Industrial Units Research Articles

Laser Based Vibration Sensor Through Mobile

Machine condition monitoring has gained momentum over the years and becoming an essential component in the today’s industrial units. A cost-effective machine condition monitoring system is need of the hour for predictive maintenance. The paper presents the design and implementation using vibration sensor, and also this system operated through smartphones. Vibration analysis plays a major role in detecting machine defects and developing flaws before the equipment fails and potentially damages. The concept of this project was to detect faulty equipment in industry machine so that before damaging the whole machine faulty equipment can be replace and improve the durability of machine.

Development of an Industrial Electrical Installation Training Unit

The purpose of this study is to obtain a modular unit for training and instruction in industrial electrical installations as a suitable learning media. This study uses research and development (RD) with ADDIE model, which consists of five phases: analysis, design, development, implementation, and evaluation. The research subject is Diploma 4 student in Department of Electrical Engineering Education, Faculty of Engineering, Universitas Negeri Yogyakarta. The research result as follows. (1) Manufacture of industrial electrical equipment training module products. (2) Application program feasibility for material-related assessment includes content aspects, learning aspects, and efficiency aspects. All aspects of the substantive feasibility study were rated as highly feasible with a score of 94.5 points. Application program feasibility for media professional evaluation includes visual, hardware, usability, and portability aspects. It has an average score of 109.5 on all aspects of the media feasibility test and is categorized as highly feasible. (3) Student user reactions, including learning, visual, hardware, usability, and portability. All aspects of student user response were rated as very good with an average score of 107.1.

The structure design and offshore oilfield experiment study of industrial compact flotation unit

The Compact Flotation Unit is widely used in the offshore oilfield produced water treatment based on the characteristics of relatively small footprint and high oil removal efficiency, but the structure details of the Compact Flotation Unit have been rarely described up to now. Few literature is talking about the Compact Flotation Unit design process and systematically analyzing the influence of operating parameters on the oil removal efficiency, especially on the large-capacity industrial-level Compact Flotation Unit products. In this paper, the working principle and structure design process of the Compact Flotation Unit from Beijing Institute of Petrochemical Technology cooperated with China National Offshore Oil Corporation Research Institute were systematically introduced. Furthermore, the single-stage Compact Flotation Unit from Beijing Institute of Petrochemical Technology of industrial scale with a treatment capacity of 120 m³/h was manufactured and tested on floating production storage and offloading unit located in the South China Sea. When the inlet average oil content was 280.3 mg/L, the outlet average oil content was 39.9 mg/L, and the corresponding average oil removal efficiency was 85.8%. The flow split ratio, back pressure, and inlet flow rate have a significant impact on the oil removal efficiency, while the effect of the gas-liquid ratio and outlet water recycle ratio are not sensitive. The main reason can be attributed to the dissolved gas components in the produced water. A large quantity of microbubbles is generated after depressurization which directly participates in the flotation process. Besides that, the single-stage Compact Flotation Unit prototype can tolerate the fluctuation of inlet flow rate and oil content.

Impact of Industrial Effluents on Crop Production in Central Brahmaputra Valley Zone of Assam

The present study assessed the impact and consequences of the industrial effluents that emerged from the Nagaon Paper Mill (NPM) and Brick Kilns Industry (BKI) in the Nagaon and Morigaon districts of Assam, respectively. The impact of the industrial effluents was analyzed with particular reference to Sali rice. The study depicted that the net sown area was less in the areas close to both industrial units due to the conversion of productive land to wastelands, which results in changes in cropping patterns and crop productivity close to industrial units compared to areas further away from industrial units. The findings also revealed that farms polluted with industrial effluents had much higher labour expenses, pesticide prices, and wastewater disposal costs, raising the overall cultivation cost. The study suggested treating the effluents appropriately before being disposed of in the environment to lessen the effect on agricultural output. For the brick kiln industry, agricultural land should not be exploited, and BKI regulations need to be strictly regulated because many unregistered BKIs are sprouting up throughout Assam.

Yeast population dynamics in Brazilian bioethanol production.

