Industrial Processing Methods Research Articles

The disposition of chromite ore processing residue (COPR) incorporating industrial symbiosis

The feasibility of using industrial symbiosis for solid waste disposal was explored via a regional industrial symbiosis case that recycled chromite ore processing residue (COPR) in the sintering, iron-making and steel-making process. The process was analyzed from three aspects: the reduction rate of Cr(VI) in chromium slag, the utilization of effective components and the environmental benefits. We found through experimental research and Sankey diagram analysis that the comprehensive reduction efficiency of Cr(VI) was as high as 98.41%, and only 1.59% of Cr(VI) got into the dedusting system and the water quenching system. This showed that the method of recycling COPR in the sintering, iron-making and steel-making process as a replacement for dolomite to reduce Cr(VI) is feasible and effective. Components of COPR such as elemental chromium, magnesium oxide, calcium oxide and ferric oxide were all used effectively, while the rest of COPR ended up in the slag and was then disposed of. The method solved the problem that the COPR need to be landfilled after dry-detoxification due to the formation of a symbiosis chain among chromic chemical plants, steel mills and cement plants. The main factors affecting waste disposal are environmental responsibility and economic cost, and the industrial symbiosis can be used as alternative way of waste disposal to achieve the balance between these factors. Industrial symbiosis can decrease the enterprise cost of waste disposal and fulfill the corporate environmental responsibility, so it can be used as an industrial waste processing method in a certain area to obtain a win–win situation for both economic and environment benefit.

Optimized designing of PID controller for variable speed wind turbine systems using PSO algorithm

Abstract - The PID controller design is a very popular method for controlling industrial processes and due to its simple structure and effective operation; it is used in a wide range of industries. In this paper, a method is provided for setting up the PID controller and Particle swarm optimization (PSO) algorithm is used to design a variable speed wind turbine system. The provided method has advantages such as easy implementation, stable convergence characteristics and high performance in computing. Finally the results are displayed.

An approximate probability graphical modelling method for complex industrial fermentation processes

Fed-batch fermentation process is an effective method for production. Due to the various feeding streams andoperational conditions in different fed-batches, usually it is difficult to formulate a kinetics-based ordinary differential equations model for industrial fed-batch fermentation process. On the other hand, there are plenty of historical data collected during the fermentation process. In this paper, we firstly applied the graphical modeling method to model the fed-batch fermentation process. In this proposed method, the missing data within records are imputed, and then, the correlations between variables are determined by the low order conditional independence method, after that, the parameters of these related variables are learned by the multivariate auto regressive method. The calculation of L-lysine fed-batch fermentation process demonstrates the effectiveness of the proposed approximate model method.

Proposition of a Supporting Method for the Generation of Ergonomic Specifications

This research proposes the initial form of a method for industrial design development process. The main goal of this method is to help industrial design student to construct product design requirements considering ergonomic information. The proposed method focused on aspects involving interaction behavior process between human and product. Aspects like body movement, contact and abilities are considered inside the method. The method aims to investigate important information of the relationships between user and product, from two ways of comprehension and analysis. The first point of view considers the user and its way he manipulates and interacts with the product. And, the other is about what the product is demanding from human capabilities and what advantages are offered to the user. The proposal applied a pilot test to improve its possibilities of use and effectiveness comprehension by the students. The methodology applied used two questionnaires. The first questionnaire researches the way the student defines his criteria to select the information to build the requirements of conceptual product. The second questionnaire applied at the end of the process evaluates the scope of the method. In the middle of both questionnaires was exposed the methodology, was observed the product development process made by students, and applied the method. Final, analyzed the results of the method, and compared the results of the questionnaires, was identified some benefits on clearance the objective of the ergonomic information, needed to define the product conceptual requirements. The method provides detailed information allowing the student to identify ergonomic aspects that weren’t considered in previous analyzes. These make corrections to the requirements of the project.

A Quality-Relevant Sequential Phase Partition Approach for Regression Modeling and Quality Prediction Analysis in Manufacturing Processes

