Optimum Process Conditions Research Articles

Effects of optimizing fermentation time and stabilizers using response surface methodology on physicochemical properties of camel milk yoghurt

The objective of this study was to produce camel milk yoghurt with desired qualities using optimized processing conditions (fermentation time) and ingredients (stabilizer and calcium chloride). The conditions were obtained through Response Surface Methodology (RSM) by lactic acid fermentation by inoculating the milk with Lactobacillus delbrueckii subsp. Bulgaricus (YF-L903, CHR Hansen, Denmark. The study also determined the effects of fermentation time and ingredients on the quality of yoghurt. Fermentation time ranged from 2 to 22 h while stabilizer (corn starch) and calcium chloride (salt) ranges were 1.65–3.34 and 0.061–1.23 % respectively. The quality was monitored hourly for a fermentation period of 2–22 h by determining pH, total titritable acidity (TTA) and viscosity. Results indicated that viscosity was influenced by fermentation time, stabilizer and calcium chloride. The viscosity was increased from 0.01 to 0.4 and 0.01 to 0.3 by fermentation time, 0.01 to 0.2 and 0.01 to 0.3 by stabilizer and 0.01 to 0.5 and 0.01 to 0.6 Pa s by calcium chloride. Whereas the combined effects of calcium chloride and stabilizer increased the viscosity of yoghurt to 0.94 Pa s. Prolonged fermentation time, led to an increase in TTA and a decrease in pH. The finding from this study indicated that the optimal conditions required to produce camel milk yoghurt with desired qualities are a fermentation time of 10 h using 2.33 and 0.60 % corn starch and calcium chloride respectively. Under these conditions the produced camel milk yoghurt quality properties were a pH of 4.07, 0.32 % TTA and a viscosity of 0.35 Pa s.

Optimization of Hot Embossing Condition Using Taguchi Method and Evaluation of Microchannels for Flexible On-Chip Proton-Exchange Membrane Fuel Cell.

Hot embossing is a manufacturing technique used to create microchannels on polymer substrates. In recent years, microchannel fabrication technology based on hot embossing has attracted considerable attention due to its convenience and low cost. A new evaluation method of microchannels, as well as an approach to obtaining optimal hot embossing conditions based on the Taguchi method, is proposed in this paper to fabricate precise microchannels for a flexible proton-exchange membrane fuel cell (PEMFC). Our self-made hot embossing system can be used to fabricate assorted types of micro-channel structures on polymer substrates according to various applications, whose bottom width, top width, height and cross-sectional area vary in the aims of different situations. In order to obtain a high effective filling ratio, a new evaluation method is presented based on the four parameters of channel structures, and the Taguchi method is utilized to arrange three main factors (temperature, force and time) affecting the hot embossing in orthogonal arrays, quickly finding the optimal condition for the embossing process. The evaluation method for microchannels proposed in this paper, compared to traditional evaluation methods, incorporates the area factor, providing a more comprehensive assessment of the fabrication completeness of the microchannels. Additionally, it allows for the quick and simple identification of optimal conditions. The experimental results indicate that after determining the optimal embossing temperature, pressure and time using the Taguchi method, the effective filling rate remains above 95%, thereby enhancing the power density. Through variance analysis, it was found that temperature is the most significant factor affecting the hot embossing of microchannels. The high filling rate makes the process suitable for PEMFCs. The results demonstrate that under optimized process conditions, a self-made hot embossing system can effectively fabricate columnar structure microchannels for PEMFCs.

ANN modeling of tincal ore dehydration

Abstract Tincal ore is a preferred material in many industrial applications, especially without water. It is important to dehydrate boron ores so that they can be used in materials engineering. For this purpose, some heat treatments must be carried out. Heat treatments are associated with additional costs. It is possible to model heat treatments using artificial intelligence methods, determine optimal process conditions and achieve the desired results with much less processing effort. In this study, a dehydration process was first carried out to dehydrate tincal ore and ANN (artificial neural networks) modeling of this process was investigated using the parameters of temperature, time and amount of ore. The possibility of achieving the desired H2O, B2O3 and Na2O concentration values in the dewatering process in the shortest time and by the shortest route was investigated using the ANN model. In the modeling, a single model was designed for the changes in concentrations and this model was trained separately for each. The result of the modeling was that the R 2 values for all three models were close to each other and were approximately 0.98. It was thus shown that the ANN method can be successfully modeled for dewatering processes.

