Improve Process Efficiency Research Articles

Industrial scale fouling of heat exchangers in isocyanate production

The fouling of a commercial stainless steel (AISI 316L) during the manufacture of polymeric methylene diphenyl diisocyanate (pMDI) has been studied using laboratory‐based fouling apparatus that simulates commercial production conditions. The goal of the work is to understand the mechanisms behind the corrosion and fouling during isocyanate production with a view to improving process efficiency, not only in this process, but also others using similar plant and processes. Steel coupons were exposed to a solution of pMDI and solid amine hydrochloride, with hydrogen chloride gas being bubbled through the reaction cell. A number of different conditions were investigated, the variables being pMDI concentration, HCl gas flow duration, immersion time and temperature. Following the fouling experiments the coupons were removed from the fouling rig, photographed, and examined by XPS and ToF‐SIMS; principal component analysis was used to extend the ToF‐SIMS analysis to identify organic fouling products. The extent of fouling is shown to be relatively insensitive to pMDI concentration, but significantly influenced by continual HCl flow and increased temperature, features which increase the extent of substrate corrosion thought to be a precursor to the fouling process itself. Both XPS and ToF‐SIMS confirm the formation of various nickel chlorides in the corrosion process. Urea and metal corrosion products are found to co‐exist on certain (random) areas of the coupon surface.

Femtosecond Laser Direct Writing of Flexible Electronic Devices: A Mini Review.

By virtue of its narrow pulse width and high peak power, the femtosecond pulsed laser can achieve high-precision material modification, material additive or subtractive, and other forms of processing. With additional good material adaptability and process compatibility, femtosecond laser-induced application has achieved significant progress in flexible electronics in recent years. These advancements in the femtosecond laser fabrication of flexible electronic devices are comprehensively summarized here. This review first briefly introduces the physical mechanism and characteristics of the femtosecond laser fabrication of various electronic microdevices. It then focuses on effective methods of improving processing efficiency, resolution, and size. It further highlights the typical progress of applications, including flexible energy storage devices, nanogenerators, flexible sensors, and detectors, etc. Finally, it discusses the development tendency of ultrashort pulse laser processing. This review should facilitate the precision manufacturing of flexible electronics using a femtosecond laser.

Virtual Power System: Novel approach for Distributed Generation and Consumption Coordination

Worldwide the introduction of dispersed generators (DG) in the distribution network is assuming a significant importance. There is an increasing relevance of the energy process efficiency improvement; as for electric power systems, the most interesting perspective concerns the capability of the system to increase the exploitation of the renewable resources. The integration of DGs in the electric distribution network requires a revision of this infrastructure, so far designed and developed assuming that power flows in one direction: from the high voltage transmission network to the medium voltage distribution, to reach final customers on the low voltage network. The attention to an efficient operation of distribution networks is increasing all over the world; this interest is becoming higher and higher also in Italy, where the high energy prices push in the direction of fostering efficiency as much as possible. This work describes a study developed in the Alpenergy project framework: an International Cooperation Program aimed at introducing an efficient operational model for the distributed production and consumption. In particular it is proposed a new model for the integration and the management of the DG in the distribution network. The new model (defined VPS: Virtual Power System) is based on a communication channel between the active users (generators), the loads and, eventually, the Distribution System Operators (DSOs).

Cu Direct Nanopatterning Using Solid‐State Electrochemical Dissolution at the Anode/Polymer Electrolyte Membrane Interface

AbstractPatterned copper (Cu) has applications in various electronic devices such as metal interconnects. Electrochemical approaches to patterning, such as electrochemical machining and electroplating, are promising methods for the direct fabrication of patterns on Cu surfaces. However, owing to the use of electrolytes, this technique suffers from issues such as low patterning resolution and significant environmental impact. Herein, a novel direct electrochemical patterning technique for the anodic dissolution of Cu using a polymer electrolyte membrane (PEM) stamp with a patterned surface instead of a liquid electrolyte, is proposed. In this technique, an electrochemical reaction selectively ionizes the Cu surface in contact with the PEM stamp, enabling the fabrication of patterns on Cu surfaces with a resolution of several hundred nanometers under a low‐temperature air atmosphere. Overall, the proposed all‐solid‐state electrochemical patterning technique employing PEM stamps offers a facile, environmentally friendly, and direct process that does not use resists or harsh chemicals, making it a cost‐effective approach that can improve processing efficiency.

