Model Of Production Process Research Articles

A techno-economic assessment of bioethanol production from switchgrass through biomass gasification and syngas fermentation

The consumption of fossil fuels, which are not economically and environmentally sustainable, can be reduced by producing biofuels, such as bioethanol. This study presents a reproducible model of the ethanol production process developed with Aspen Plus® software. The work's goal is to enhance the amount of ethanol produced per tonne of biomass and, therefore, the carbon yield of the process. The main steps of the process are the gasification of the pretreated switchgrass, the cleaning of the syngas obtained, the fermentation of the syngas to ethanol and its purification. The parameters relating to gasification were set to produce syngas with an optimal composition for the fermenter. A discounted cash flow analysis was used to determine the minimum ethanol selling price for different plant scales and H2 prices. By enriching the syngas with green H2 and adopting an optimal bioreactor, a remarkable ethanol yield of 1015.04 L/t of switchgrass can be obtained. Considering a plant size of 750,000 t/y of switchgrass, the minimum ethanol selling price is 1.07 $/L for the base scenario and is further lowered to 0.77 $/L for the 2050 H2 scenario. The potential savings of building more plants were also assessed thanks to the learning effects.

Techno-economic analysis and life cycle assessment of cellulose nanocrystals production from wood pulp

Cellulose nanocrystals (CNCs) are biobased materials with many desirable properties such as high aspect ratio, mechanical strength, crystalline nature, and biodegradability. This study developed a commercial-scale process model of CNC production from wood pulp using sulfuric acid treatment and evaluated its techno-economic and environmental performance with and without acid recovery. The results indicated that CNC produced with acid recovery process was financially more profitable with higher project net present values than without acid recovery process but required higher capital which resulted in a longer payback period and lower return on invested capital. The estimated minimum selling prices of CNC produced with and without acid recovery were $4.69/kg and $4.89/kg, respectively. The global warming (GW) impacts of 1 kg CNC production with and without acid recovery were 11.39 and 11.18 kgCO2eq, respectively, showing that higher steam use and consequently more fossil fuels were needed in the acid recovery process.

Модель процесса создания картографической продукции для решения задачи синтеза системы картографического производства

The article deals with solving the tasks of designing a cartographic support system and arranging the process of its targeted application. The definition of its concept is given. Within the framework of the paper, electronic maps of the area are considered as products. The system functioning for the consumer is described. During the research, the results’ quality indicators vector of the production and publishing processes are substantiated. The functional-stochastic dependencies between the components of the results’ quality indicators vector are established and the operational functionality linking the performance indicator with the cost of resources and time is justified. A mathematical model of the purposeful production process of cartographic products is constructed, which enables predicting the degree of the goal achievement, a priori assessing its quality and synthesizing a system of cartographic production by means of a directional enumeration of the model parameters values. The simulation results let us formulate proposals on the structure of the cartographic support system based on the requirements imposed by the results. An illustrative numerical example demonstrating the operability of the offered method is given.

Virtual Reality Based Decision Support Model for Production Process of Museum Exhibition Projects

Quality and time are uncompromisable performance indicators of the physical exhibition production process. Design changes during the installation phase of the process, which arise from poor design representations, cause expensive rework and therefore cost increase. Since non-AEC (architecture/engineering) construction) decision-makers can only partially imagine the outcome through traditional 2D and 3D design representations; we proposed a model incorporating virtual reality technologies to solve design miscommunications and improve stakeholder participation. We adopted a qualitative method and tested the model through case studies with five expert museum professionals. We confirm that VR enhances the design communication among the contributing professionals and, unlike other traditional methods, makes it possible to present multimedia, lighting, sound effects, and other digital elements throughout the exhibition production process. Findings indicate that VR has the potential for significant cost reductions and quality improvement in the construction phase of the exhibitions.