The large-scale and nonaseptic fermentation of sugarcane feedstocks into fuel ethanol in biorefineries represents a unique ecological niche, in which the yeast Saccharomyces cerevisiae is the predominant organism. Several factors, such as sugarcane variety, process design, and operating and weather conditions, make each of the ∼400 industrial units currently operating in Brazil a unique ecosystem. Here, we track yeast population dynamics in 2 different biorefineries through 2 production seasons (April to November of 2018 and 2019), using a novel statistical framework on a combination of metagenomic and clonal sequencing data. We find that variation from season to season in 1 biorefinery is small compared to the differences between the 2 units. In 1 biorefinery, all lineages present during the entire production period derive from 1 of the starter strains, while in the other, invading lineages took over the population and displaced the starter strain. However, despite the presence of invading lineages and the nonaseptic nature of the process, all yeast clones we isolated are phylogenetically related to other previously sequenced bioethanol yeast strains, indicating a common origin from this industrial niche. Despite the substantial changes observed in yeast populations through time in each biorefinery, key process indicators remained quite stable through both production seasons, suggesting that the process is robust to the details of these population dynamics.

Performance assessment and exergy analysis of hydrogen production from natural gas in a petrochemical unit (A real case study)

The present study is focused on the hydrogen production from natural gas (NG) as input in the large-scale industrial petrochemical unit located in Ilam province, west of Iran. The influence of flow rate, temperature, time, and pressure on the hydrogen production is discussed. This case study is based on accurate operating data from the actual plant in operation. In producing hydrogen, primary method SMR (Steam Methane Reforming) is used with different types of catalysts (CoMo, Zinc oxide, and Nickel-oxide). The optimum hydrogen is produced with 75.61% purity at the end of the system's cycle, and several factors are simultaneously responsible. However, temperature and flow rate have a considerable effect, but the necessity of pressure and the presence of other components are apparent. Additionally, exergy analysis results for the system indicate that the significant exergy destruction is related to the burner by 644.26 MW, and minimum exergy destruction belongs to Heater 1, which worked as a condenser, with 4.42 MW. Furthermore, the highest exergy efficiency was obtained for Drum with 66.53%, and the lowest exergy efficiency belongs to Desulphurization Reactor with 1.5%. The exergy efficiencies of gas products were calculated as well as hydrogen, methane, and nitrogen as the highest, middle, and the lowest achieved 68.06, 16.54, and 0.00064%, respectively. In the final part, the overall exergy efficiency of the system was calculated as 20.93%. Considering the components which the most exergy destruction occurred and controlling the input parameters such as pressure, flow rate, temperature, and catalysts leads to the exergy efficiency and hydrogen production improvement substantially.

The Role of Green Process Reengineering in Improving the Performance of Total Productive Maintenance

Abstract In light of the contemporary developments in all the different sciences and technological changes, and the increase in the environmental impacts of production processes, it is required of the Iraqi economic units to use modern technologies applied in the world, to keep abreast of these developments and adhere to the legislation related to environmental protection on the one hand, and to increase the efficiency and effectiveness of labor activities and techniques, and this leads to consequently reduce production costs, and providing environmentally friendly production processes at the same time, and this requires the application of modern and advanced methods and methods, and accordingly, this research came to clarify the application of one of the modern techniques in cost management, which is the technique of re-engineering green processes and its role in improving the overall performance of the economic unit in particular, and the performance of in particular Total productive maintenance, Thus, the aim of the research is to highlight that green process reengineering technology has a role in improving the performance of Total productive maintenance. To develop the Iraqi industrial sector, the sulfuric acid plant in Al-Furat Company for Chemical Industries and Pesticides was adopted as a sample for research, as it is one of the Iraqi industrial economic units seeking development and facing great and growing competition. Total production maintenance, this hypothesis has been proven by applying green process reengineering to the production processes of the research sample factory. The research reached several conclusions, the most important of which is that the application of green process reengineering technology steps contributes to reducing costs by improving the performance of Total productive maintenance, and helps the research sample to protect the environment, and presented a set of recommendations that contribute to the development of the research sample and environmental protection.