Application of the sono-Fenton/UV process on the treatment of table olive processing wastewater

AbstractThe Mediterranean Basin economies of Spain, Italy, Greece, and Turkey depend on the table olive and olive oil industries. Table olive processing wastewater characteristics and quantity depend on olive varietal and processing methods. Olives and processing methods provide phenol, suspended particles, dissolved inorganic solids, and refractory organics. Due of its complexity, conventional methods struggle to tackle table olive processing wastewater. A novel approach to enhanced oxidation processes integrates many ways to boost hydroxyl radical formation and scale up efficiency. UV assisted sono-Fenton process as a modified Fenton process was applied to table olive washing wastewater to achieve high formation of hydroxyl radicals. When UV assisted sono-Fenton experiments executed to determine the optimum reaction conditions, the effects of hydrogen peroxide, ferrous ion concentrations and reaction time on the oxidation of table olive washing wastewater investigated by using a statistical experimental design. Chemical oxygen demand (COD), total organic carbon (TOC) and phenol removal efficiencies were examined by keeping the pH constant. The UV assisted sono-Fenton process achieved 53% phenol, 68% TOC, and 80% COD removal efficiencies. The results show that the UV assisted sono-Fenton process can treat effectively table olive processing wastewater. Optimum reaction conditions for the UV assisted sono-Fenton process were determined. UV assisted sono-Fenton process provides a significant reduction in reaction time and minimizes the costs of process associated with low chemical requirements. So, these optimum reaction conditions were resulted in low sludge production at the UV assisted sono-Fenton process while treating table olive processing wastewater.

Stabilization of polyacrylonitrile-based fiber with a quasi-traveling microwave applicator

This study introduces a novel microwave applicator and optimized processing conditions to enhance the stability of Polyacrylonitrile (PAN)-based precursor fiber (PF). The innovative microwave applicator facilitates the propagation of the electromagnetic (EM) field akin to a quasi-traveling wave, thus circumventing standing wave nodes. This ensures a uniform thermal distribution and broadens the heating zone. Utilizing this applicator, the PF undergoes thermal stabilization in a streamlined two-step process, completing in just 13 min, a significant improvement over the conventional 90-min process. This not only saves manufacturing time, promoting energy efficient manufacturing but also aligns with the global trend towards green energy and lightweight carbon fiber-reinforced polymer matrix composites, potentially catalyzing rapid economic growth. Fiber characterization through Raman spectroscopy (RS), X-ray diffraction (XRD), differential scanning calorimetry (DSC), and complex permittivity measurements reveals that the microwave-processed fiber meets the standard of commercial stabilization fiber (SF).

Copper Ion Removal by Adsorption Using Fly Ash-Based Geopolymers: Process Optimization Insights from Taguchi and ANOVA Statistical Methods.

The present study aimed to use geopolymer materials synthesized from different fly ashes, which are promising for the adsorption of copper ions from aqueous solutions. The characterization of fly ashes and prepared adsorbents was performed by energy-dispersive X-ray spectroscopy (EDS) analysis, Brunauer-Emmett-Teller (BET) surface area analysis, and Scanning Electron Microscopy (SEM). Taguchi and ANOVA methods were used to predict the effect of different working parameters on copper ion removal by prepared geopolymers. Based on data obtained by the Taguchi method, it was found that the factor most influencing the adsorption process is the type of adsorbent used, followed by the solution pH, the reaction time, the adsorbent dose, and the initial copper ion concentration. The ANOVA results agree with the Taguchi method. The optimal conditions of the adsorption process were: fly ash C modified by direct activation with 2 M NaOH, at 70 °C for 4 h, solution pH of 5, initial pollutant concentration of 300 mg/L, 40 g/L adsorbent dose, and 120 min of reaction time. Copper ion removal efficiency was determined experimentally under optimal conditions, achieving a value of 99.71%.