Remote Sensing from Different Sources for Crop Growth Monitoring in the Area of the Lower Northern Mississippi

Remote sensing monitoring of crop growth began from airborne photography to assist in crop pest management and has evolved into monitoring from satellites, manned aircraft, unmanned aerial vehicles (UAVs), and ground-based systems for crop production process modeling, optimization, and control. In recent years, for crop growth remote sensing monitoring, apart from satellites, manned aircrafts, and ground-based systems, UAVs have been developed and widely used for low-altitude remote sensing of crop fields to uniquely provide a cost-effective, flexible tool for field crop growth remote sensing. Additionally, their data create a critical layer between all other remote sensing platforms. This paper overviews the use of remote sensing from difference sources, especially airborne remote sensing from manned aircraft and UAVs, to monitor crop growth in the area of the lower northern Mississippi from the Mississippi Delta to the Black Prairie, one of the most important agricultural areas in the U.S. In this paper, three sites typical in the area are demonstrated for remote sensing monitoring of crop growth, and the issues and challenges are identified and discussed for future opportunities to integrate remote sensing data from different sources to improve crop monitoring in this area and surrounding areas.

Brazilian Circular Economy Pilot Project: Integrating Local Stakeholders’ Perception and Social Context in Industrial Symbiosis Analyses

This paper aims to analyze organisations’ behaviour in the Industrial Symbiosis implementation process in the Circular Economy Pilot Project, in Brazil from the actors’ perception. We conducted an exploratory and descriptive study with a qualitative approach to attain the research objective. The data collection involved in depth interviews with eighteen actors. Data were analyzed using the Content Analysis technique. The study results in show a still incipient industrial symbiosis network, with few connections between industrial actors, based on bilateral exchanges of materials, water and energy. From the analysis, it was possible to identify the elements that influence the behaviour of organisations. When it comes to exogenous elements, it is clear that laws and sanctions are the ones that most determine organisational action. However, this pressure is still focused on the traditional and unidirectional model of production processes. Economic viability was identified as a primary factor for the objective elements of organisational action. Regarding the subjective elements, it was found that there was already an interaction before the project between some companies, especially those from automotive sector. With the project’s initiative, this social interaction was intensified, including between companies from different sectors. Regarding the barriers, we found the absence of governmental actions, unavailability of time and involvement of the managers to fully participate in the project, high cost of waste disposal versus the cost of investment and, discontinuity of actions. Overall, the study indicates that the project increased the institutional capacity of the region to develop industrial symbiosis, as it advanced in sharing new knowledge, promoted more significant interaction between organisations and identified business opportunities for companies. However, it appears that the project’s continuity will be conditioned to improve some aspects of the governance structure, regulatory framework and collective engagement. These results can be helpful for researchers studying this topic and managers in Brazil and other emerging countries in Latin America, as well as, policymakers involved in public policies aimed to enable the transition to a circular e more sustainable model.

Цифровизация в практической подготовке студентов технических вузов

Importance. One of the key tasks of the production practice is the experience of transferring knowledge to independently solve new tasks. Modeling of production processes in virtual laboratories, VR training sessions, blockchain can be considered as technologies aimed at development the ability to data transfer, analyze, and systematize. Digitalization of practical training is able to solve the problems of non-standard thinking development, the need to strengthen the responsibility of students, the specialist qualification dependence on the digital technologies possession degree. The possibilities of digital technologies, intellectual information and educational systems in the focus of practical training of students and the development of thinking formed the purpose of the research. Materials and Methods. The review of information sources is carried out, the own experience of practical training organization is systematized. The survey method investigated the attitude of students to online interaction, the attitude of enterprises to the admission of trainees to production facilities. A model of the procedure for evaluating and storing practice results is proposed. Results and Discussion. Artificial intelligence and process automation shift the emphasis of education from algorithmized activities (reading material, drawing up a text plan, selecting key ideas, etc.) to the development of specific non-standard skills – the ability to find a non-stereotypical optimal solution, conduct expertise, apply knowledge in unusual conditions. At the same time, the reduction in the volume of subject material allows us to pay more attention to the development of non-routine actions, autonomy in the workplace, and the development of a proactive attitude to the profession. The virtual model of the technological process allows to see in detail any element of the complex, while the VR operator perceives the object and forms a response. The analysis of the spatial position and state of the object, the transfer of existing theoretical knowledge into a specific production situation, the formation of an objects holistic perception develop both thinking and practical skills. Evaluation of students practical training results with the use of blockchain increases the efficiency of the process, makes the data storage system reliable. Conclusion. Modernization of vocational education through the introduction of adaptive and practice-oriented educational programs, learning and evaluation algorithms based on artificial intelligence solutions will ensure effective digital training.