Experimental Evaluation of Vibrational Stability of SOPs in Aerospace Industry Using PCB Strain Effectiveness of a PCB-Strain-Based Design Methodology

Steinberg’s theory, which is based on the fatigue failure theory, has been widely used for predicting the structural safety of solder joints in aerospace electronic units under vibration during launches. However, theoretical limitations are encountered when evaluating the structural safety of highly integrated electronic packages mounted on printed circuit boards (PCBs) under various boundary conditions. Therefore, in our previous study, a PCB-strain-based methodology was proposed to overcome the technical limitations of the conventional Steinberg theory, and its effectiveness was validated by conducting fatigue life tests on various types of specimens, such as the ball grid array, column grid array, and quad flat package. In this study, the aim was to increase its completeness and reliability by targeting small outline packages (SOPs) that have not yet been considered. The finite element (FE) model of the SOP was proposed to guarantee the reliable prediction of the structural safety of the solder joints used in the PCB-strain-based methodology. The proposed modeling technique contributes to enable the rapid construction of an FE model for the electronic unit because it was greatly simplified into a zero-dimensional lumped mass and rigid link element to simulate the package mass and solder joint, respectively. The effectiveness of the methodology was validated by performing fatigue life tests on PCB specimens under various boundary conditions. Those experimental and analytical results indicated that the proposed methodology was much more effective in predicting the structural safety of a solder joint for various cases of tested specimens compared with the Steinberg’s theory. The simplified FE model of SOP with the rigid link element connected to six points on the package mounting area of the PCB was effective for estimating margin of safety of solder joint. The results of this study would contribute to increase the availability of the proposed methodology for rapid mechanical design of electronic units in aerospace industries.

Identification of Key Production Factors in China's Environmental Protection Industry Based on Deep Learning

Analyzing from the micro level of the basic unit of environmental protection industry -- enterprise, this paper takes   relevant information of more than 8000 key enterprises in China's environmental protection industry from 2018 to 2020 as the big data training samples, and uses BP neural network method to identify the key production factors that have great impact on the output of the whole China's environmental protection industry and its main subdivisions. The results show that China's environmental protection industry is still in the growing stage in the current stage, with significant capital pulling, technological innovation driving, and management innovation also plays an important role. There are differences in the performance of water, air and solid waste in the environmental protection industry. In detail, R&D expenses from the government plays the most important role in water pollution prevention and control industry. Technology innovation plays the most important role in air pollution prevention and control industry. And staff play the most important role in solid waste treatment and resource recycling industry.

CFD simulation and optimization of turning different waste gases into energy in an industrial steam methane reformer

BackgroundOne of the most important processes of industrial hydrogen production is steam methane reforming (SMR). However, the biggest drawback of steam reformer processes is high energy consumption. In methanol production units, 40% of the energy consumed in the steam reformer is provided by methane burning. The best solution to reduce the consumption of methane gas is to use the waste gases of the units. InnovationTo boost the thermal performance of the furnace, as well as the reduction in natural gas utilization, the effects of the kinds of fuel in an industrial unit are investigated. Furthermore, the waste gas is studied to whether it can be used as fuel in an SMR or not. SignificanceCFD is one of the most powerful tools for simulation of the industrial by which a new unit can be set up or the performance of the old units can be developed. Additionally, the effect of diverse parameters on industrial processes can be examined, and the optimal operating conditions of the industrial unit can be found. MethodsIn this study for five different cases of fuel, the furnace of an industrial SMR unit, at the operating conditions, was simulated using Computational Fluid Dynamics, (CFD) and the results were validated by the industrial data. Moreover, regarding the higher thermal efficiency of the furnace and the lower consumption of natural gas, two cases called design, and the suggested modes, were investigated and suggested mode was proposed as the most suitable fuel. FindingBased on the results, removing purge gas and adding waste gases with lower hydrogen content are recommended. Compared with the operational fuel, the suggested mode decreases the flue gas temperature by 11.78 K and increases the temperature of the first row of the reformer tubes by about 4.17 K, while declining the natural gas molar flow rate by 32%. A 64% reduction in hydrogen content of the suggested mode leads to an increase 10% flame length and 14% enhancement of adsorbed radiative heat flux. Moreover, in the suggested mode it is possible to recycle the purge gas to the methanol synthesis reactor and enhance the methanol production to 1% which is 50 ton/day.

