MA structure and the appointment of a rational set of technological equipment; determining the requirements for technological equipment, focused on ensuring the flexibility of their use; determining the correlations between the multiple-path design of parts manufacturing process and the requirements for accuracy indicators in the assembly of products. The developed formalized models for the implementation of the stages of technological preparation of machining industries are a background for full automation of MA design and highly efficient functionality of machine-building complexes.

Formulation and Characterization of Deep Eutectic Solvents and Potential Application in Recycling Packaging Laminates.

Deep Eutectic Solvents (DESs) show promising abilities for the delamination of multilayer packaging films that are used in food packaging and in pharmaceutical blister packs. Due to the complexity of their structure, the recycling of such materials is a challenging task, leading to the easiest or cheapest disposal option of either landfill or incineration. Towards the development of 'green' solvents for efficient waste management and recycling, this research focuses on the preparation of a range of hydrophobic and hydrophilic DESs based on carboxylic acids in combination with various naturally derived aliphatic and aromatic organic compounds as well as amino acids. Chemical and physical characterization of the solvents was undertaken using differential scanning calorimetry, rheometry, and density measurements for the determination of their properties. Subsequently, batches of solvent were tested against different types of consumer packaging to evaluate the ability of the DES to delaminate these structures into their component materials. The laminate packaging waste products tested were Al/PE, PE/Al/PET, Al/PE/paper, and PVC/PE/Al. Separated films were collected and studied to further examine the effect of solvent delamination on the materials. Depending on the DES formulation, the results showed either partial or full delamination of one or more of the packaging materials, albeit there were challenges for certain solvent systems in the context of delivering a broad delamination efficiency. Variables including temperature, agitation rate, mixing time, and solvent ratios were investigated via a Design of Experiments process to assess the effects of these parameters on the delamination outcome. The results showed that the DESs presented in this research can offer an efficient, low-energy, affordable, and green option for the delamination of laminate packaging materials.

Structural Equations Modeling Approach: Issues in selecting a University

Higher education is a continuation of secondary education that is organized to prepare students to become members of the community with academic or professional abilities. Therefore, selecting a university is essential for helping students acquire knowledge and skills and prepare themselves to be independent individuals. This study intends to determine the distribution of decision-making students who select the university based on factors of academic ability, individual characteristics, psychology, instrumental, and environmental factors. The study's methodology, which involves the collection of primary data from 474 respondents from high schools in the Indonesian-Timor Leste border region, is robust and rigorous, instilling confidence in the reader. The method used for data analysis is quantitative, which involves applying structural equation modeling to identify factors that influence students’ selection of universities. The study results showed that out of the six structural models formed, they could provide evidence that factors such as academic ability, individual characteristics, psychology, instrumental factors, and environment influence students’ selection of universities. This can be seen from the test values of the regression model formed in the structural modeling, which gives a P-value of less than 5%. The variable that provided the largest percentage, partially influencing student interest in selecting a state university, was the school environment, which was 98%. The value was based on the path coefficient of structural equation modeling. These findings have significant implications for the design of university admission processes and the development of student support programs.

Fabrication Time Diagrams for In-Space Manufacturing of Large Reticulated Structures

Abstract In-space manufacturing (ISM), or the on-orbit construction of structures from raw feedstock materials, is a promising approach for building large structures for future space missions. Most research and development on ISM to date has focused on ground-based or microgravity-based demonstrations of candidate fabrication processes; however, the combined design of the fabrication process and the ISM spacecraft has not been fully investigated. In this paper, we estimate the fabrication times for ISM of reticulated support structures subject to various spacecraft constraints, including the available fabrication power, the available attitude control authority, and the avoidance of undesirable control-structure interactions. We summarize the insights in fabrication time diagrams which depict the dominant constraints and estimates of the fabrication time for a wide range of structural geometries. Our results indicate that for large, dense structural geometries such as the curved gridshell and tetrahedral truss, the angular momentum storage of the ISM spacecraft's attitude control system (ACS) is the dominant constraint on fabrication time. Additionally, our results suggest the following strategies for reducing fabrication time: manufacturing with multiple spacecraft; using stiff, lightweight feedstock; maximizing fabrication power and ACS capability; and minimizing spacecraft bus mass. Altogether, our results emphasize how the design of an ISM spacecraft cannot be considered independently of the fabricated structure and motivate future work on selecting optimal fabrication paths and attitude control strategies to fabricate large structures in the shortest time.