Production Flow Research Articles

The Effect of Cone Area Variations on the Continuous Discharges Flow (CDF) Method Sedimentation Unit as a New Method for Raw Water Turbidity Removal

The Sedimentation Unit Continuous Discharges Flow (CDF) method is a modification by adding a continuous and controlled discharge flow as a net force acting on the particles to increase the efficiency of turbidity removal by applying the principle of a leaky tank at the bottom of the settling zone. The production capacity of the sedimentation unit using the CDF method is reduced due to the CDF flow of 6% of the flow rate so it needs to be recirculated. This study aims to maintain the production flow rate of the system and increase the efficiency of turbidity removal by recirculating the CDF flow. The research reactor consisted of a coagulation unit, flocculation unit, and sedimentation method using 6% CDF with a flow rate of 240 L/hour and 360 L/hour, and variations in the recirculation flow of 6% CDF to the flocculation unit were 0%, 25%, 50%, 75%, and 100 %. The sedimentation detention time at a flow rate of 240 L/hour and 360 L/hour was 90 minutes and 60 minutes, respectively. Research on a laboratory scale with raw water turbidity of 25,536 NTU. The results showed that the greater the CDF flow recirculation value, the higher the turbidity removal efficiency. Rank Spearman analysis, the correlation value of the CDF flow recirculation value to the efficiency of removal of turbidity is 0.980 and the significance value is 0.00 which means strong and significant. The highest turbidity removal efficiency was achieved at the 100% CDF flow recirculation value, ie at 240 L/hour flow rate was 87.21% with final turbidity 3.267 NTU, while at 360 L/hour flow rate was 82.50% with final turbidity 4,528 NTU. Uprating the flow rate in the experiment was able to produce a final turbidity value that met the drinking water quality standard, which was 5 NTU

ALUR PROSES PRODUKSI SAYUR ORGANIK PADA CV. REJA MAYUR

Vegetables are food ingredients that are needed by humans, but there are other things that must be known that most vegetables consumed today cannot be separated from the influence of chemical substances. Vegetables cultivated under the influence of chemicals will mostly contain chemical residues which can be bad for humans who consume them continuously. Therefore, it is necessary to have an agricultural system that is more environmentally friendly or commonly referred to as organic farming to deal with this problem. The purpose of this study is to describe the process flow of organic vegetable production at CV. Reja Mayur. This research is expected to provide information to the public regarding the flow of organic vegetable production and can become a database for further research. The research method used is the method of active participation and interviews, where the results will be analyzed using descriptive methods. The results of this study are on CV. Reja Mayur has 7 stages of organic vegetable production which consist of tillage, seeding, transfer of seeds, nutrition, maintenance, pest control, and harvest and post-harvest.

Review of simulation software for cyber-physical production systems with intelligent distributed production control

ABSTRACT Many intelligent distributed production control architectures have been developed for cyber-physical production systems (CPPSs), but the difficulty in predicting performance has hindered acceptance by industry. Performance predictions for systems with conventional control can be made by simulating product flow using discrete-event simulation (DES) software. However, DES is inadequate for capturing the intricacies of intelligent distributed production control architectures. Alternatively, agent-based simulation (ABS) software is more effective for capturing distributed intelligence. A hybrid discrete-event and agent-based simulation tool combines the strengths of both approaches, making it effective for capturing the intertwined physical and cyber layers of a CPPS. In this paper, a review is carried out to determine which off-the-shelf simulation tools are capable of using hybrid discrete-event and agent-based simulation for performance predictions in the conceptual design phase of a CPPS. This review is carried out using the following structured steps. First, the scope and evaluation criteria are identified. Next, a selection of simulation tools is collected. The selected tools are then evaluated and classified. Finally, the most promising simulation tool according to this evaluation – Anylogic – is subjected to a case study to assess if hybrid simulation can be used to predict the performance of a CPPS.