Valorization potential of dried tannery fleshing wastes (TFW) through pyrolysis in the leather industry: Kinetic and thermodynamic investigations

Since the moisture content of the tannery fleshing waste (TFW) of the leather industry is too high, this paper evaluates the effects of open air and greenhouse drying pretreatment on the valorization potential of these wastes by pyrolysis. The pyrolysis behavior and kinetics were studied using KAS and Starink model-free methods and the reaction mechanisms of both dried TFW samples were established by the Coats-Redfern model. The activation energy (Eα) calculated by KAS and Starink methods were similar for both samples, resulting in 121.71, 149.32 and 169.80 kJ mol−1 for TFW-OD and 155.41, 203.33 and 175.19 kJ mol−1 for TFW-GD in the first, second and third stages respectively. Moreover, the performance of two drying approaches on the behavior of TFW slow pyrolysis was studied at 500 °C and focused on biochar production to improve the feasibility of the TFW pyrolysis process, with the main goal of moving towards circular economy in the leather industry. The obtained results revealed that produced biochars are not suitable for either subsequent energetic valorization as fuels (H/C > 0.7). However, they showed a great potential for soil amendment (R50 = 0.11–0.12), long-term carbon storage (O/C < 0.4), fertilizers or sorbent for tannery wastewater treatment where adsorption of dyes is essential. Amongst the drying pretreatments, the open-air drying method proved to be the most suitable for industrial scale unit to convert TFW into economic value biochar.

Energy and exergy analysis based on an energy saving process of waste tires pressurized catalytic reforming

The pressurized catalytic reforming technology had a positive impact on product quality, but the energy consumption for industrial applications remained uncertain. To achieve the need for energy-efficient and environmentally-friendly conversion of waste tires, this study developed a system of pressurized catalytic reforming and exhaust gas combustion to produce high-quality oil, char, and industrial steam. The process was analyzed and evaluated based on the energy and exergy balance. The simulation results closely matched the experimental results, demonstrating the accuracy of the developed model. Significant energy savings were realized in the pyrolysis unit at 2.82 GJ/h and reforming unit at 7.57 GJ/h, respectively. The energy loss rates of the pyrolysis unit, heat transfer for the industrial steam unit, reforming unit, and combustion unit were 2.77%, 5.24%, 0.75%, and 0.77% of the system input energy, respectively. In addition, the heat transfer for the industrial steam unit recovered 12.93% of the system input energy. The exergy loss rates of the pyrolysis reactor, combustion reactor, and heat exchanger HEATER6 in the whole simulation system were 38.91%, 12.07%, and 32.29%, respectively.

High risk water pollution hazards affecting Aveiro coastal lagoon (Portugal) – A habitat risk assessment using InVEST

Anthropogenic pressures put at jeopardy ecosystem services (ES) provided by natural habitats. Ecosystem Based Management (EBM) approaches can support policymakers dealing with physical, chemical, and biological stresses caused by high-risk water pollution (HRWP) and sudden-accidental pollution (SAP). The objective of this study is to evaluate how alarming HRWP pressures might become in fragile marine, coastal, estuarine, and freshwater socio-ecological systems (MCEF-SES) surrounded by heavily industrialized and urbanized areas. To this end a spatially explicit analysis, using the InVEST-Habitat Risk Assessment (InVEST-HRA) model in combination with expert judgement from researchers from various fields, is performed. An application is provided for the case of the Ria de Aveiro (RdA) coastal lagoon in Portugal. Results show high spatial variance of HRWP hazards across RdA, with one major multi-layer risk hotspot at the center of the research area and a second patch of multiple risk hotspots towards the North of RdA. Salines emerge as the most threatened habitat followed by Intertidal flats and Saltmarshes. The most significant water pollution risk sources contributing to Salines cumulative risk are Fossil fuel processing, storage and sale units, Industrial units, Aquaculture, and the Marinas. Industries involving dangerous substances in the region threaten primarily Watercourses. This study confirms the InVEST-HRA model in combination with expert judgement is a transparent and easily replicable approach to build ES-based knowledge about habitat risks threatening MCEF-SES in a Natura 2000 site heavily pressured by HRWP hazards. After further valuation analysis, pondering gains and losses from regional development and environmental protection, this knowledge can support the planning and management of coastal areas and the prioritization of pollution abatement interventions. In particular, by estimating the loss that HRWP causes in the value of ecosystem services, defining HRWP abatement policies, assessing the effectiveness, costs and benefits of those abatement policies and, ultimately, evaluating the results for the well-being of local communities through global efficiency analysis, cost-benefit analysis or cost-effectiveness analysis. Hence, it bridges the gap between an informed EBM and the development policies of fragile regions.