Reputation-based Raft-Poa layered consensus protocol converging UAV network

Integration of blockchain technology offers a robust solution for ensuring reliable data transmission within unmanned aerial vehicle (UAV) networks. Nevertheless, it is crucial to address challenges associated with UAV networks, including their dynamic nature, high latency, limited scalability, and algorithmic inefficiencies. Hence, our proposal involves integrating UAV networks with blockchain technology to enhance their performance by optimizing the consensus algorithm based on network efficiency. We first propose a comprehensive framework for optimizing network performance based on network tomography, incorporating a systematic analysis of network performance and fault avoidance strategies. To improve analysis of the core network’s real-time performance, we also propose a topology prediction method based on an effective probability matrix. Additionally, we establish a calculation method for optimally placing network monitoring points in the core network for enhanced efficiency. We then introduce an adjustable reputation-based Raft-Poa layered consensus protocol that improves consensus protocol scalability and efficiency. To tackle data and node security concerns, we further propose a trust management mechanism based on group signatures. This mechanism verifies the authenticity of node data and identifies malicious nodes. Finally, we validate the protocol’s effectiveness and compare the algorithm’s effectiveness with MMP, Raft, Poa, etc. The simulation results of this protocol show remarkable improvements in network communications and consensus process efficiency, and reductions in communication latency and node utilization rates.

Apply EZStrobe to simulate the finishing work for reducing construction process waste

Vietnam, classified as a developing nation, encounters numerous challenges within its construction sector, including the scarcity of comprehensive and documented historical data regarding risks and a deficiency in embracing contemporary methodologies to mitigate the impact of risk factors on construction project objectives. This paper outlines initial findings from an ongoing research endeavor that centers on implementing Lean Construction (LC) techniques to enhance construction management practices specifically for marble floor finishing work within Vietnam. Therefore, this study aims to apply the construction lean principle combined with discrete-event simulation (DES) by using EZStrobe to simulate the marble floor finishing process in reality, from observing and collecting data of each activity in the actual process on the site. By building, running simulations, and resulting from real-world simulations, we'll understand the sources of waste, and then apply lean construction principles through methods such as just in time, reduce the batch size and resources priorities, and multi-skilled teams for the initial construction process. The study's lean modeling results has led to a 13% reduction in construction cycle time, a 141% improvement in process efficiency, a 268% enhancement in average productivity, and a 96% reduction in labor cost. The result has become the reference document resource for the managers and construction engineers to improve the performance of not only general finishing work but also marble floor finishing work.

Using lean manufacturing to improve process efficiency in a fabrication company

This article presents a case study on improving process efficiency in a mining equipment part fabrication company. The company was facing issues concerning communication, organisation, and workflow processes. This study investigated that ineffective communication among departments was the major weakness which was responsible for the long lead or idle time. This lead time was a waste that affected the company’s productivity. A great amount of time was spent on non-value-added processes. The Kanban Centralised Communication System was implemented. Time study and value stream mapping were also used. A significant improvement in process efficiency from 34% to 85% was achieved by reducing lead time from 4200 minutes to 1680 minutes after streamlining the communication in the company using Kanban.

Autonomous closed-loop photochemical reaction optimization for the synthesis of various angiotensin II receptor blocker molecules

Optimization is gaining huge attention in industries like pharmaceuticals, fine chemicals, and petrochemicals to maximize reaction yield, minimize waste, and improve process efficiency.