Ecological accounting of the Chinese society 2012–2020 based on extended exergy

China's social system has undergone unprecedented economic transformation in the past decade. It is essential that the relationship between the country's socio-economic development and natural ecosystem be revealed, thereby revealing the evolutionary trajectory of its biophysical sustainability. The extended exergy accounting (EEA) method offers a thermodynamics-based tool to evaluate the structure and function of a social system and objectively estimate the impacts of human activities on sustainable development and broader ecosystems. This study aims to perform extended exergy analysis to trace the flows of resources, labor, capital, and environmental remediation exegetics in China's society from 2012 to 2020. During the accounting period, the average annual growth rate of total extended exergy (TEE) was just 1.2%. The TEE in the conversion and tertiary sectors ew noticeably faster than those in other sub-sectors, while the TEE in the extraction and agriculture sectors showed a declining trend. The TEE in 2020 reached 764.50 EJ, of which 179.13 EJ were attributed to Cumulative Exergy Consumption, 74.89 EJ were attributed to labor, 68.85 EJ to capital, and 441.63 EJ to environmental remediation costs. The indicator assessment reflects an enhancement in the sustainability of the Chinese social system, particularly the rapid improvement in labor and capital-related indicators. Comparing the results with other countries demonstrates that the gap between China and developed nations has narrowed, with China's indicators for balancing resource production and capital flows rivaling those of the U.S. and the U.K. The objective revelation of the developmental and transitional trajectory of Chinese society, based on the EEA approach, provides valuable insights for other developing countries in achieving sustainable development.

Microstructure, Mechanical Properties, and Fatigue Resistance of High-Carbon Steel for Tensile Wires Used in Flexible Pipes for Offshore Oil and Gas Transportation

Abstract Tensile armor carbon steel wires are structural elements assembled in the complex construction of flexible pipes used in the oil and gas industry. Recently, failures of flexible pipes were associated with tensile armor fractures. Despite the relevant key of these elements in the structure of flexible pipes, manufacturers and steelmakers do not provide sufficient information about the materials and their production flow. The objective of the present study was to characterize a tensile wire made of cold worked high carbon steel regarding the microstructure and mechanical properties. The microstructure was investigated by high resolution scanning electron microscopy. The steel has nearly eutectoid chemical composition (0.69 % carbon) and presents a microstructure of very fine and deformed pearlite. Some cementite carbides appeared fragmented and spheroidized in the ferrite matrix. These microstructural features are typical of patented steel, which was subsequently cold deformed by rolling and drawing. The tensile curve of the material was obtained and modeled by Hollomon’s, Voce’s and Ludwik’s constitutive equations. The S– N fatigue curve of the wire was constructed with four-point bending tests with ratio R = 0.1. The endurance limit for R = 0.1 was estimated, and the correspondent value for R = −1 was calculated based on Goodman’s relation.

Pollen production, release and dispersion in Himalayan alder (Alnus nepalensis D. Don.): a major aeroallergens taxa

Abstract Alnus nepalensis is a medium-sized, deciduous tree that occurs in the Indian sub-continent, South America, Hawaii, and China. It is a prolific pioneer species in freshly exposed soil in landslide areas of the western Himalayas and has the potential of fixing nitrogen. A study was conducted to assess the reproductive phenology, pollen production, pollen release, and pollen-mediated gene flow of Alnus nepalensis by considering a patch of trees as a pollen source in the temperate forest of Garhwal Himalaya to develop sustainable management strategies relating to the plantation geometry in seed orchards. Staminate flowers of A. nepalensis are composed of “cymules”. The presence of bifid stigma and protandry condition were the unique features of the species. Flowering in the male phase was initiated in the last week of September and continued till November. Peak shedding of pollen generally proceeds peak receptivity by 1–2 weeks. The time between onset and peak flowering was 2 weeks 4 days and the total average duration of the flowering period was about 24.8 days. Temperature and relative humidity played a major role in pollen release and the maximum pollen release occurred at 29.2 °C at 13.00 hrs of the day. Pollen production per catkin varied significantly among trees. The average pollen grains per tree were 2.20 × 1010. The pollen-ovule ratio suggests that the breeding system of A. nepalensis falls under the class xenogamy. Pollen mediated gene flow revealed that the significant pollen which can cause pollination of A. nepalensis can travel up to 40 m uphill and 80 m in downhill directions. Thus, an isolation strip of 80 m is sufficient to manage the seed orchard of A. nepalensis in the western Himalayan region.

