Low-waste Technology Research Articles

Development and Implementation of Die Forging Technology Eliminating Flange Welding Operations in Conveyor Driver Forging.

This article presents research results regarding the development of a new manufacturing technology for an element assigned to belt conveyor flights in the extractive industry through hot die forging (of a forging with a double-sided flange) instead of the currently realized process of producing such an element by welding two flanges onto a sleeve or one flange onto a flange forging. The studies were conducted to design an innovative and low-waste technology, mainly with the use of numerical modelling and simulations, partially based on the current technology of producing a flange forging. Additionally, during the development of the forging process, the aspect of robotization was considered, both in respect of the forging tools and the process of transportation and relocation of forging between the impressions and the forging aggregates. A thermo-mechanical model of the process of producing a belt conveyor flight forging with deformable tools was elaborated by means of the Forge 3NxT program. The results of the conducted numerical modelling made it possible, among other things, to develop models of forging tools ensuring the proper manner of material flow and filling of the impressions, as well as temperature and plastic deformation distributions in the forging and also the detection of possible forging defects. For the technology elaborated this way, the tools were built together with a special instrument for flanging in the metal, and technological tests were performed under industrial conditions. The produced forgings were verified through a measurement of the geometry, by way of 3D scanning, as well as the hardness, which definitively confirmed the properness of the developed technology. The obtained technological test results made it possible to confirm that the elaborated construction, as well as the tool impressions, ensure the possibility of implementing the designed technology with the use of robotization and automatization of the forging process.

Establishment of quality standards for syrup from viburnum fruit meal

An adjusted dosage form has been developed in the form of a syrup using low-waste technology — from the meal of the fruits of Viburnum viburnum. Viburnum fruit meal contains higher fatty acids, triterpenoids, phytosterols, and carotenoids. Medicines of plant origin have a number of undeniable advantages compared to synthetic ones, since their composition ensures safety and better tolerability due to the variety of biologically active substances (BAS) of plants, they can have a complex effect on the body, and they can be used for a long time. However, the main issue is that, despite their high bioavailability and cost-effectiveness, herbal medicines are complex to design and require the development of a number of technological solutions. Equally important are the issues of establishing quality standards — standardization of the developed dosage form. The syrup was prepared from simple sugar syrup with the addition of dry extract from viburnum fruit meal. Purpose of work. Development and establishment of quality standards for the developed dosage form — syrup from viburnum fruit meal. Materials and methods. High performance liquid chromatography (HPLC) method. Let us use it to establish standards in quantitative terms for chlorogenic acid. Permanganatometry. This technique was used to determine the quantitative content of the amount of tannins in terms of gallic acid. Results. It was established that the content of chlorogenic acid in the developed syrup is 0.214 ± 0.006 %, the content of tannins in terms of gallic acid is 0.494 ± 0.014 %. Indicators acidity (pH) — 3–5, density — 1,360 to 1,420 g/cm3, microbiological purity — category 3 B. Conclusion. The result of the research was the establishment of the main indicators of syrup quality, namely the quantitative content of the main biologically active substances — chlorogenic acid and tannins in terms of gallic acid. In addition, such indicators as acidity (pH), density, and microbiological purity were determined.

Low waste technology for mine waters treatment using lime and aluminum coagulants

In this paper the process of reagent desalination of mineralized mine waters was studied. The peculiarity of mine waters in many regions of Ukraine is that, along with hardness ions, they also contain sulphates in fairly high concentrations. Therefore, the task of desalination of mineralized waters consists in effective removal of sulphates along with softening of the solution. For effective purification of water from sulphates and hardness ions, 5/6 aluminum hydroxychloride (Al2(OH)5Cl) and sodium tetrahydroxoaluminate (Na[Al(OH)4]) were used during liming. A significant increase in efficiency of the treatment process was achieved when the solution was acidified with carbon dioxide after treatment with reagents. The directions of processing of the formed sediments as part of building materials have been determined. Complex processing of the generated waste in the process of water treatment allows creating a low-waste technology for the purification of mineralized water.