A novel rice plant leaf diseases detection using deep spectral generative adversarial neural network

The farming industry widely requires automatic detection and analysis of rice diseases to avoid wasting financial and other resources, reduce yield loss, improve processing efficiency, and obtain healthy crop yields. The proposed Deep Spectral Generative Adversarial Neural Network (DSGAN2) method is used for detecting rice plant leaf disease. Initially, fed into the input of healthy and non-healthy leaves from the collected dataset. Then, apply an Improved Threshold Neural Network (ITNN) method to enhance the image quality. Next, it uses a Segmentation using a Segment Multiscale Neural Slicing (SMNS) algorithm to identify the support-intensive color saturation based on the enhanced image. After that, the Spectral Scaled Absolute Feature Selection (S2AFS) method is applied to select optimal features and the closest weight from segmented rice plant leaves. Social Spider Optimization will select the feature using the Closest Weight (S2O-FCW) algorithm to analyze the feature weight values. Finally, the proposed Soft-Max Logistic Activation Function with Deep Spectral Generative Adversarial Neural Network (DSGAN2) algorithm detects rice plant disease based on selected features. With an accuracy of 97 %, the model helps farmers identify and identify Rice Plant diseases. The proposed system Deep Spectral Generative Adversarial Neural Network (DSGAN2) produces a decreasing false rate compared to the existing system of ACPSOSVM-Dual Channels Convolutional Neural Network (APS-DCCNN) is 55.2 %, Alex Net is 50.4 %, and Convolutional Neural Network (CNN) is 49.5 %.

Exploring structure, temperature and activity correlations in the selective oxidation of lower olefins over Bi–Mo–Co–Fe–O catalysts by spatial reactor profile measurements

Improving process efficiency in selective oxidation of lower olefins over mixed metal oxide catalysts requires profound knowledge of the dynamic behaviour of exothermic reactions along the reactor.

Impact of Electron Beam Melting process recycling on defects and microstructure of Ti-6Al-4V powders

Metal powders are used as the feedstock material during the Electron Beam Melting processes. The process involves using an electron beam as the energy source to produce intricate parts with complex shapes in a layer-by-layer production system. The electron beam is directed by information from an STL file, and the process takes place in a pre-heated chamber that is maintained under vacuum. Once the production cycle is complete, the process yields the desired components along with a certain amount of residual powders that were not melted.To improve process efficiency and reduce costs associated with powder atomization, it is feasible to reuse the excess powder for subsequent production cycles. Prior to starting a new cycle, the excess powder is initially sieved to ensure a more uniform powder batch, and subsequently, the sieved powder can be mixed with other virgin powder to decrease oxygen content.This study examines the microstructure and defects present in a batch of virgin powders produced through plasma atomization and a batch of powders that were reused five times and mixed with Ti-6Al-4V grade 23 (ELI powders) at each cycle. The ELI powders are characterized by a low oxygen content.The results of the analysis indicate a connection between the powder atomization process and the formation of porosities in virgin powders resulting from trapped gas, as well as surface irregularities, including the presence of satellites. With an increase in the number of reuses, there is a reduction in the number of satellites, potentially due to surface partial melting due to the pre-heating of the EBM chamber, leading to rougher surfaces on the recycled particles.The microstructure of virgin powders is predominantly characterized by a fine acicular α’ phase, known as martensitic, formed due to the rapid cooling rate during the atomization process. Conversely, recycled powder tends to exhibit a coarser grain microstructure due to lower cooling rates. However, it is common to observe particles with a microstructure similar to that of newly manufactured powders, indicating that each individual particle has undergone a distinct thermal history.