Design and optimization study of a resistance structure for an industrial storage platform supporting injection molding tools for the automotive industry

The paper offers an optimized solution for an industrial storage platform supporting injection molding tools used to produce thermoplastic components in the automotive sector. After analyzing the current situation for storing the massive tools, a work platform was proposed in order to ensure the conditions imposed by the extension of the company’s implementation of LEAN methods to streamline the production flow. The design of the resistance structure was modeled in the program Autodesk Inventor Professional 2020, taking into account realistic loads and their statistical distribution in the construction of the static and loading scheme of the main beam. The analysis of stress and strain in the main beam under the action of external loads was performed using the finite element method of the program Autodesk Inventor Nastran. The optimized solution for the main beam has been found by analyzing the optimization possibilities in three steps: structural optimization, dimensional optimization and the validation of the proposed optimization options, by verifying the safety of the structure. This paper presents in detail the choice of optimization criteria, decision variables, constraints and objective function. Based on the numerical analysis of mechanical stress and safety coefficient in operation, an optimal variant was chosen from the analyzed models: recessed articulated structure simple and with intermediate support, using laminated profiles IPE 200 and IPE 140.

An approach to computing the equilibrium product flows of competitive firms through supply chain networks under resource constraints and risky conditions

An approach to computing the equilibrium product flows of competitive firms through supply chain networks under resource constraints and risky conditions

Towards an ontology-based dictionary for production planning and control in the domain of injection molding as a basis for standardized asset administration shells

The use of digital technologies in the industrial environment enables great potential for increasing efficiency in manufacturing. One building block are production environments that plan and control their production flow autonomously and decentrally. To this end, all machines and systems (so-called “assets”) need to communicate with each other and derive suitable actions based on the exchanged information. Therefore, all assets need to be represented in the virtual world. This can be realized with digital twins. A concrete implementation of digital twins is the asset administration shell, which comprises all the assets’ properties and the endpoint of the corresponding asset, so intercommunication is possible. Here, the challenges comprise establishing a manufacturer-independent vocabulary that standardizes the assets’ properties and enabling the machines and systems to interpret this vocabulary semantically. Existing standards and information models represent only a fraction of the information requirements (i.e., terms) in this domain, making autonomous production planning and control (PPC) challenging to implement. Furthermore, the information requirements of the machines and peripheral assets as well as the corresponding information flows are insufficiently defined. Therefore, this contribution aims to build a comprehensive vocabulary for the domain of PPC, which serves as a basis for standardized asset administration shells that realize machine-to-machine communication. In particular, PPC processes concerning the injection molding domain’s characteristics are considered since the interaction between the domain’s assets, i.e., injection molding machines, molds, peripheral assets, raw materials, and operators, are especially complex. For this purpose, the relevant input and output information within the injection molding domain was first collected for each process step in PPC. After that, a UML class diagram was modeled under consideration of established standards. The result of this work is an ontology, which can be used as a dictionary for the PPC in the injection molding domain and as a foundation of standardized digital twins in the form of asset administration shells.

A Game Theoretic Competitive Supply Chain Network Model with Green Investments and Labour

In light of the recent severe Supply Chain (SC) disruptions that have occurred across multiple industries around the globe, three essential and linked themes have emerged in SC management: the well-being of employees, SC sustainability, and competition between SCs for limited resources. In this paper, we create a game-theoretic SC network model that incorporates together non-cooperative SC competition, employee productivity and engagement, and green investing. Each competing firm within the network seeks to maximise its profit by determining an optimal flow of products and allocation of green investments across the SC according to a predetermined budget. A carbon tax on emissions and consumer sustainability preferences are also included in the model. The model is solved using a Variational Inequality reformulation. The illustrative numerical examples presented in this paper have been inspired by the Maltese dairy industry and demonstrate the applicability of the model to real-world problems. The results highlight the significance of the employee engagement factor in enabling firms to adopt and realise more sustainable SC practices.