Competition and demand for consistent and high-quality product have spurred the development of quality prediction methods for industrial manufacturing processes. Mul- tiplicity of phases is, in general, common nature of many batch manufacturing processes. Considering that different phases may have different effects on qualities, one of the key issues is how to partition the whole batch process into multiple phases. In the present work, an automatic quality-relevant step-wise sequential phase partition (QSSPP) algorithm is developed for phase-based regression modeling and quality prediction. It considers the time sequence of operation phases and can capture the time-varying quality prediction relationships. Using this algorithm, phases are separated in order from quality-relevant perspective, revealing different quality prediction relationships. The phase-based re- gression system is set up for online quality prediction and the online prediction results are quantitatively evaluated for each phase. The feasibility and performance of the proposed algorithm are illustrated by an important manufacturing process, injection molding. Note to Practitioners—This paper was motivated by competition and demand for consistent and high-quality product for indus- trial manufacturing processes with multiphase characteristics. Industrial experts have noted that events taking place in different phases may have different impacts on the final product yield and quality. Phase-based quality prediction has drawn their attention by providing quality information before the end of processes. This paper suggests an automatic sequential phase partition algorithm for phase-based regression modeling and quality prediction which can identify phases in sequence from the quality-relevant per- spective. The division result is easy to read and does not need a heavy postprocessing as what is done for clustering-based result. The phase information is identified in order by directly relating changes of process characteristics with their influence on quality prediction performance. More accurate regression models and online quality prediction results can thus be readily obtained. Preliminary experiments suggest that this approach is feasible but it has not yet been incorporated into a quality control system nor tested in practical industrial production. In future research,

On the relevance of large scale pulsed-laser deposition: Evidence of structural heterogeneities in ZnO thin films

Pulsed-laser deposition is known as a well-suited method for growing thin films of oxide compounds presenting a wide range of functional properties. A limitation of this method for industrial process is the very anisotropic expansion dynamics of the plasma plume, which induces difficulties to grow on large scale films with homogeneous thickness and composition. The specific aspect of the crystalline or orientation uniformity has not been investigated, despite its important role on oxide films properties. In this work, the crystalline parameters and the texture of zinc oxide films are studied as a function of position with respect to the central axis of the plasma plume. We demonstrate the existence of large non-uniformities in the films. The stoichiometry, the lattice parameter, and the distribution of crystallites orientations drastically depend on the position with respect to the plume axis, i.e., on the oblique incidence of the ablated species. The origin of these non-uniformities, in particular, the unexpected tilted orientation of the ZnO c-axis may be attributed to the combined effects of the oblique incidence and of the ratio between oxygen and zinc fluxes reaching the surface of the growing film.

Online process operating performance assessment and nonoptimal cause identification for industrial processes

Although industrial processes are usually operated at the optimal point in the early stage of the production, the operating performance may deteriorate with time due to process disturbances. In order to pursue optimal comprehensive economic benefit (CEB), online process operating performance assessment on optimality has become a key issue. However, a little work has been published in this research area. In this paper, a new online operating performance assessment and nonoptimal cause identification method for industrial process are proposed. The contributions of this paper can be summarized as follows: a novel performance-similarity-based online operating performance assessment method is proposed; total projection to latent structures (T-PLS) is applied to the area of process performance assessment for the first time; the online assessment results include not only the deterministic performance grades, but also the performance grade conversions which were not covered in the existing assessment method; when the assessment result is nonoptimal, a novel automatic nonoptimal cause identification strategy is developed based on variable contributions, which is meaningful for guiding the further production adjustment. Finally, the feasibility and efficiency of the proposed method are illustrated with a case of gold hydrometallurgical process.

Rice industrial processing worldwide and impact on macro- and micronutrient content, stability, and retention.

Various processing methods are used in the food industry worldwide to produce numerous rice products with desirable sensory qualities based on cultural and cooking preferences and nutritional considerations. The processes result in variable degrees of macro- and micronutrient content, stability, and retention, depending on rice variety and original nutritional quality. In this article, modern and traditional premilling, milling, and postmilling processing methods of different rice types are comprehensively reviewed. The implications of industrial rice processing methods, especially milling, as well as techniques for nutrient extraction, transfer, and enhancement, such as rice parboiling, sprouting, and fortification, for macro- and micronutrient content and consumer acceptance of the products, are documented. Socioeconomic constraints facing various aspects of rice processing methods are also discussed. This article reviews up-to-date research on rice industrial processing worldwide and aims to benefit engineers dealing with food processing, nutritionists and dieticians, food companies, education and research institutions, and quality-control and safety managers.