Effect of the Saccharin Concentration on Electrodeposition of the Fe-Ni Alloy

The FMM (Fine Metal Mask) used in the OLED display manufacturing process is a metal sheet with holes formed to allow the deposition of diode material only in the sub-pixel area. To prevent deformation and misalignment of the FMM (Fine Metal Mask) caused by heat during the RGB organic deposition process, an Invar plate with a thermal expansion coefficient (CTE) close to 0 is used. The Invar sheet applied to the current FMM is manufactured through a metallurgical process, and its final thickness after rolling is 20 micron. However, due to limitations in reducing thickness with the rolling process, for manufacturing FMM with a thickness of under 10 micron for next-generation high-resolution (UHD-level) displays, the bottom-up electroplating process is suitable. However, to maintain the shape of the electroplated Invar sheet while ensuring commercial-grade low CTE, heat treatment at temperatures exceeding 600℃ for an extended period is required, utilizing thermo-mechanical processing methods. If uniformity in the microstructure composed of nano-grains is ensured in the electroplated Invar alloy in the As-deposited, it is possible to increase the efficiency of the process by reducing the heat-treatment processing cost.Therefore, in this study, we investigated the microstructural evolution in the Invar alloy by controlling the surface stress of the electroplated layer during pre-plating. We controlled the key additive, saccharin, in the Fe-Ni alloy electrolyte to assist the diffusion of iron and nickel ions. By examining the relation between microstructural uniformity, determined by the plated layer, and CTE, we propose optimized process conditions for the pre-plated Invar sheet.

Manufacture of the Invar Film Using a Continuous Electrodeposition Technique for the OLED FMM

In the manufacturing processes of red-green-blue (RGB)-type organic light emitting diode (OLED) displays, Invar is used as a material for the fine metal mask (FMM), which guides the evaporated diode materials through its small holes onto the correct positions of the substrate glass. The electroforming of Invar is an immediate hot issue in the RGB-type OLED display industries. Contrary to the conventional top-down method of pyrometallurgically producing Invar, a bottom-up approach of electroforming is a promising technology for producing very thin FMMs to achieve high-quality images in such displays. The present authors have recently presented that the electroformed Invar via sophisticated heat treatment exhibits the coefficient of thermal expansion (CTE) as low as that of the conventional Invar. The current work has been aimed at investigating the effect of the microstructure evolution on the CTE during heat treatment of the electroformed Invar. Finally, we propose optimal process conditions to manufacture the Invar FMM applied for an ultra high definition (UHD) grade of the OLED display.

Water recovery and treatment of spent filter backwash from drinking water using chemical reactor-ultrafiltration process

During routine operations of water treatment plant (WTP), production of spent filter backwash water (SFBW) is inevitable that imposes high operation and maintenance costs. The study investigates treatment and water recovery from SFBW from WTP via combined chemical reactor-ultrafiltration (CR-UF) process. The daily generated SFBW from full-scale treatment plants were treated by the pilot pant of CR-UF process, which is comprised of a primary sedimentation basin, coagulation and flocculation tank immersed UF membrane module. The optimum conditions for CR process were pH 7.5 and FeCl3 dose 20 mg/L, which led to significant removal of turbidity, color, and UV254 that are equal to 97.11 ± 0.10 %, 63.31 ± 1.98 %, and 30.74 ± 0.72 %, respectively. The CR-UF produced permeate with very low turbidity (0.3 ± 0.01 NTU and 93.0 ± 1.1 % removal) has met the water standard of 5 NTU. During the continuous operation of CR-UF process and after three consecutive cycles of UF backwashing, initial flux slightly declined from 8.57 L/m2.h in the 1st cycle to 8.20 L/m2.h in the 3rd cycle, demonstrating the irreversible fouling due to nanoparticle blocking. In four proposed blending of SFBW, the amount of UV254 and TOC did not change significantly (<1 % increase), and additional coagulant was not needed. The hazard index (HI) values for all the population groups were <1, suggesting a minimal adverse health risk regarding the consumption of treated SFBW by the CR-UF process. Overall, the permeate stream of CR-UF process can be reused as a source of raw water for drinking water treatment plant.