An analytical model for simulating the rainfall-interception-infiltration-runoff process with non-uniform rainfall

The rainfall runoff process is a critical factor in determining the transport of surface materials. Simulating the surface runoff process is fundamental to accurately characterize soil erosion and soil nutrient loss. This research aims to develop a comprehensive simulation model for rainfall-interception-infiltration-runoff under vegetation cover conditions. The model integrates three key components: a vegetation interception model, Philip's infiltration model, and a kinematic wave model. By combining these models, an analytical solution is derived to simulate slope runoff considering vegetation interception and infiltration during non-constant rainfall events. To validate the reliability of the analytical solution, a numerical solution was obtained using the Pressimann Box scheme method and compared with the analytical results. The comparison confirms the accuracy and robustness of the analytical solution (R2 = 0.984, RMSE = 0.0049 cm/min, NS = 0.969). Moreover, this study investigates the influence of two significant parameters, Intm and k, on the production flow process. The analysis reveals that both parameters exert a significant impact on the timing of production initiation and the magnitude of runoff. Specifically, Intm exhibits a positive correlation with runoff intensity, while k displays a negative correlation. This research introduces a novel simulation method that enhances our understanding and modeling of rainfall production and convergence under complex slope conditions. The proposed model provides valuable insights into rainfall-runoff dynamics, particularly in scenarios characterized by varying rainfall patterns and vegetation cover. Overall, this study contributes to advancing the field of hydrological modeling and offers a practical approach for quantifying soil erosion and nutrient loss under different environmental conditions.

IMPACT OF E – COMMERCE ON THE STORAGE OPERATIONS OF AIR CARGO

Like wildfire, the e-commerce boom has spread to virtually every industry. The impact of this new digital commerce model on the air cargo sector is far-reaching and complex. By understanding how e-commerce affects the business operations of traditional air cargo companies, we can better prepare for its future development. Storage occupies a central role in any Supply Chain. The primary purpose of storage activity is to act as a buffer to adopt to the variability of the flow of production, consolidation of products and to add marginal value such as pricing, labelling or customization. Thus, in this research work the main aim of the researcher is to highlight the impact of E- commerce on Air cargo storage operations, followed by the opportunities and challenges associated with it. This study is based on the review of various literatures related to the topic of study. The study highlights that e commerce is changing the way people consume. The goal of increasing delivery speed while remaining cost effective poses significant new challenges for supply chains as they move on to satisfy the growing and fast-changing demand.

Fe–Ni–Ce–Zr-modified CuO–ZnO catalyst for methanol steam reforming

Four copper-based catalysts were prepared by co-precipitation method. The catalysts were characterized by scanning electron microscopy, N2 adsorption-desorption, temperature programmed reduction process (H2-TPR), X-ray diffraction (XRD) and in-situ diffuse reflectance infrared Fourier transform spectroscopy (in situ DRIFTS) to explore the effects of different components on catalyst activity. The performance of different catalysts for hydrogen production via methanol steam reforming was evaluated on a fixed-bed reactor. The effects of different components, reaction temperature and gas hourly space velocity (GHSV) on the catalytic performance were investigated. The results exhibited that among the investigated catalysts, 1# and 2# catalysts had the higher catalytic activity and stability. Under the conditions of 280 °C, a molar ratio of methanol to water of 1:1.3, and a GHSV of 13.3 L/(g·h), the methanol conversion rate reached 99.9%, the CO concentration was as low as 0.29%, and the selectivity was only 1.16%. The H2 production flow rate per unit mass of catalyst was 270 mL/(min·g). After 60 h of start-stop experiments, the methanol conversion rate remained above 98.4%, the CO concentration was always lower than 0.5%, and the start-up speed was significantly faster than that of the commercial catalyst M650. This study provided an effective method for the preparation of catalysts for methanol steam reforming.

Difficulties Faced By Pharmaceutical Industries Associated With COVID-19 Pandemic in Obtaining Raw Materials for Production of Certain Drugs in Sudan in 2021

Background Pharmaceuticals industries play a significant role in health care, especially in developing countries and under-devolving countries since it produced more affordable medications. Many factors contributed to ensure continuous production flow, the key factor is the availability of raw material. After COVID-19 outbreak scarcity in raw material became a major obstacle in drug production. The goal of this study is to identify barriers faced by pharmaceuticals industries in Sudan in acquiring raw materials due to COVID-19 pandemic. Method An analytical, qualitative structured focus group discussion (FGD) was performed with major factories in Khartoum, Sudan. To address issues regarding obstacles faced by this factories during COVID-19 pandemic. Result All participants’ encountered problems because of the pandemic such as fuel shortage, difficulty in transportation, economic instability but the biggest issue was the closure of international borders that resulted in insufficient raw materials and other essential chemicals needed in production. Conclusion overall COVID-19 had a marked impact in drug manufacturing in Sudan which is reflected in the availability of drugs locally.