Building materials production process carbon emission analysis and optimization of Low-Carbon manufacturing

In order to study the carbon emission characteristics of building materials production process, the material, energy consumption and carbon emission characteristics of building materials production process were analyzed, the carbon emission boundary conditions of building materials production process were proposed, and the carbon emission calculation model of building materials production process was established. Based on the data provided by a manufacturing company, we calculated and analyzed the carbon emissions of the building materials production process, identified the waste in this production line, and proposed an analysis method based on lean thinking to propose corresponding improvement measures from the production management level to address the waste problems. Reduce non-value-added carbon emissions caused by waste, thus improving the lean level of gear production lines and transforming to low carbon manufacturing.

ПОДХОДЫ К УПРАВЛЕНИЮ ОРГАНИЗАЦИОННЫМИ ИЗМЕНЕНИЯМИ НА ОСНОВЕ РАЗНОУРОВНЕВЫХ ЦИФРОВЫХ ДВОЙНИКОВ

The article deals with the implementation of organizational changes in enterprises in the context of digital transformation processes, which are associated with the active introduction of digital twins at different organizational levels (product, production, organization as a whole). In the context of a multi-level system of digital twins, the authors describe the structure of the relationship between digital twins of different levels and it is noted that the combination of digital product models and digital modeling of production processes within a single digital model leads to the formation of a smart digital production model, which is a reflection of the key stages of the product life cycle. A three-dimensional model of the architecture of a digital enterprise is formed and described, the parameters of which are the levels of business process management, the product life cycle depending on production volumes and the types of resources used.

A neural network-based production process modeling and variable importance analysis approach in corn to sugar factory

A neural network-based production process modeling and variable importance analysis approach in corn to sugar factory

Optimisation of the Logistics System in an Electric Motor Assembly Flowshop by Integrating the Taguchi Approach and Discrete Event Simulation

An electric motor assembly flowshop (EMAF) is a type of classical mixed-product assembly line that uses automatic guided vehicle (AGV) systems for material handling. To optimise the logistics system configuration and alleviate the impact of the AGV parameters on the efficiency of the EMAF, a modelling and optimisation method based on discrete event simulation (DES) combined with Taguchi orthogonal experimental design was proposed. A DES model of the entire production process for the EMAF was constructed using the Tecnomatix Plant Simulation software package. After optimisation of the principal layout in the DES model, the number of assembly stations was decreased from 13 to 9, and the balance ratio was increased from 65.08% to 84.65%. In addition, the combination of the Taguchi method with the DES model was further developed to achieve the optimal parameter combination of the AGVs in order to allow the AGVs to operate more efficiently under various states. The final overall theoretical throughput was increased from 134 to 295 units within the seven-hour observation period.

Учет осенне-зимнего увлажнения почвы в динамико-статистической модели прогноза урожайности озимых культур

The results of improving methods for the yield prediction of two winter crops (wheat and rye) taking into account the autumn-winter period moisture content are presented. The dynamic-statistical forecast method is based on the “weather-harvest” base long-term model of the plant production process. The yield forecasting is carried out taking into account two components of the yield time series (a trend and deviations from it) by assessing agrometeorological conditions based on the dynamic model of the plant production process. The correction coefficient that takes into account the autumn-winter moisture content is introduced into the winter crops dynamic model, which improves the quality of winter wheat and winter rye average yield forecasts for the subjects of the Russian Federation. The average relative forecast error for 5 years of the author’s tests from 2017 to 2021 amounted to 13 and 9% for the first and second forecast time moments, respectively. Keywords: dynamic-statistical forecasting method, yield, winter crops, rye, wheat, photosynthesis, vegetation conditions

Research on Using the Tecnomatix Plant Simulation for Simulation and Visualization of Traffic Processes at the Traffic Node

Simulation software Tecnomatix Plant Simulation was originally created for a modelling and subsequent simulation of production and logistics processes. Its variability, however, opens its use also in other areas such as transport in urban agglomerations. Based on that, research was implemented to verify the program’s application in urban transport, specifically to visualize and simulate traffic processes at the traffic node. The paper describes a methodology which made it possible to create a simulation program for traffic light intersections, and presents examples of the simulation model application. The proposed methodology will enable the application of Tecnomatix Plant Simulation to create a complex simulation model of the logistics process. It will mainly enable to simulate the field of production logistics and city logistics within one simulation model.