Low waste technology for the removal of nitrates from water

Low waste technology for the removal of nitrates from water

A NEW APPROACH TO THE SYNTHESIS OF HIGHLY DISPERSED DOUBLE LITHIUM-NICKEL AND DOUBLE LITHIUM-COBALT PHOSPHATES WITH THE DESIGNED PARTICLE MORPHOLOGY

The paper presents a new low-temperature method for the synthesis of highly dispersed powders of double phosphates LiCoPO4 and LiNiPO4 using low-waste technology. It has been shown that the morphology and particle size of the obtained materials depend on the type of initial precursors. The obtained compounds are characterized by elemental, XRD, SEM, cyclic volammetry, cyclic chronopotentiometry analyses. A new approach to the synthesis of submicron powders of lithium double phosphates and transition metal (nickel, cobalt) is more effective compared to current methods.

PHYTOCHEMICAL SUBSTANTIATION OF INTEGRATED PROCESSING OF PERICARP OF JUGLANS NIGRA L.

Relevance. Both highly active pharmaceutical substances and excipients can be target products for the complex processing of medicinal plant raw materials. For example, naphthoquinones are used as antimicrobal, antifunginal and polysaccharides are used as fillers, thickeners, and sorbents. Fruits, roots, and waste from the wood processing industry serve as raw material sources of polysaccharides. The development of low-waste technologies for processing medicinal plant raw materials is a current area of research. The purpose of the work is to substantiate the possibility of complex processing of black walnut pericarp with the production of biologically active and auxiliary substances using low-waste technology based on phytochemical research. Material and methods. The object of study is the pericarp of Juglans nigra L. (Juglandaceae). The raw materials were collected in October 2021 in a park in Pyatigorsk. It was dried and crushed into powder. Naphthoquinones (juglone and its derivatives) were detected by thin layer chromatography. The content of naphthoquinones was determined by spectrophotometry, extractives released by chloroform, polysaccharides by gravimetry, the average molecular weight of water-soluble polysaccharides by viscometry, the surface activity of water-soluble polysaccharides by stalagmometry, and the distribution coefficient of polysaccharides in the diethyl ether-water system by conductometry. Results. The possibility of obtaining two products in one technological process is justified by the results of experiments: 1) active pharmaceutical substance (yield 1.5%) for obtaining external forms (ointments, creams) with antifungal, antiviral activity, containing naphthoquinones (naphthoquinones in terms of juglone 12.41±0.3%); 2) excipients polysaccharides (yield 8.8%), whose molecules have a thread-like structure, which explains their good solubility in water, surface activity and polyelectrolyte properties. Conclusions. As a result of a phytochemical study of the pericarp of Juglans nigra L., it was established that both a substance containing polyphenolic compounds and polysaccharides suitable as auxiliary substances can be obtained in the process of complex processing.

Study of calcium-containing compounds as catalysts for the esterification of glycerol with higher carboxylic acids

Objectives. To investigate the catalytic activity of calcium-containing basic catalysts for the esterification of glycerol with higher carboxylic acids in order to develop a low-waste technology for the production of multifunctional additives, as well as to assess the possibility of using the reaction products for the processing of polyvinyl chloride.Methods. The consumption of oleic acid during synthesis was monitored using a titrimetric method of analysis with visual indication. The structure of the synthesized calcium-containing catalysts was confirmed by infrared spectroscopy; elemental analysis was additionally performed for calcium glyceroxide. Quantitative and qualitative analyses of the resulting mixtures of oleic acid glycerides were carried out using chromato-mass spectrometry. A sample of a multifunctional additive was tested in a model formulation of a medical plastic compound based on polyvinyl chloride.Results. It is shown that the catalytic activity of calcium derivatives in the reaction of esterification of glycerol with higher carboxylic acids increases in the series СаО < Са(ОН)2 < Ca(C17H33COO)2 < Ca(C2H5O)2 < Ca(C4H9O)2 < Ca(C3H7O3)2, while the use of calcium glyceroxide as a catalyst in an amount from 1 to 6 mol % increases the conversion of carboxylic acid from 58 to 86% in 10 h of synthesis. However, varying the amount of calcium glyceroxide from 1.5 to 6 mol % results in no observed changes in the conversion of carboxylic acid. The multifunctional additive obtained by selecting calcium glyceroxide as a catalyst has a thermally stabilizing and plasticizing effect on the polymer composition. The introduction of the developed additive into the formulation of a polyvinyl chloride composition for medical purposes reduces the processing torque and time to reach the dry point. By combining these factors, energy costs during production were reduced by more than 11% compared to the control composition.Conclusions. It is established that calcium alcoholates catalyze the reaction of esterification of glycerol with oleic (or higher) acid to increase the conversion of the initial substances and selectivity for the formation of monoglycerides as compared with calcium oxide, hydroxide, and oleate. By optimizing the ratio of glycerol : oleic acid : calcium glyceroxide at 1 : 1 : 0.015, the maximum conversion of oleic acid of up to 86% in 10 h was obtained via synthesis. The proposed method for esterification of glycerol with higher carboxylic acids in the presence of a calcium-containing catalyst avoids the stage of purification from the catalyst to obtain a composition with multifunctional additive properties for the processing of polyvinyl chloride.