State of Art of Pipeline Distribution of Oil Products in Kenya-Threats, Challenges and Prospects

Finally, in 2012, Kenya hit significant commercial oil deposits that could potentially, position it among prospective world oil exporters. Unparalleled expectations from this find is arousing long dead pipedreams of economic bonanza and overnight transformation among all stakeholders. However, to avail this resource to the markets, for the expected fiscal changes to occur, it has to be transported. This paper, therefore, seeks to microscopically review the current status of the pipeline transport of oil products in Kenya in the last decade. A summarized outlook of pipeline oil distribution globally is availed, especially in well-developed oil jurisdictions. This is sequenced with a comprehensive history of oil pipeline transport in the country. The flow mechanism of white and black oil products in pipelines is then briefly addressed in view of the waxy Turkana oil. A sneak preview of the legal landscape on oil pipeline transport in Kenya is likewise highlighted. The current content and context of pipelines, flow of white and black oil products in pipelines, and new pipeline infrastructure are then discussed with Kenya Pipeline Company Limited as the central denominator. Additionally, assertions on the upcoming new crude oil pipeline are evaluated. Finally, it exposes the prospects and challenges in the pipeline transport of oil products and sums up with vials of viable recommendations for its long term progress.

RELAYOUT LANTAI PRODUKSI SPRINGBED MENGGUNAKAN METODE SLP, CORELAP SERTA SIMULASI PROMODEL, DAN FLEXSIM

PT. Alpha Jaya Manunggal Mandiri is manufacturing company engaged in furniture sector. There are several problems with old layout such high material handling costs, long distances between work stations, and alternating flow. Therefore, relayout and lean manufacturing approach were carried out. Alternative layouts made using SLP method, and CORELAP. The initial steps in making alternative layouts are measuring floor area, making production flows, and measuring production standard times. Next step is forecasting product demand for next 10 years for routing sheet. Routing sheet used to determine number of machines needed to meetproduct demand. Alternative layout was created using 2 methods. Based on alternative layout, material handling costs and moving moments are calculated to find layout with minimum material handling costs and moving moments moments. The selected layout is alternative layout SLP method cause it reduces material handling costs by 50.12%, moving moments by 17.86%, and distance by 53.42%. Then lean manufacturing approach carried out to increase productivity. A simulation was carried out with Promodel and Flexsim software to simulate new and old layout to find product improvements using new layout. Based on Promodel simulation, there was decrease in the average time in system by 21.82%, decrease in the average time in operation by 22.36%, and increase in total production by 15.29%. Based on Flexsim simulation, there was increase in amount of daily production by 58.52%, and decrease in staytime by 33.47% per product. Through research, it can be concluded that layout can be implemented as new layout on springbed production floor.

Reduction of changeover time through SMED with RACI integration in garment factories

Purpose Shorter lead time with low price and quality product demand is pivotal in the garment industry. Pressure on production lead time stresses the importance of reducing style changeover time in manufacturing factories, and this paper aims to contribute to solving the challenge by showing how the single minute exchange of die (SMED) methodology in practice can be adapted to garment factories in developing countries. Design/methodology/approach The paper investigates three cases of SMED implementation integrated with responsible, accountable, consulted, informed (RACI) matrices in garment factories in an action research approach. Both quantitative and qualitative methods are applied. Findings The study shows a reduction of 50% to 64% of changeover time with SMED implementation measured with two key indicators – throughout time and time to reach peak production. Moreover, the implementation depends on the application of the RACI matrix for the distribution of responsibility as well as integration with the basic production flow before and after the application of SMED. Practical implications The study can guide better SMED implementation in garment factories with limited investment by stressing the need to adapt to the specifics of the garment industry, secure the division of responsibility and integrate SMED in the production flow before and after the changeover. Originality/value Limited research on the application of SMED in the garment industry. This paper contributes to understanding the specific conditions for successful implementation in the garment industry in developing countries and addresses additional activities that help secure a sustainable implementation process.

Development of two devices for high-throughput screening of ethanol-producing microorganisms by real-time CO2 production monitoring.