ОСОБЛИВОСТІ УПРАВЛІННЯ БІЗНЕС-ПРОЦЕСАМИ НА ОСНОВІ РЕФЛЕКСИВНОГО ПІДХОДУ: ТЕОРЕТИКО-МЕТОДОЛОГІЧНІ АСПЕКТИ

In the context of the war in Ukraine and the rapidly changing business environment, the implementation of innovative approaches to business process management has become increasingly relevant. The reflexive approach ensures continuous analysis and optimisation of business processes, enhancing the competitiveness and adaptability of enterprises amidst uncertainty and risks. Thе article examines the theoretical and methodological aspects of managing business processes based on the reflexive approach during the war in Ukraine. The main principles and stages of reflexive management, its impact on the efficiency of business processes, and the organisational structure of enterprises are analysed. The article aims to develop a theoretical and methodological foundation for implementing the reflexive approach to business process management in wartime. It is established that the reflexive approach to business process management during wartime ensures improved process efficiency, cost reduction, and enhanced quality of products and services. Research aims to expand scientific knowledge on new management methods that can enhance the effectiveness of business processes in challenging environments. The development of new management approaches and tools tailored to wartime conditions will enable Ukrainian enterprises to operate effectively, maintain competitiveness, and increase resilience even amidst uncertainty. The research results demonstrate that applying the reflexive approach enables enterprises to adapt to external changes, respond promptly to wartime challenges, and improve their competitiveness. The use of modern reflexive approach tools in business process management in Ukraine is substantiated, allowing for the rapid collection and analysis of data, process modelling and optimisation, effective knowledge and collaboration management, decision support, and performance evaluation, thus maintaining business competitiveness in challenging conditions. The article provides practical recommendations for implementing the reflexive approach in business process management and identifies prospects for further research in this direction.

Efficient shielding gas supply for laser-based Powder Bed Fusion of metals (PBF-LB/M)

The inert gas supply during laser-based powder bed fusion of metals (PBF-LB/M) is one of the most important sub-processes influencing the quality of the end products and the efficiency of the printing process. However, improper distribution of the shielding gas flow can result in poor part quality and excessive energy and gas consumption. Thus, the formation of a homogeneous protective gas flow over the powder melting region is crucial to minimize the negative effects mentioned above. In this investigation, a modified system for supplying shielding gas to the building chamber of PBF-LB/M machine is developed with the possibility of creating localized and uniform gas flows over the area where the melting process takes place. The aim of the selectively localizable shielding gas supply is to improve process efficiency of PBF-LB/M while giving the opportunity to enhance part properties such as surface roughness.

The relationship of inspirational leadership and green supply chain management to reinforce the performance of SMEs

The aim of this research is to analyze the relationship between inspirational leadership and performance and the relationship between green supply chain management and performance improvement. This research method is quantitative. Research data was obtained by distributing online questionnaires via social media, the questionnaire was designed using statement items with a Likert scale of 1 to 7. The respondents for this research were 678 SMEs owners in Indonesia who were determined using the simple random sampling method. The data analysis technique for this research uses partial least squares (PLS) structural equation modeling (SEM) analysis with SmartPLS 3.0 software data processing tools. The stages of research analysis are validity testing, reliability testing and hypothesis testing (significance). The results of the research show that inspirational leadership has a positive and significant effect on performance. With the existence of inspirational leadership on HR performance it will have a positive effect if employees get trust and good examples from leaders, and employees get inspiration and motivation so they can create new innovations that make the company more advanced. Green supply chain management has a positive and significant effect on improving performance. The concept in green supply chain management provides the possibility for organizations to improve process efficiency, waste recycling management, the ability to attract new suppliers and consumers, organizations can save costs, reduce delivery times through collaboration with suppliers and consumers which can ultimately improve operational performance.