Assessment of potential health risks from heavy metal pollution of surface water for drinking in a multi-industry area in Mali using a multi-indices approach

The Niger River, Bamako's population's primary drinking water source, is threatened by human activities. This study examines the Niger River pollution trend using heavy metals pollution indexes and Bamako's population's non-carcinogenic and carcinogenic related health risks. Parameters were monitored at fifteen sampling locations in low and high flow seasons. pH (7.30-7.50) and fluoride (0.15-0.26mg/L) were within the normal drinking water range. Among seven heavy metals (copper, zinc, cadmium, nickel, iron, manganese, and lead), the latter three were above the drinking water standard. The degree of contamination was negative, pointing to better water quality. However, the heavy metal evaluation index (HEI) was below the mean (5.88), between the mean and twice the mean, indicating a low and medium degree of pollution. Besides, heavy metal pollution indexes (HPI) were above the standard value (100), explaining a low-medium pollution level. High values of HPI could be explained by the industrial units' intensive activities coupled with the runoff effect. The hazard index (HI) indicated a low and medium non-carcinogenic health risk for adults and children. The probability of cancer risk (PCR) of nickel showed a cancer risk. Therefore, the river was polluted with trace elements and could not be used for drinking water without any treatment.

Economic Impact of Industrial Water Pollution on Agriculture and Rural Households in Bhavani River Basin of Tamil Nadu, India

Aim: To study the impact of industrial water pollution on Agriculture and rural households in Bhavani River basin of Tamil Nadu.&#x0D; Study Design: Multistage random sampling.&#x0D; Place and Duration of the Study: The study was conducted in the Sathyamangalam block of Erode district of Tamil Nadu during September 2021 to December 2021.&#x0D; Methodology: Erode district of Tamil Nadu has been purposively selected due to high intensity of industrial units. In the second stage, Sathyamangalam block of Erode district, was selected based on the extent of external effects on land and water. In total, 360 respondents are selected as a sample, constituting ten persons in each affected and unaffected village. Both primary and secondary data were collected for the present study.&#x0D; Results and Conclusion: The industrial water pollution in Bhavani River basin of Tamil Nadu leads to changes in agricultural pattern, reduction in farm income, decline in agricultural activities and most of the rural households were shifted to non-farming activities in this study area. In order to overcome these issues, it is suggested to develop alternative sources of water for irrigation.

Modeling and simulation of an industrial adsorption process of dehydration of natural gas in 4A molecular sieves: Effect of adsorbent aging

Adsorption in molecular sieves is the number one choice for the dehydration of natural gas in offshore platforms. Many phenomenological and mathematical approaches have been used to describe this unit operation. However, the effect of aging on the operation performance, and consequently the adequacy of these models to describe operational field conditions, has been seldom assessed. This work presents the simulation of an industrial unit of natural gas dehydration with 4A molecular sieves in different cycle numbers using a phenomenological model. First, the most adequate equilibrium isotherm to describe experimental data of pure compound adsorption (viz., the dual-site Langmuir isotherm) was determined. Second, momentum, mass, and energy transfer equations were implemented, and the modeling of literature adsorption data was used to verify the adequacy of the developed equations. Finally, an industrial dehydration unit was modeled using the same approach, and calculated breakthrough times were compared to field data. In conclusion, the premature aging of molecular sieves in industrial operation appears as a defining factor in equipment performance.