Generalized model of heat transfer and volatiles evolution inside particles for coal devolatilization

Devolatilization is acknowledged as the first important step in coal conversion techniques. A comprehensive heat transfer and devolatilization model was established, with special consideration of the particle‐scale physics and chemistry, to predict the internal heat transport and pyrolysis behavior of particles. The chemical percolation devolatilization model with corrected kinetic parameters and structure parameters was validated with a lot of experimental data and then adopted to describe the devolatilization behaviors under a broader range of temperatures, heating rates, and coal types. The newly achieved understanding of the integrated effect of heating rate and coal type on coal devolatilization could help to provide a preliminary coal rank selection method for industrial processes. In particular, in‐depth discussion of the influences of heat conduction, volatiles diffusion, and endothermic heat of devolatilization inside particle indicated the dominant roles of these factors when the intensity of heat transfer was strong or the release of volatiles was rapid. © 2014 American Institute of Chemical Engineers AIChE J, 60: 2893–2906, 2014

Swelling agent adopted decal transfer method for membrane electrode assembly fabrication

The decal transfer method is regarded as an effective membrane electrode assembly (MEA) fabrication method for industrial processes due to the improved adhesion between the catalyst layers and the hydrocarbon membrane. In this study, three swelling agents (ethanol, 1,5-pentanediol and glycerol) are introduced to the conventional decal methods in order to improve both the transfer ratio of electrodes on the membrane surface and the electrochemical properties. These swelling agents affect the surface energy differences between the swollen catalyst layer and the membrane substrate. Swelling agents also change the structure of the catalyst layer during the preparation (hot pressing) of the MEA. Changing the catalyst layer structure by introducing swelling agents diminishes the charge transfer resistance and internal resistances of MEAs. These improved electrochemical properties lead to the remarkably enhanced single cell performance of a SPAES MEA of 1380mAcm−2 at 0.6V, compared to a SPAES MEA fabricated by the conventional decal method (500mAcm−2).

A Numerical Methodology for the Multi-objective Optimization of the DI Diesel Engine Combustion

DI Diesel engine are widely used both for industrial and automotive applications due to their durability and fuel economy. Nonethe- less, increasing environmental concerns force that type of engine to comply with increasingly demanding emission limits, so that, it has become mandatory to develop a robust design methodology of the DI Diesel combustion system focused on reduction of soot and NOx simultaneously while maintaining a reasonable fuel economy. In recent years, genetic algorithms and CFD three-dimensional combustion simulations have been successfully applied to that kind of problem. However, combining GAs op- timization with actual CFD three-dimensional combustion simulations can be too onerous since a large number of calculations is usually needed for the genetic algorithm to converge, resulting in a high computational cost and, thus, limiting the suitability of this method for industrial processes. In order to make the optimization process less time-consuming, CFD simulations can be more conveniently used to generate a training set for the learning process of an artifical neural network which, once correctly trained, can be used to forecast the engine outputs as a function of the design parameters during a GA optimization performing a so-called virtual optimization.In the current paper, a numerical methodology for the multi-objective virtual optimization of the combustion of an automotive DI Diesel engine, which relies on artificial neural networks and genetic algorithms, was developed.

低分子ヘパリン中の夾雑ムコ多糖類の工業的除去方法

低分子ヘパリン（LMWH）であるダルテパリンナトリウム（DN）の純度試験法と，その中の他のムコ多糖類（MS）夾雑物の工業的除去方法について検討した．高純度の DN (DN-W）に高分子デルマタン硫酸（DSH）および高分子過硫酸コンドロイチン硫酸（OSH）を添加して粗DN（DN-C）を調製し，2段階のエタノール（EtOH）分画処理を行い，各不純物の挙動と DN-C の精製度を確認した．加えて，商業用 DN についても同様の EtOH 分画処理を行い，EtOH 分画処理の有効性を確認した．各分画物を HPLC法と1H-NMR（NMR）法により分析した結果，全ての検体で純度が向上した．また，本試験で用いた商業用 DN 中の高分子 MS 不純物はおもに高分子 DS であることが確認された．以上の結果から，LMWH の調製工程において，亜硝酸分解抵抗性不純物を高感度で検出できる亜硝酸分解/HPLC 法による純度検査を行い，さらに，2段階の EtOH 分画処理を実施することで，高品質な LMWH 原料を安定的に調製できると考えられた．

Folate content in processed legume foods commonly consumed in Egypt

Industrial food processing and household cooking are reported to affect folate content. This study examined the effects of industrial and household processing methods on folate content in traditional Egyptian foods from faba beans (Vicia faba) and chickpeas (Cicer arietinum). Overnight soaking increased folate content by ∼40–60%. Industrial canning including soaking, blanching and retorting did not affect folate content (p = 0.11) in faba beans, but resulted in losses of ∼24% (p = 0.0005) in chickpeas. Germination increased folate content 0.4–2.4-fold. Household preparation increased the folate content in germinated faba bean soup (nabet soup) one-fold and in bean stew (foul) by 20% (p < 0.0001). After deep-frying of falafel balls made from soaked faba bean paste, losses of 10% (p = 0.2932) compared with the raw faba beans were observed. The folate content (fresh weight) in the traditional Egyptian foods foul and falafel and in the beans in nabet soup was 30 ± 2, 45 ± 2 and 56 ± 6 μg/100 g, respectively. The traditional Egyptian foods foul, falafel and nabet soup are good folate sources and techniques like germination and soaking, which increase the folate content, can therefore be recommended.