Integrated Experimental Phase Equilibria and Thermodynamic Modelling Research and Implementation in support of progress of process pyrometallurgy towards sustainability

Responding to the many sustainability challenges facing the metallurgical industry, we report progress that has been made on the development of predictive tools that can be applied to a wide range of technologies. The aim is to provide accurate, fundamentally-based thermodynamic tools that can be used by industry to improve process efficiencies, metal recoveries and productivities, and reduce energy requirements of pyrometallurgical systems. The program involves an integrated experimental and thermodynamic modelling research on phase equilibria in complex multi-component, multi-phase gas-slag-matte-speiss-metal-solids system with the Cu2O-PbO-ZnO-FeO-Fe2O3-CaO-Al2O3-MgO-SiO2-S major and As-Sn-Sb-Bi-Ag-Au-Ni-Co-Cr-Na minor elements. The experiments involve high temperature equilibration in controlled gas atmospheres, rapid quenching and direct measurement of equilibrium phase compositions with quantitative microanalytical techniques, including electron probe X-ray microanalysis and Laser Ablation ICP-MS. The thermodynamic modelling is undertaken using FactSage software package with advanced thermodynamic solution models. The continuing development of analytical and research methodologies has resulted in significant advances in predictive capability. Implementation of the results of fundamental studies involves ongoing collaboration of researchers and industry technologists, and the provision of advanced professional training. An overview of recent progress in research, implementation and applications in industrial practice will be presented in the paper.

Evolution in geosynthetics starts with utilizing data technology

This paper focuses on the automation of the geosynthetics installation QA/QC process by way of software integration in the field data entry and office data management. Technology is essential to the advancement of geosynthetic installations, especially data application. In its most basic form, data application is a means of gathering, storing, and utilizing information more easily than its predecessor(s). If implemented appropriately, data application technology improves process efficiency. Users and downstream stakeholders of process improvements can then capitalize by delivering quicker, higher-quality, more economical products. The geosynthetics industry is lagging in the area of data application. From a feasibility perspective and assessing practical implementation opportunities, many workflows widely used for tracking geosynthetic installations and its associated means and methods are antiquated and, furthermore, lack reliable authenticity verification. The current accountability requirements require a robust catalog of information reporting to substantiate this important environmental construction practice. The combination of room to evolve in practice and existing data requirements make the geosynthetics industry an ideal suitor for this technology integration. While advancements in materials manufacturing, welding equipment, and post-installation leak surveys already contribute to progress, there is a lack of universally accepted information infrastructure to aggregate all facets of an installation. Software automation creates a cyclical geosynthetics ecosystem that benefits the industry as a whole.

Toward microfluidic continuous-flow and intelligent downstream processing of biopharmaceuticals.

Biopharmaceuticals have emerged as powerful therapeutic agents, revolutionizing the treatment landscape for various diseases, including cancer, infectious diseases, autoimmune and genetic disorders. These biotherapeutics pave the way for precision medicine with their unique and targeted capabilities. The production of high-quality biologics entails intricate manufacturing processes, including cell culture, fermentation, purification, and formulation, necessitating specialized facilities and expertise. These complex processes are subject to rigorous regulatory oversight to evaluate the safety, efficacy, and quality of biotherapeutics prior to clinical approval. Consequently, these drugs undergo extensive purification unit operations to achieve high purity by effectively removing impurities and contaminants. The field of personalized precision medicine necessitates the development of novel and highly efficient technologies. Microfluidic technology addresses unmet needs by enabling precise and compact separation, allowing rapid, integrated and continuous purification modules. Moreover, the integration of intelligent biomanufacturing systems with miniaturized devices presents an opportunity to significantly enhance the robustness of complex downstream processing of biopharmaceuticals, with the benefits of automation and advanced control. This allows seamless data exchange, real-time monitoring, and synchronization of purification steps, leading to improved process efficiency, data management, and decision-making. Integrating autonomous systems into biopharmaceutical purification ensures adherence to regulatory standards, such as good manufacturing practice (GMP), positioning the industry to effectively address emerging market demands for personalized precision nano-medicines. This perspective review will emphasize on the significance, challenges, and prospects associated with the adoption of continuous, integrated, and intelligent methodologies in small-scale downstream processing for various types of biologics. By utilizing microfluidic technology and intelligent systems, purification processes can be enhanced for increased efficiency, cost-effectiveness, and regulatory compliance, shaping the future of biopharmaceutical production and enabling the development of personalized and targeted therapies.

