Simulation Of Technological Processes Research Articles

Simulation-Based Design for Recycling of Car Electronic Modules as a Function of Disassembly Strategies

Modules (or parts) of a car are a complex functional material combination used to deliver a specified task for a car. Recovering all materials, energy, etc., into high-grade materials at their end of life (EoL) is impossible. This is dictated by the second law of thermodynamics (2LT) and thence economics. Thus, recyclability cannot be conducted with simplistic mass-based approaches void of thermodynamic considerations. We apply, in this paper, a process simulation model to estimate the true recyclability of various SEAT (Volkswagen Group) car parts within the EU H2020 TREASURE project. This simulation model is developed with 190 reactors and over 310 feed components with over 1000 reaction species in the 880 streams of the flowsheet. The uniqueness of the work in this paper is to apply the full material declaration (FMD) and bill of materials (BOM) of all 310 materials in the parts as a feed to the process simulation model to show the parts’ true recyclability. We classified all parts into categories, i.e., copper-rich, steel-rich and plastic-rich, to maximally recover metals at the desired material quality, as well as energy. Recyclability is understood to create high-grade products that can be applied with the same functional quality in these parts. In addition, disassembly strategies and related possible redesign show how much recyclability can be improved. Process simulation permits the creation of alloys, phases, materials, etc., at a desired quality. The strength of the simulation permits any feed from any End-of-Life part to be analyzed, as long as the FMD and BOM are available. This is analogous to any mineral and metallurgical engineering process simulation for which the full mineralogy must be available to analyze and/or design flowsheets. This paper delivers a wealth of data for various parts as well as the ultimate recovery of materials, elements, and energy. The results show clearly that there is no one single recycling rate for elements, materials, and alloys. It is in fact a function of the complexity and material combinations within the parts. The fact that we use a thermochemical-based process simulator with full compositional detail for the considered parts means full energy balances as well as exergy dissipation can be evaluated. This means that we can also evaluate which parts, due complex mixtures of plastics, are best processed for energy recovery or are best for material and metal recovery, with thermochemistry, reactor technology and integrated flowsheets being the basis.

Model validation of hollow embossing rolling for bipolar plate forming

Hollow embossing rolling is a promising forming technology for metallic bipolar plates because of the high achievable production rates. However, the simulation-based process optimization is impeded by the incremental forming character and modeling of fine channel structures, which leads to large model sizes and long computation times. This paper presents a shell-based finite element approach validated by experimental forming tests using a miniaturized test geometry with typical discontinuities and varying channel orientations. The rolling experiments demonstrated that implementing restraining tension effectively decreases wrinkling, allowing successful forming of the selected test geometry by hollow embossing rolling. It was found that representing the manufacturing-related decreased rolling gap combined with the rolling gap changes due to roll system elasticity in the numerical model is essential for model accuracy. An optimized model approach with spring-controlled rollers was developed, which considers the effect of load-dependent rolling gap changes. With this approach the applied model achieves sufficient model accuracy for technological process simulation and optimization.

Automated method based on a neural network model for searching energy-efficient complex movement trajectories of industrial robot in a differentiated technological process

Purpose of the work: Researching possibility of creating a method for improving the energy efficiency of differentiated robotic technological process (RTP) in the food industry. The high rates of development of production processes robotization, including in the food industry, leading to increase the cost of electrical energy, determine the research tasks relevance in finding energy-efficient methods for controlling industrial robots.Methodology: The proposed approach is based on principles of object-oriented design and possibility of classifying robotic technological process: Applying specific model sets and methods to improve energy efficiency to individual classes. The existing possibility of energy consumption synthesizing models of robots inside differentiated robotic technological process, such as stacking loads, in reduced form, made it possible to use neural network methods to identify non-linear dependencies. At the same time, training sample for intelligent modules was formed on the basis of classical experiment planning algorithms. The synthesis of methods, models and procedures was implemented on the basis of high-level programming languages C++, MATLAB.Results: A mathematical model and automated algorithms for its synthesis are proposed, which make it possible to adjust robotic technological process simulation model taking into account its specifics and implement a method for finding the optimal parameters of its functioning. To confirm the effectiveness of proposed solution, the obtained neural network model and optimization method were tested on real robotic technological process, and the calculation of economic efficiency of proposed solution was also given.Conclusion/recommendations: The application of this approach will significantly reduce energy costs for robotic operations in the food industry.