Recovery rate and quality of rotary peeled veneer from 30-year-old Pinus taeda L. logs

In the construction sector, wood is facing competition with other materials such as concrete, steel or plastics. Therefore, there is a need for more efficiency in the forest–wood chain by improving silvicutural management and wood processing technologies. The objective of the study is to analyse the influence of log diameter and quality to recovery rate, veneer quality and economic benefit. The trees used in the study came from a 30-year-old Pinus taeda L. thinning trial in Southern Brazil. In total, 57 logs (20.7 to 67.0 cm) were peeled following the standard industrial processing methods of the plywood mill. Average recovery rate was 54 % ranging from 35 to 72.6 %, with a linear trend (R 2 = 0.48) of increasing recovery with an increment on the log small-end diameter. Results show that the gap between theoretically possible and real recovery was lower in the logs with bigger diameters, indicating their higher efficiency in industrial processing. Moreover, the economic analysis detected that the current prices for log assortments reflect only the industrial potential of low-quality pruned logs. An optimised pruning strategy would result in higher industrial efficiency, which would allow higher log prices. The results indicate that the recovery rate of bigger logs is higher in terms of volume of peeled veneer. The quality and therefore the value obtained from each log were negatively influenced by inadequate pruning strategies. Management of pines for higher value utilisation requires optimized thinning and pruning strategies in order to meet high growth rates and proportionally bigger dimensions of clear wood.

Characteristics of Isolation and Functionality of Protein from Tomato Pomace Produced with Different Industrial Processing Methods

The seeds separated from tomato pomace may contain valuable protein with unique functional properties. The objectives of this research were to study the impact of industrial hot and cold break tomato processes on protein isolation from defatted tomato seed meal and determine the protein-related functional properties of defatted and non-defatted seed meals. The results showed that the high temperature of hot break process denatured the protein, resulting in the lower protein extraction yield from 9.07 % to 26.29 % for defatted hot break tomato seed (DHTS) compared to from 25.60 % to 32.56 % for defatted cold break tomato seed (DCTS) under various extraction conditions. Hot break process also significantly influenced protein-related functional properties of seed meals. Compared to DCTS, DHTS had higher water absorption capacity (WAC) and oil absorption capacity (OAC) based on the protein weight in the seed meal, but lower emulsifying ability (EA), emulsifying stability (ES), foaming capacity (FC), and foaming stability (FS) based on the whole seed sample weight. When compared to commercial soybean protein isolate (SP), the meals of hot break tomato seed (HTS), DHTS, and DCTS showed higher bulk density and WAC values. The FC and FS of tomato meals were inferior while the ES was superior to SP. High alkaline pH was beneficial to the protein extraction and achieved better EA, ES, FC and FS of all the samples. The results indicated that tomato seed meals have a great potential to be used as functional food ingredients.

Fatty Acid Composition Including Trans‐Fatty Acids in Edible Oils and Fats: Probable Intake in Indian Population

The susceptibility of trans-fat to the human health risk prompted the Food and Agriculture Organization (FAO) and World Health Organization (WHO) to prepare regulations or compulsory claims for trans-fatty acids (TFA) in edible oils and fats. In this study, analysis of fatty acid composition and TFA content in edible oils and fats along with the possible intake of trans-fat in Indian population was carried out. The analysis was carried out as per the Assn. of Official Analytical Chemists (AOAC) methodology and the results were statistically analyzed. The average TFA content in nonrefined mustard and refined soybean oils exceeded by 1.16- to 1.64-fold as compared to the Denmark limit of 2% TFA in fats and oils destined for human consumption. In branded/nonbranded butter and butter oil samples, average TFA limit exceeded by 4.2- to 9.5-fold whereas hydrogenated vegetable oil (HVO) samples exceeded the limit by 9.8-fold, when compared to Denmark standards. The probable TFA intake per day through different oils in Indian population were found to be less than WHO recommendation. However Punjab having highest consumption of HVO (-15 g/d) showed 1.09-fold higher TFA intake than the WHO recommendation, which is alarming and may be one of the factors for high cardiovascular disease mortality rate that needs further elucidation. Thus there is a need to prescribe TFA limit for edible oil, butter, and butter oil in India and to reduce the already proposed TFA levels in HVO to safeguard the health of consumers. The probable daily intake of trans-fatty acid (TFA) especially through hydrogenated vegetable oil (HVO) was assessed. In absence of any specification for TFA and fatty acid composition for edible oils, butter, and butter samples, a pressing need was felt to prescribe TFA limit in India. The study indicates that TFA intake through HVO consumption is higher in States like Punjab than the recommended daily intake prescribed by WHO. Hence, strategies should be adopted to either decrease the consumption of HVO or to modify the industrial processing method of HVO with less content of TFA to safeguard the health of consumers.