OPTIMIZATION OF RAWHIDE COLLAGEN DEFIBRILLIZATION PROCESS

The paper features the rawhide collagen defibrillization process in the elastic leather materials manufacturing. Optimal colloid-chemical properties of semi-processed products were defined by way of using mathematical optimization of rowhide liming process. It was found that during the alkaline treatment of raw material (in the operating temperature range) the degree of defibrillation of raw material raises (in proportion to the derm collagen swelling) with increase in the ratio of process solution to the mass of raw material, and the extremum of hydrothermal stability and leather yield can be estimated. It was also shown that the degree of swelling decreases with a decreasing ratio of sodium sulphide and sodium hydrosulphide, and the leather area yield reaches the maximum value at the equal proportion of these reagents. Multicriteria optimization of rawhide liming process using the Harrington’s desirability function was carried out. The developed technology of soaking and liming was tested under production conditions. The above-mentioned low-waste technology provides elastic leather materials with a yield increase by 3.5%, which meet the industry standards requirements.

Carbon footprint of the Novosibirsk region Waste sector

To achieve carbon neutrality in Russia by 2060, it is necessary to regulate the volume of greenhouse gases at the regional level. Among all regions of Russia, the balance of greenhouse gases by sectors of the economy is calculated only for the Sakhalin region. The study of this article aims to assess the level of greenhouse gas emissions from the Waste sector in Novosibirsk region, taking into account territorial and sectoral characteristics. During the study, the authors used the methodology of the Intergovernmental Panel on Climate Change and the methodological recommendations of the Ministry of Natural Resources and Environment of Russia № 15p, through which the authors evaluated methane (CH4) and nitrogen oxide (N2O) emissions from solid waste disposal and from the treatment of liquid waste and effluents. Greenhouse gas emissions in 2020 were 1.57 mln. t CO2 equivalent, including 1.09 mln. t CO2-equivalent from solid waste disposal and 0.48 mln. t CO2 equivalent from liquid waste and sewage treatment. The main contributor to the growth of greenhouse gas emissions was emissions from solid municipal waste disposal, increasing by 0.06 million tons of CO2-equivalent over the past four years. Analysis of the current state and calculation has shown that the Novosibirsk Region has a low level of infrastructure development for separate waste collection, capacities of waste-sorting plants, as well as equipment of the centralized sewage system and quality of waste and effluent treatment. Therefore, it is necessary to introduce resource-saving and low-waste technology, the formation of a closed-cycle economy, the implementation of the transition to the multi-container separate collection of waste. It is advisable to disseminate technologies for collection of landfill gas and its use as fuel, the direction of organic waste for the production of commercial compost, biogas or feed and feed additives, as well as the development of technologies for obtaining biochar from organic waste and its further use in agriculture.

Promising methods for hydrometallurgical processing of copper slag

Metals are important in many modern industries. Due to the depletion of their natural resource base, it is necessary to adapt, which means developing new and optimizing existing methods of extraction of valuable components from ore materials. Only comprehensive processing of copper metallurgical slags will solve the problem of resource recovery and the creation of low-waste technology, which has great economic, environmental, and social importance. Hydrometallurgical technologies take into account the specific conditions of the system and the physical and chemical properties of metals when developing and selecting the method of extraction. This article provides a review of the current state and prospects of development technologies used for base metal extraction by leaching with the use of inorganic acids and environmentally safe reagents, the methods are conditionally divided into two groups. The listed studies have made a significant contribution to solving the problem of processing metallurgical slags, however, none of the technologies has gone beyond the scope of laboratory and semi-industrial tests. Noted a tendency to reduce the concentrations of leaching agents by certain pre-treatment of raw material, as well as the transition to ubiquitously use "green technologies": such as bioleaching and organic acid leaching. Directions are suggested to solve the problem of rational use of raw materials and increase the sustainability of the future material cycle.