THE IMPACT OF A COMPANY'S FINANCIAL PERFORMANCE ON THE RELATIONSHIP BETWEEN FREE CASH FLOW AND CAPITAL STRUCTURE

This study aims to examine the impact of the financial performance of the business unit in the relationship between free cash flow and capital structure, and the regression equation was relied upon for testing, analysis and measuring the impact through the statistical program (SPSS), based on the annual financial reports data for a sample of industrial business units listed on the Iraq Stock Exchange, which numbered (8) business units over a period of (10) years from (2011-2020). ), the results show that although free cash flow does not directly affect capital structure, financial performance has been shown to affect the relationship between free cash flow and capital structure.

Modelling and operation of industrial vibrocooling units

Product quality is paramount for companies to maintain the trust from their customers. Powder products and in particular fertilizers can suffer damage during storage if the temperature and moisture are not appropriate. Most of the work has focused on drying, but the last stage of cooling is responsible for avoiding product out of specification. A first principles model has been developed for industrial fluidized vibrating cooling units following a multiscale approach, from the particle to the entire unit, to evaluate their operation. The unit consists of two sections using atmospheric and cool air, respectively. A refrigeration cycle is also modelled to compute the needs to cool the air. The unit’s model only includes two adjustable parameters, the heat transfer efficiency from the particle to the air as well as for the losses from the unit to atmosphere. The model has been validated using industrial data, resulting in heat flow efficiency from the particle equal to 0.30 and the flow of losses of 1.17 kW/K. The model can reproduce the industrial data within reasonable error and allows predicting the cooling cycle needs and estimating the cost of its operation as a function of the weather. The location of the facility results in the fact that during June-August the atmospheric air cannot cool the product below the critical temperature and the refrigeration cycle needs to operate.

Photovoltaic supply chain and government subsidy decision-making based on China's industrial distributed photovoltaic policy: A power perspective

As a clean energy source, photovoltaic (PV) power generation best meets the current demand for energy transformation. In particular, industrial distributed PV projects in China have developed rapidly, forming a mature market trading mechanism, and the Chinese government's subsidy policy has strongly supported their development. However, lucrative government subsidies often lead to PV enterprises not paying attention to technological innovation and blind production. Therefore, to improve the efficiency of government subsidies, enhance the overall performance of the PV supply chain, and achieve the healthy and long-term development of the PV industry. In this paper, we consider the actual demand preference characteristics of users, and construct game models of the PV supply chain under different power structures. We explore the optimal decisions of the PV supply chain enterprises and the formulation of optimal government subsidies under different power structures. The results show that (1) reasonable government subsidies have an incentive effect, which can increase manufacturers' profits, service providers' profits and social welfare level, and improve the demand for PV products. (2) Different power structures significantly affect the government's optimal subsidy, PV system manufacturer (PSM)'s and PV system service provider (PSSP)'s optimal decision-makings, while it does not affect social welfare. (3) Government subsidies are much larger in the Stackelberg case than in the Nash equilibrium case. Government subsidies are positively proportional to PV product market size, user quality preference factor (QPF), user product coverage preference factor (PCPF), industrial unit electricity price, photovoltaic conversion efficiency, and effective generation hours, and inversely proportional to PV product discount sensitivity, production cost, quality innovation cost factor (QICF), and effort performance cost factor (EPCF).

Impact of Lean Management Implementation Practices on Operational Performance: An Empirical Study of the Pharmaceutical Industry in Sri Lanka

The purpose of this paper is to investigate and explore lean management implementation practices for operational performance in the pharmaceutical industry in Sri Lanka. The study investigates the impact of lean management implementation practices with the lean bundle on the operational performance of each business unit of the pharmaceutical industry. The methodology study has been conducted with 412 business unit managers of the pharmaceutical industry. SPSS has been used for descriptive statistics. The AMOS version has been used for structural equation modelling. SEM technique has been used to develop the measurement model. This study has investigated how lean management practices have an impact to gain operational performance in the pharmaceutical industry in Sri Lanka. Lean management practices have implemented the lean bundle TQM, HRM, JIT, and TPM to succuss the operational performance. This study has been limited only to the pharmaceutical industry in Sri Lanka and measured lean management with the lean bundle. Also, operational performance has been measured with seven dimensions. The findings of this study have given a high value to implementing lean management using the lean bundle. This lean bundle can be used to gain high operational performance in any industry.