Utilization of RESOLV with polymer to produce prazosin hydrochloride nanoparticles and optimization of the process parameters

In this study, rapid expansion of a supercritical solution into a Liquid Solvent (RESOLV) was used for the first time to produce pharmaceutical nanoparticles of Prazosin hydrochloride (PRH). The Taguchi method (robust design) was utilized to design the experiments and ensure obtaining the optimal process conditions. The pressure (15–25 MPa), temperature (308–328 K) and nozzle diameter (300–700 μm) effects on the morphology and size distribution of the resulting particles were also examined. The size of the particles decreased from about 40 μm to the range of (252–418 nm). FTIR, DLS, FESEM, XRD, DSC were used to characterize the primary and processed PRH particles. According to DSC investigations, RESOLV-produced PRH showed lower crystallinity than original PRH.

Waste ramie fiber/EVA composites with wideband sound-absorbing performance with mixing and foaming process

Increasing noise pollution and ramie fibers waste resource problems need to be solved urgently. In order to resolve the problems, the porous sound-absorbing composites with high sound-absorbing performance were prepared by using waste ramie fibers as reinforcement materials, vinyl acetate copolymer (EVA) as matrix materials, azodicarbonamide(AC) as foaming agent, ZnO as auxiliary foaming agent, and dicumyl peroxide (DCP) as cross-linking agent, which were mixed in a two-stick mixer according to a certain ratio and then hot-pressing process. The process conditions were optimized using single factor analysis. Under the optimal process conditions, the sound-absorbing composites had a maximum sound absorption coefficient (SAC) of 0.72, an average SAC of 0.37, and a noise reduction coefficient (NRC) of 0.41. The sound absorption performance grade reached level III, and the sound absorption performance was excellent in the frequency range of 600 ∼ 6300 Hz. The introduction of foaming agents made the composites with more pores, and the average SAC of foamed composites increased by 346 %(compared with the unfoamed composites). Then, the sound-absorbing mechanism was analyzed. This study presents a novel approach to the recycling and reusing of the waste ramie fibers. It also provides a theoretical and experimental basis for the development of sound-absorbing composites with wider sound absorption band, larger (sound absorption coefficient) SAC and wider application, which is of great significance for sound absorption in the building fields.

The hybrid approach of genetic algorithm and particle swarm optimization on reduced weld line defect in plastic injection molding

Weld lines are a serious defect observed in plastic injection molded parts, impacting both their cosmetic appearance and mechanical properties. Controlling the conditions of plastic injection is crucial to mitigate these weld lines. This study introduces a novel approach to identify polypropylene injection molding (PIM) conditions aimed at reducing weld lines in polypropylene parts. The PIM conditions considered in this study include melt temperature, injection pressure, packing pressure, packing time, and cooling time. An orthogonal array Taguchi L27 design was employed for the experimental setup, producing 27 polypropylene parts with varying combinations of process conditions. The width of weld lines generated on the parts’ surfaces was measured using an optimum microscope for all trials. Parametric analysis was conducted using response surface plots and contour plots to estimate the process conditions yielding minimum weld lines. Analysis of variance and regression analysis were employed to interpret the experimental data, with the resulting regression equation used to predict weld lines for a set of PIM process conditions. Finally, two efficient optimization algorithms, genetic algorithm (GA), and particle swarm optimization (PSO), were implemented using MATLAB programming to estimate the optimum process conditions for minimizing weld lines. The GA and PSO predicted weld line widths of 6.12302 μm and 6.123 μm, respectively, representing an 18.51% improvement in results. These findings demonstrate that the novel approach presented in this study can be effectively and reliably applied to address plastic product defects in the industry.