STUDY OF THE INFLUENCE OF THE MODERN ROBOTISATION LEVEL ON THE CHALLENGES AND RISKS OF THE ECONOMIC SECURITY OF AN INDUSTRIAL ENTERPRISEG

Industry 4.0 envisages a comprehensive transformation of all industries by combining digital technologies and the Internet with traditional industries. It is important to emphasize that Industry 4.0 relies heavily on robotics. Robotization opens up new opportunities for an industrial enterprise, completely transforming the technologies and organization of its production process and business model. Many of today’s threats to the economic security of an industrial enterprise can be mitigated due to digitalization and flexible robotization of production and promotion of goods. But at the same time, processes related to the robotization of the economy create new threats to economic and social security. The consequences of their influence and the mechanisms of their leveling are the subject of research. The goal of the work is to study the impact of robotics on the economic security of an industrial enterprise. The following tasks are solved in the article: an overview of the areas of application and trends in the development of industrial robots; overview of the robotics market; analysis of risks and threats to the economic security of industrial enterprises arising as a result of robotization. The methods of system analysis, graphic generalization and classification are used. The results of the work include an analysis of the current state of robotics and the introduction of industrial robots in production, a brief analysis of the robotics market and a study of external challenges, uncertainties and risks arising from robotics: political-economic, technological, financial and environmental. Conclusions. The development of robotics is a priority direction for innovative industrialization not only in the long term, but also in the short term. Robotics can also become a locomotive for general economic growth, given that the most advanced developed countries are currently creating their own robotic enterprises and transferring production from developing countries to them. However, in the context of robotization, it should be taken into account that these processes, along with potential benefits for the industrial enterprise, can also create new threats to economic and social security.

Process model and techno-economic analysis of natural astaxanthin production from microalgae incorporating geospatial variabilities

Microalgae possess tremendous potential to meet the ever-increasing demand for food, feed, energy and fuels in a sustainable manner. Microalgae-based natural products are poised to compete with synthetic products in the market. A comprehensive theoretical approach was developed to determine economic feasibility of natural astaxanthin production from microalgae at various locations in the United States. A detailed economic analysis was conducted to determine natural astaxanthin production costs considering residual biomass utilization for various locations. Baseline production costs of astaxanthin were found to range from 1400 to 5000 $ kg−1 for the different locations. The results suggest that both microalgae productivity potential and astaxanthin production costs are heavily influenced by geographic location and type of bioreactor used. While production costs of natural astaxanthin are found to be higher than those of synthetic astaxanthin, economic analysis reveals significant opportunity for the economic viability of natural microalgae-based astaxanthin production in commercial scales.

Development of an integrated process for the production of high-purity γ-aminobutyric acid from fermentation broth

γ -Aminobutyric acid (GABA), a natural non-protein amino acid, plays an irreplaceable role in regulating the life activities of organisms. Nowadays, the separation and purification of food-grade GABA from fermentation broth is still a great challenge. This research utilized monosodium glutamate as a substrate for the production of high-purity GABA via an integrated process incorporating fermentation, purification, and crystallization. Firstly, 147 g·L −1 GABA with a yield of 99.8% was achieved through fed-batch fermentation by Lactobacillus brevis CE701. Secondly, three integrated purification methods by ethanol precipitation were compared, and crude GABA with a purity of 89.85% was obtained by the optimized method. Thirdly, GABA crystals with a purity of 98.69% and a yield of 60% were further obtained through a designed crystallization process. Furthermore, the GABA industrial production process model was established by Superproper Designer V10 software, and material balance and economic analysis were carried out. Ethanol used in the process was recovered with a recovery of 98.79% through Aspen simulated extractive distillation. Then the fixed investment (equipment purchase and installation costs) for an annual production of 80 t GABA will be about 833000 USD; the total annual production cost (raw material cost and utility cost) will be about 641000 USD. The annual sale of GABA may be at the range of 2400000−4000000 USD and the payback period will be about 1−2 year. This integrated process provides a potential way for the industrial-scale production of food-grade GABA.