Unexpected molecular weight dependence of shish kebab in water-assisted injection molded HDPE

As a part of continuous efforts to systematically understand the morphological development in water-assisted injection molding, high density polyethylene with different molecular weights was molded in this study. Unexpectedly, it was found that shish kebab with high lamellar and molecular orientations was formed in the sample with a lower molecular weight (LMW) rather than in the higher one, especially in the water channel layer. Present finding is obviously inconsistent with the general consensus, that is, higher molecular weight (HMW) polymer is much easier to form preferential orientation in flow field than LMW one. Such anomalous phenomenon is explained by the fact that even though melts experienced the same processing, lower shear rate is practically achieved in HMW sample due to its high viscosity. The result indicates that the flow history in industrial processing method is far from that in laboratory one. Copyright © 2012 John Wiley & Sons, Ltd.

Purification of Anti-Japanese Encephalitis Virus Monoclonal Antibody by Ceramic Hydroxyapatite Chromatography Without Proteins A and G

Antibody purification using proteins A and G has been a standard method for research and industrial processes. The conventional method, however, includes a three-step process, including buffer exchange, before chromatography. In addition, proteins A and G require low pH elution, which causes antibody aggregation and inactivates the antibody's immunity. This report proposes a two-step method using hydroxyapatite chromatography and membrane filtration, without proteins A and G. This novel method shortens the running time to one-third the conventional method for each cycle. Using our two-step method, 90.2% of the monoclonal antibodies purified were recovered in the elution fraction, the purity achieved was >90%, and most of the antigen-specific activity was retained. This report suggests that the two-step method using hydroxyapatite chromatography and membrane filtration should be considered as an alternative to purification using proteins A and G.

Poly-Lactic Acid: Production, Applications, Nanocomposites, and Release Studies.

Environmental, economic, and safety challenges have provoked packaging scientists and producers to partially substitute petrochemical-based polymers with biodegradable ones. The general purpose of this review is to introduce poly-lactic acid (PLA), a compostable, biodegradable thermoplastic made from renewable sources. PLA properties and modifications via different methods, like using modifiers, blending, copolymerizing, and physical treatments, are mentioned; these are rarely discussed together in other reviews. Industrial processing methods for producing different PLA films, wrappings, laminates, containers (bottles and cups), are presented. The capabilities of PLA for being a strong active packaging material in different areas requiring antimicrobial and antioxidant characteristics are discussed. Consequently, applications of nanomaterials in combination with PLA structures for creating new PLA nanocomposites with greater abilities are also covered. These approaches may modify PLA weaknesses for some food packaging applications. Nanotechnology approaches are being broadened in food science, especially in packaging material science with high performances and low concentrations and prices, so this category of nano-research is estimated to be revolutionary in food packaging science in the near future. The linkage of a 100% bio-originated material and nanomaterials opens new windows for becoming independent, primarily, of petrochemical-based polymers and, secondarily, for answering environmental and health concerns will undoubtedly be growing with time.

Content and Profile of Isoflavones in Soy-Based Foods as a Function of the Production Process

Soy has been traditionally incorporated in diet as processed foods, such as soymilk, tofu, miso, tempeh, etc., and the consumption is commonly associated with a reduction of the development of chronic diseases due to their antioxidant, anti-inflammatory, and anti-allergic properties, among others. Many of the health benefits of soy have been attributed to isoflavones. They comprise a group of naturally occurring flavonoids consisting of heterocyclic phenols. Soy contains three types of isoflavones in four chemical forms: the aglycones daidzein, genistein, and glycitein; the β-glucosides daidzin, genistin, and glycitin; their 6″-O-malonyl-β-glucosides (6OMalGlc); and their 6″-O-acetyl-β-glucosides (6OAcGlc) conjugates. Industrial processing methods of soy-based food products commonly lead to the loss of isoflavones through removal of undesirable fractions. On the other hand, isoflavones can be transformed into different conjugates, which may have significant effects on the food texture and on the bioavailability and pharmacokinetics of the isoflavones. This article reviews the effect of a number of soybean processing treatments on the isoflavone content and profile. The preparation and manufacturing of different soy-based food and food ingredients, fermented and non-fermented, has been analyzed in terms of content and distribution of the three major isoflavone derivatives, daidzein, genistein, and glycitein, and their respective conjugates.