Optimization of Processing Conditions for Rice Bran-based Bioplastics Through Extrusion and Injection Molding

Optimization of Processing Conditions for Rice Bran-based Bioplastics Through Extrusion and Injection Molding

Protective silicide coating fabricated on ductile VNbTa refractory complex concentrated alloy: Microstructure, high-temperature oxidation and wear behaviors

VNbTa refractory complex concentrated alloy (RCCA) possesses broad application prospects in a wide temperature window owing to its remarkable strength-ductility synergy and super rolling formability, whereas poor oxidation resistance will give rise to excessive wear above 800 ℃. In this contribution, we aim to fabricate a protective silicide coating on VNbTa RCCA for the purposes of enhancing high-temperature oxidation as well as wear resistance. Microstructural characterizations revealed that a uniform and intact coating was obtained under the optimized processing condition of pack cementation. The coating is mainly composed of a single-phase (VNbTa)Si2, along with a thin M5Si3-type interdiffusion zone. Compared with bare alloy, the coated specimens exhibit remarkable oxidation resistance at 1000 ℃ due to the preferential formation of protective SiO2 scale. Meanwhile, the coated specimens maintain desirable wear resistance from 800 ℃ to 1000 ℃. The results of this study would offer a valuable reference to expedite the future engineering applications of RCCAs.

Strongly active and environmentally friendly WO3/C3N4 photocatalysts for converting cyclohexane to cyclohexanone under ambient conditions

C–H bond activation under mild conditions remains a great challenge in the chemical industry, while catalytic cyclohexane oxidation is inefficient and often requires organic solvents and strong oxidants. This study constructed a C3N4/WO3 Z-type heterojunction catalyst to efficiently convert cyclohexane into cyclohexanone and cyclohexanol (KA oil) through aqueous phase oxidation by O2 under visible light irradiation. With strong redox performance and high photogenerated carrier separation ability, the proposed composite catalyst can produce the key active species for cyclohexane oxidation in the H2O–O2 system. The reaction mechanism was clarified through experiment and DFT theory calculation. Cyclohexane was converted into cyclohexyl radical under the action of ·OH, and ·O2− converted most products into cyclohexanone. The catalyst can be recycled under optimized process conditions while reaching a KA oil yield of 139.73 μmol g−1 h−1 and a selectivity of 93.1%.

Advanced orthogonal analysis of multi-factorial interactions influencing co-combustion performance and pollution reduction potential of coal gangue and biomass in oxy-fuel combustion conditions

In the current scenario of increasing energy scarcity and stricter environmental protection requirements, the utilization of coal gangue and biomass energy is gaining attention worldwide. Biomass and coal gangue are complementary in nature, and their co-combustion can improve the burnout efficiency of coal gangue and reduce pollutant emissions. In this study, coal gangue and wheat straw are selected as research subjects, the optimal process conditions for their co-combustion under the coupling of multiple parameters in oxy-fuel atmosphere through orthogonal experiments are investigated. The results indicate that the most significant factor influencing combustion characteristics is the heating rate. When the biomass content is 45 %, O2 concentration is 50 %, heating rate is 30℃/min and particle size is 180–250μm, the flammability and comprehensive combustion indexes of the samples are maximized, which indicates the optimum combustion characteristics. The primary factor affecting pollutant release is biomass content. When the biomass content is 45 %, O2 concentration is 75 %, combustion temperature is 700℃, and particle size is 180–250μm, the pollutant release concentration is minimized.

Exploring optimal high-pressure processing conditions on a (poly)phenol-rich smoothie through response surface methodology

Fruit and vegetable-based smoothies offer an excellent way to increase the consumption of (poly)phenols. Among preservation technologies, required to extend their shelf-life, high-pressure processing (HPP) coped with the main drawback of traditional treatments. In this study, response surface methodology (RSM) was used to predict the optimal combination of pressure and holding time to obtain a microbiologically safe beverage without compromising sensory properties and (poly)phenols. Thus, different pressure levels (300–600 MPa) and holding times (2–10 min) were applied to a (poly)phenol-rich green smoothie. All HPP-treated smoothies showed reductions in microbial counts compared to untreated smoothie, and no changes in pH, total soluble solids, total phenolic content, antioxidant capacity and colour parameters, except a decrease of red/green coordinate (a*), and then maintaining the original green colour. The several (poly)phenol subclasses determined by LC-MS/MS were differently influenced by HPP conditions, even total (poly)phenolic compounds were similarly affected among HPP treatments. The overall desirability function revealed 600 MPa and 6 min as the optimal combination of pressure and holding time on the smoothie. Our research highlights the effectiveness of pressure-based technologies as preservation tool in fruit and vegetable-based beverages, along with the maintenance of their appreciated characteristics, such as colour or (poly)phenolic compounds.