Low-waste technology for the production of bioethanol from sorghum grain: Comparison of Zymomonas mobilis and Saccharomyces cerevisiae in fermentation with stillage reusing

Zymomonas mobilis and Saccharomyces cerevisiae have been used for simultaneous saccharification and fermentation of sorghum grain with the reuse of the stillage. This study investigated the effects of replacing half the water by a stillage liquid fraction on ethanol yield and volatile compound synthesis. Studies have shown that Z. mobilis is more efficient in ethanol production (55.96–61.48 g/L) than S. cerevisiae (55.26–58.38 g/L). Additionally, Z. mobilis had the advantage of a shorter fermentation time (48 h) and lower fermentation temperature (35 °C) than distillery yeast. No relationship was observed between successive stillage reusing and ethanol content. Reusing the liquid fraction of the stillage did not increase the amount of volatile compounds identified in the raw distillates. Significant differences were observed in the volatile compounds profile of bacterial and yeast raw distillates. Acetaldehyde was the dominant compound in bacterial raw distillates, whereas 3-methylbutan-1-ol was the dominant compound in yeast raw distillates. The characteristic of Z. mobilis was the production of fewer (4.31–6.03 g/L spirit 100%) volatile compounds compared to yeast (4.04–7.44 g/L spirit 100%). The fermentation process reusing the liquid part of the stillage made it possible to reduce process water consumption and waste generation in bioethanol production from sorghum grain. In addition, Z. mobilis made ethanol production from sorghum grain grown in Eastern Europe more beneficial.

ИССЛЕДОВАНИЕ ТЕРМОРЕАГЕНТНОГО МЕТОДА ВОССТАНОВЛЕНИЯ РЕГЕНЕРАЦИОННЫХ РАСТВОРОВ NA-КАТИОНИТОВЫХ ФИЛЬТРОВ

In this paper, we analyzed a method for the thermochemical recovery of spent regeneration solutions of Na-cation exchange filters containing chlorides, calcium and magnesium ions, with the introduction of one precipitant (soda ash) and heating in an autoclave at a pressure of 0.2–0.41 MPa, as well as proposed on its basis the technology of recycling solutions of sodium chloride. Spent regeneration solutions after the process are still discharged into wastewater or directly into natural reservoirs. The concentration of chlorides in such effluents significantly exceeds the MAC for wastewater sent to water bodies (MAC = 350 mg/dm3), which affects the properties of water in natural water bodies.It should also be noted that the MAC of wastewater discharged after regeneration and washing of cationexchangers is also higher in terms of magnesium content (MAC Mg = 50 mg/dm3), and in regeneration solutions the concentration reaches 200 mg-eq/l. Known reagent methods for the recovery of sodium chloride solutions (alkaline, lime-sulfate, phosphate, oxalate, etc.) allow the precipitation of hardness salts only when they are used in combination, which leads to a multi-stage purification process, and also increases the number of pieces of equipment used.According to technical and economic indicators, these methods are not implemented in production. The method developed and proposed in the article can eliminate and prevent the discharge of spent sodium chloride solutions into water bodies while obtaining products suitable for sale, which will ensure the recycling of Na-cationite filter solutions and the low-waste technology for their purification. When developing the method, special attention was paid to indicators of residual hardness and filtering properties of the resulting suspension.Guided by the results obtained on the content of calcium and magnesium ions and the removal of the solid phase, the influence of the content of sodium carbonate and sodium chloride on the solubility of calcium and magnesium carbonates in aqueous systems is also considered: NaCl − CaCO3 − H2O, NaCl – CaCO3 – Na2CO3 − H2O and NaCl − (MgOH)2 CO3 − H2O и NaCl – (MgOH)2 CO3 – Na2CO3 − H2O in the temperature range 120÷140 0C.

Optimization of Conditions for Processing of Lead–Zinc Ores Enrichment Tailings of East Kazakhstan

This article presents the results of studies of a low-waste technology for processing enrichment tailings using a combined enrichment–hydrometallurgical method. After washing the enrichment tailings from harmful products and reducing their size, multi-stage flotation of the crushed material of the enrichment tailings was carried out. The use of a new reagent in the flotation process was studied in order to ensure the maximum recovery of the main valuable components from the enrichment tailings. A new collector of Aero 7249 (Shenyang Florrea Chemicals Co., Ltd., Shenyang, China) type was used for the flotation. The recovery of valuable components was as follows: Cu, 6.78%; Zn, 91.69%; Pb, 80.81%; Au, 95.90%; Ag, 82.50%; Fe, 78.78%. Tailings of the flotation were re-enriched using a fatty acid collector (sodium oleate). Additional (reverse) flotation resulted in obtaining a product corresponding to the composition of building sand in terms of the content of valuable components of the waste rock. The studies of the conditions for processing the enrichment tailings of lead–zinc ore indicate the possibility of its optimization in order to maximize the involvement of waste in the production.