Bioethanol's importance as a renewable energy carrier led to the development of new devices for the high-throughput screening (HTS) of ethanol-producing microorganisms, monitoring ethanol production, and process optimization. This study developed two devices based on measuring CO2 evolution (an equimolar byproduct of microbial ethanol fermentation) to allow for a fast and robust HTS of ethanol-producing microorganisms for industrial purposes. First, a pH-based system for identifying ethanol producers (Ethanol-HTS) was established in a 96-well plate format where CO2 emission is captured by a 3D-printed silicone lid and transferred from the fermentation well to a reagent containing bromothymol blue as a pH indicator. Second, a self-made CO2 flow meter (CFM) was developed as a lab-scale tool for real-time quantification of ethanol production. This CFM contains four chambers to simultaneously apply different fermentation treatments while LCD and serial ports allow fast and easy data transfer. Applying ethanol-HTS with various yeast concentrations and yeast strains displayed different colors, from dark blue to dark and light green, based on the amount of carbonic acid formed. The results of the CFM device revealed a fermentation profile. The curve of CO2 production flow among six replications showed the same pattern in all batches. The comparison of final ethanol concentrations calculated based on CO2 flow by the CFM device with the GC analysis showed 3% difference which is not significant. Data validation of both devices demonstrated their applicability for screening novel bioethanol-producer strains, determining carbohydrate fermentation profiles, and monitoring ethanol production in real time.

China, the Democratic Republic of the Congo, and artisanal cobalt mining from 2000 through 2020

From 2000 through 2020, demand for cobalt to manufacture batteries grew 26-fold. Eighty-two percent of this growth occurred in China and China's cobalt refinery production increased 78-fold. Diminished industrial cobalt mine production in the early-to-mid 2000s led many Chinese companies to purchase ores from artisanal cobalt miners in the Democratic Republic of the Congo (DRC), many of whom have been found to be children. Despite extensive research on artisanal cobalt mining, fundamental questions about its production remain unanswered. This gap is addressed here by estimating artisanal cobalt production, processing, and trade. The results show that, while total DRC cobalt mine production grew from 11,000 metric tons (t) in 2000 to 98,000 t in 2020, artisanal production only grew from 1,000 to 2,000 t in 2000 to 9,000 to 11,000 t in 2020 (with a peak of 17,000 to 21,000 t in 2018). Artisanal production's share of world and DRC cobalt mine production peaked around 2008 at 18 to 23% and 40 to 53%, respectively, before trending down to 6 to 8% and 9 to 11% in 2020, respectively. Artisanal production was chiefly exported to China or processed within the DRC by Chinese firms. An average of 72 to 79% of artisanal production was processed at facilities within the DRC from 2016 through 2020. As such, these facilities may be potential monitoring points for artisanal production and its downstream consumers. This finding may help to support responsible sourcing initiatives and better address abuses related to artisanal cobalt mining by focusing local efforts at the artisanal processing facilities through which most artisanal cobalt production flows.

Review on Applications of Ionic Liquids (ILs) for Bitumen Recovery: Mechanisms, Challenges, and Perspectives

Water- and solvent-based ex situ extraction processes have been employed to extract bitumen from mineable oil sands. On the other hand, bitumen is recovered in situ from deeper deposits most efficiently by injecting steam to reduce viscosity and increasing production flow to the surface. However, the water-based process with or without solvent (including steam injection) is not sustainable due to various challenges including water requirement and treatment, high energy consumption, and related environmental pollution problems emanating from high volatility of solvents. Ionic liquids (ILs) have become desirable in several industrial applications due to many unique properties including low volatility compared with traditional organic solvents. The potential for application of ILs for bitumen extraction is reviewed in this work, with a focus on the mechanistic aspect. Depending on the properties and/or functionality, the ILs can be used in bitumen extraction (with or without organic solvents) with minimal clay fines contamination and lower water and energy requirements. In the solvent-assisted IL recovery system, the IL–clay interaction is responsible for reducing the adhesive force between bitumen and the sand, which subsequently facilitates separation. Conversely, considering the types of ILs explored in the absence of solvent, the IL–bitumen interaction plays an additional role. Hitherto, applications of ILs in bitumen recovery are at a very preliminary stage. Apart from understanding the mechanisms, the major impediment lies in the high cost and environmental impact due to toxicity. Therefore, to make ILs more attractive for bitumen recovery, concerted efforts should be intensified to reduce the cost of producing ILs, ameliorate environmental impacts, and facilitate field scale applications through technoeconomic analysis of the process.