Production processes modelling within digital product manufacturing in the context of Industry 4.0

Industry 4.0 aims to establish highly flexible production, enabling effective and efficient mass customisation of products. Modelling techniques and simulation of production processes are among the core techniques of the manufacturing industry that facilitate flexibility and automation of a shop floor in the era of Industry 4.0. In this paper, we present an approach to support production process modelling and process model management. The approach is based on Model-Driven (MD) principles and comprises a Domain-Specific Modelling Language (DSML) named Multi-Level Production Process Modelling Language (MultiProLan). MultiProLan uses a set of concepts to specify production process models suitable for automatic instruction generation and execution of the instructions in a simulation or on a shop floor. By using MultiProLan, process designers may create process models independent of the specific production system. Such process models can either be automatically enriched by matching and scheduling algorithms or manually enriched by a process designer via MultiProLan’s modelling tool. In this paper, we also present an application of our approach in the assembly industry to showcase its dynamic resource management, generation of production documentation, error handling and process monitoring.

Novel production prediction model of gasoline production processes for energy saving and economic increasing based on AM-GRU integrating the UMAP algorithm

Gasoline, as an extremely important petroleum product, is of great significance to ensure people's living standards and maintain national energy security. In the actual gasoline industrial production environment, the point information collected by industrial devices usually has the characteristics of high dimension, high noise and time series because of the instability of manual operation and equipment operation. Therefore, it is difficult to use the traditional method to predict and optimize gasoline production. In this paper, a novel production prediction model using an attention mechanism (AM) based gated recurrent unit (GRU) (AM-GRU) integrating the uniform manifold approximation and projection (UMAP) is proposed. The data collected in the industrial plant are processed by the box plot to remove the data outside the quartile. Then, the UMAP is used to remove the strong correlation between the data, which can improve the running speed and the performance of the AM-GRU. Compared with the existing time series data prediction method, the superiority of the AM-GRU is verified based on University of California Irvine (UCI) benchmark datasets. Finally, the production prediction model of actual complex gasoline production processes for energy saving and economic increasing based on the proposed method is built. The experiment results show that compared with other time series data prediction models, the proposed model has better stability and higher accuracy with reaching 0.4171, 0.9969, 0.2538 and 0.5038 in terms of the mean squared error, the average absolute accuracy, the mean squared error and the root mean square error. Moreover, according to the optimal scheme of the raw material, the inefficiency production points can be expected to increase about 0.69 tons of the gasoline yield and between about $645.1 and $925.6 of economic benefits of industrial production.

Lessons of DRDSI pilot projects in Ukraine

The work considers practical examples of processes realization of product-process model of the National (N) Spatial Data Infrastructure (SDI, together – NSDI) of Ukraine [Chabaniuk, Dyshlyk, 2021], which meet two of the four dynamic principles of the latter building [Chabaniuk, 2018]. They were obtained in 2016 as part of pilot projects (pilots) of the regional European project to create the so-called Danube Reference Data and Services Infrastructure [DRDSI, Dusart, et al., 2016]. Pilots were implemented for the territory of 3 districts of Odessa region of Ukraine adjacent to Moldova. Despite the 6 years that have passed since then, these results not only remain, but become even more actual. The growing actuality is explained by several reasons, among which the most important are three: 1) [Law of Ukraine “About NGDI”, 2020] noncompliance with the recommendations (requirements) of INSPIRE; 2) inconsistency of the SDI (Spatial Data Infrustructure) model enshrined in the said Law with the Ukrainian reality; 3) the needs of practice. The results of the work are useful for determining [Law of Ukraine “About NGDI”, 2020] changes, the model of which must be changed to “correct” and “feasible” [Chabaniuk, Dyshlyk, 2021]. Due to the use of open technologies in pilots, the latter can be used in practical projects without the cost of purchasing commercial software.

THE PETRI NET SIMULATION OF TEMPEH PROCESSING PROSESS WITH FOUR OPERATORS

The model obtained in this study is expected to be able to describe the dynamics of the resources and processing of soybeans into tempeh. An understanding of the tempeh production process is obtained from direct observation and also from appropriate references. Furthermore, a petri net model and simulation of the tempeh production process was made with several assumptions that have been adjusted to the results of observations in the field. Obtained a petri net consisting of 14 places and 10 transitions. From the simulation results, must be reachable to reach the final state that has been determined with several assumptions.