Low-Waste Mining Technology for Structurally Complex Deposits with Mixed-Type Process Flows of Ore Extraction and Processing

Low-Waste Mining Technology for Structurally Complex Deposits with Mixed-Type Process Flows of Ore Extraction and Processing

Low-Waste Technology for Water Purification from Iron Ions

Low-Waste Technology for Water Purification from Iron Ions

Canary in the coliform mine: Exploring the industrial application limits of a microbial respiration alarm system.

Fundamental ecological principles of ecosystem-level respiration are extensively applied in greenhouse gas and elemental cycle studies. A laboratory system termed CEMS (Carbon Dioxide Evolution Measurement System), developed to explore microbial biofilm growth and metabolic responses, was evaluated as an early-warning system for microbial disturbances in industrial settings: in (a) potable water system contamination, and (b) bioreactor inhibition. Respiration was detected as CO2 production, rather than O2 consumption, including aerobic and anaerobic metabolism. Design, thresholds, and benefits of the remote CO2 monitoring technology were described. Headspace CO2 correlated with contamination levels, as well as chemical (R2 > 0.83-0.96) and microbiological water quality indicators (R2 > 0.78-0.88). Detection thresholds were limiting factors in monitoring drinking water to national and international standards (0 CFU/100 mL fecal coliforms) in both open- (>1500 CFU/mL) and closed-loop CO2 measuring regimes (>100 CFU/100 mL). However, closed-loop detection thresholds allow for the detection of significant contamination events, and monitoring less stringent systems such as irrigation water (<100 CFU/mL). Whole-system respiration was effectively harnessed as an early-warning system in bioreactor performance monitoring. Models were used to deconvolute biological CO2 fluctuations from chemical CO2 dynamics, to optimize this real-time, sustainable, low-waste technology, facilitating timeous responses to biological disturbances in bioreactors.

Technology and Technical Support for Rough Feed Treatment for Ecological and Low-Waste Cattle

The article provides a brief analysis of technological solutions for preparing rough feeds for feeding with an emphasis on the existing shortcomings in the implementation of the technological process, taking into account its technical support. There have been proposed and considered two technical and technological schemes for the preparation of rough feeds, the effectiveness of which is aimed at their rational use as a factor of low-waste technology and reducing the influence of a secondary factor when performing the considered technological process. The pollution of the airspace of the livestock building and the skin of animals with dust particles, including small particles of feed and microflora of dry food, can be considered as the very factor affecting the environmental safety of the internal space of the livestock building and indirectly the quality of products (milk). This is confirmed by the presented research results for separate technological operations.

Low-Waste Mining Technology for Structurally Complex Deposits with Mixed-Type Process Flows of Ore Extraction and Processing

Low-Waste Mining Technology for Structurally Complex Deposits with Mixed-Type Process Flows of Ore Extraction and Processing

Substantiation of parameters low-waste technology of extraction of blocks

By definition, the appearance and surface quality of the units (deviation from a right angle of two adjacent faces for the entire height; the presence of the projections and depressions; the number of chipped corners and the total length of the chip edges; the number of diagonal cracks) subject to the methods of their production, has allowed to establish the influence of these factors on the output plates when cutting.

Production of mint whey drink at private and collective farms and agricultural holdings

This research aimed the development production of prophylactic whey drinks which allows enhancing the efficient use of resources of high-value dairy byproducts including cheese and curd whey. High level of safety and quality of milk supplied, soft, semi-hard cheeses and dry-curd cottage cheese, as well as curd whey were adapted. Pepper mint was added as a source of extra vitamins, mineral salts, macro- and micronutrients, dietary supplements. The first recipe for a whey drink with the addition of mint syrup includes curd whey 1 L, mint 1 g, sugar 30 g, water 25 mL, citric acid 4 g. The second recipe differs from the first in that peppermint contains 2 g, the third recipe for mint contains 3 g. The amount of whey, sugar and citric acid in the second and third recipes corresponds to the first recipe. Plant-based components of whey drink act as analeptics and expand the assortment. Also, the research aimed to develop zero waste and low waste technology for private and collective farms and agricultural holdings and as a result, provide the solution to whey disposal issue.