Optimizing delignification and saccharification process for sawdust processing using a central composite design

AbstractLignocellulosic mass consists of cellulose, hemicelluloses, and lignin. Although biomass promises to be efficiently used for biofuel production and many other value‐added products, lignin present in lignocellulosic biomass affects the hydrolysis of cellulose and hemicelluloses, making it necessary to develop techniques that provide better lignin removal efficiency and high cellulose hydrolysability. The current work aims to maximize lignin removal in sawdust and develop an understanding of the hydrolysis of pretreated biomass for sugar production. Different parameters such as solvent to solid ratio, temperature, and reaction time have been considered based on the design of experiment to understand the effect on the delignification and saccharification processes. After treating sawdust for 1.5 h, it was observed that a maximum of 85% lignin was removed at a temperature of 131°C and solid loading of 16 g. Subsequent hydrolysis of delignified sawdust at 131°C temperature, solvent to solid ratio 15, and 0.5 h resulted in a maximum reducing sugar production of 26.82 mg/mL. The study elucidated the optimum conditions for the effective processing of sawdust in terms of delignification and saccharification, leading to maximum benefits in lignin removal and sugar production.

Non-Thermal Technology Approaches to Improve Extraction, Fermentation, Microbial Stability, and Aging in the Winemaking Process

Research into non-thermal wine processing technologies is constantly evolving due to the increasing trend towards high-quality, minimally processed, and preservative-free wines. Technologies such as high-power ultrasound, high hydrostatic pressure, pulsed electric field, ultra-high pressure homogenization, and, more recently, cold plasma are some of the best examples currently being explored. This article provides an overview of the latest scientific research into these five non-thermal technologies and their current status in relation to winemaking. By exploring the potential applications of these technologies, it becomes possible to enhance extraction, shorten maceration time, inactivate microorganisms and oxidative enzymes, reduce the addition of chemical additives, accelerate aging, improve wine quality, and much more. However, further experiments are necessary to better comprehend the short- and long-term impacts on the overall quality of the wines produced, especially in terms of sensory characteristics and consumer acceptance. Optimizing processing conditions and scaling up are also of paramount importance to ensure better performance of these technologies at the various stages of winemaking. Additionally, a combined technologies approach has been highlighted as one of the future directions to overcome the limitations of processing with a single technology.

Efficient continuous synthesis of long-chain alkylbenzenes catalyzed by ionic liquids in microreaction systems

Alkylbenzene (LAB) is an important benzene derivative that can be used as a raw material for high-performance anionic surfactants such as alkylbenzene sulfonates (LAS) to meet the new requirements for surfactants in many fields. LAB can be synthesized through Friedel-Crafts reaction in the presence of acidic catalysts as alkylating agents, which is commonly used in the production of fine chemicals. In this work, a novel and efficient continuous flow micro reaction system was introduced to enhance the production of long-chain alkylbenzene catalyzed by [(CH3)3NH][Al2Cl7] ionic liquid. The optimal conditions were investigated for the synthesis of long-chain alkylbenzenes with the 1-tetradecene and mixing α-alkenes of C14-C16 from Fischer-Tropsch process. The results showed that the yield of benzene alkylation can achieve 99 % under the optimal process conditions which the reaction tube length was 2000 mm, the reaction temperature was 30 ℃, the catalyst dosage was 0.30 mL/min and the molar ratio of aluminum chloride to trimethylamine hydrochloride was 2:1. In addition, α-alkenes with C14-C16 lead to deactivation of the ionic liquids catalyst easier because of transfer of AlCl3 from the ionic liquid to the organic phase compared to the pure 1-tetradecene as an alkylating agent. Continuous synthesis of the long-chain alkylbenzenes catalyzed by ionic liquids can achieve in the microchannel reaction system by controlling the flow patterns.