Atomistic-Continuum Study of an Ultrafast Melting Process Controlled by a Femtosecond Laser-Pulse Train.

In femtosecond laser fabrication, the laser-pulse train shows great promise in improving processing efficiency, quality, and precision. This research investigates the influence of pulse number, pulse interval, and pulse energy ratio on the lateral and longitudinal ultrafast melting process using an experiment and the molecular dynamics coupling two-temperature model (MD-TTM model), which incorporates temperature-dependent thermophysical parameters. The comparison of experimental and simulation results under single and double pulses proves the reliability of the MD-TTM model and indicates that as the pulse number increases, the melting threshold at the edge region of the laser spot decreases, resulting in a larger diameter of the melting region in the 2D lateral melting results. Using the same model, the lateral melting results of five pulses are simulated. Moreover, the longitudinal melting results are also predicted, and an increasing pulse number leads to a greater early-stage melting depth in the melting process. In the case of double femtosecond laser pulses, the pulse interval and pulse energy ratio also affect the early-stage melting depth, with the best enhancement observed with a 2 ps interval and a 3:7 energy ratio. However, pulse number, pulse energy ratio, and pulse interval do not affect the final melting depth with the same total energies. The findings mean that the phenomena of melting region can be flexibly manipulated through the laser-pulse train, which is expected to be applied to improve the structural precision and boundary quality.

Improved Soil Amendment by Integrating Metal Complexes and Biodegradable Complexing Agents in Superabsorbents.

The superabsorbents' application as materials for the preparation of modern mineral fertilizers of controlled activity is presented. Under the static conditions, the commercial acrylic-based Agro® Hydrogel was used as a sorbent for Cu(II), Fe(III), Mn(II), and Zn(II) ions in the presence of three biodegradable complexing agents of the new generation: (N-1,2-dicarboxyethyl)-D,L-aspartate acid (IDHA), N,N-ethylenediaminedisuccinic acid (EDDS) and N,N-bis(carboxymethyl) glutamic acid (GLDA). The ions and complexes concentrations were determined by the inductively coupled plasma optical emission spectrometer (ICP-OES). The characterization of hydrogel before and after the adsorption process was made using the Fourier transform infrared spectroscopy (FT-IR), surface area determination (ASAP), scanning electron microscopy (SEM-EDS) as well as the thermogravimetric (TGA) methods. The influence of the phase contact time, initial concentration, and pH on the adsorption capacities was investigated. The kinetic and adsorption parameters were determined. The Langmuir, Freundlich, Dubinin-Radushkevich, and Temkin adsorption models were applied to describe the experimental data. The Langmuir isotherm model accurately characterized the equilibrium process. The adsorption process was fast, and it reached equilibrium after 60 min of the phase contact time. The research on the adsorption of Cu(II), Fe(III), Mn(II), and Zn(II) onto Agro® Hydrogel with IDHA, EDDS, and GLDA indicates that these complexing agents improve process efficiency.

Tiny swabs: nasal swabs integrated into tube caps facilitate large-scale self-collected SARS-CoV-2 testing.

The COVID-19 pandemic spurred the development of innovative solutions for specimen collection and molecular detection for large-scale community testing. Among these developments is the RHINOstic nasal swab, a plastic anterior nares swab built into the cap of a standard matrix tube that facilitates automated processing of up to 96 specimens at a time. In a study of unsupervised self-collection utilizing these swabs, we demonstrate comparable analytic performance and shipping stability compared to traditional anterior nares swabs, as well as significant improvements in laboratory processing efficiency. The use of these swabs may allow laboratories to accommodate large numbers of sample collections during periods of high testing demand. Automation-friendly nasal swabs are an important tool for high-throughput processing of samples that may be adopted in response to future respiratory viral pandemics.