Protocol: identifying policy, system, and environment change interventions to enhance availability of blood for transfusion in Kenya, a mixed-methods study

BackgroundSafe blood is essential for the care of patients with life-threatening anemia and hemorrhage. Low blood donation rates, inefficient testing procedures, and other supply chain disruptions in blood administration affect patients in low-resource settings across Sub-Saharan countries, including Kenya. Most efforts to improve access to transfusion have been unidimensional, usually focusing on only point along the blood system continuum, and have excluded community stakeholders from early stages of intervention development. Context-appropriate interventions to improve the availability of safe blood at the point of use in low-resource settings are of paramount importance. Thus, this protocol proposes a multifaceted approach to characterize the Kenyan blood supply chain through quantitative and qualitative analyses as well as an industrial engineering approach.MethodsThis study will use a mixed-methods approach in addition to engineering process mapping, modeling and simulation of blood availability in Kenya. It will be guided by a multidimensional three-by-three-by-three matrix: three socioeconomic settings, three components of the blood system continuum, and three levels of urgency of blood transfusion. Qualitative data collection includes one-on-one interviews and focus group discussions with stakeholders across the continuum to characterize ground-level deficits and potential policy, systems, and environment (PSE) interventions. Prospectively-collected quantitative data will be used to estimate blood collection and transfusion of blood. We will create a process map of the blood system continuum to model the response to PSE changes proposed by stakeholders. Lastly, we will identify those PSE changes that may have the greatest impact on blood transfusion availability, accounting for differences across socioeconomic settings and levels of urgency.DiscussionIdentifying and prioritizing community-driven interventions to improve blood supply in low-resource settings are of utmost importance. Varied constraints in blood collection, processing, delivery, and use make each socioeconomic setting unique. Using a multifaceted approach to understand the Kenyan blood supply and model the response to stakeholder-proposed PSE changes may lead to identification of contextually appropriate intervention targets to meet the transfusion needs of the population.

A Design Approach of a Dedicated Exhaust-Gas Recirculation-System for a Naturally Aspirated Gas Engine—From One-Dimensional Engine Process Simulation and Design of Experiments Up to the Experimental Validation

Abstract This work presents a systematic approach proceeding from the engine process simulation (one-dimensional (1D)-computational fluid dynamics (CFD)) and design of experiments (DoE) up to the experimental validation to build a dedicated exhaust-gas recirculation (EGR) system for a stationary four-cylinder naturally aspirated gas engine. This system should ensure an equal distribution of the recirculated exhaust gas, coming entirely from the rich-operated dedicated cylinder. The rich combustion enables an in-cylinder production of highly reactive species (mainly H2 and CO), resulting in increased EGR reactivity, which improves the dilution tolerance, leading to reduced wall heat losses and lower knock tendency in the EGR receiving cylinders. However, the EGR system design represents a challenge due to the pulsating exhaust gas flow from the dedicated cylinder, which leads to a considerable EGR maldistribution in the receiving cylinders. A numerical analysis of this effect demonstrated that the EGR distribution uniformity depends on the design and dimensions of the EGR path. Considering the numerous design parameters and taking into account that the optimum design of the EGR path is not necessarily the sum of optima from the one-factor-at-a-time variations, efficient DoE methodologies were applied. They enabled identifying the optimum set of the EGR path design-parameters, with an EGR rate maldistribution of about 1% points. To evaluate the quality of the numerical results, the dedicated EGR path with the optimum parameters set was built on the engine test bench. The experimental results confirm the simulative prediction accuracy, demonstrating the reliability of the pursued approach.

THE PROBLEM OF LIQUEFACTION OF NATURAL GAS CONTAINING NITROGEN IN SMALL-SCALE PLANTS

One of the problems in the implementation of natural gas liquefaction technology in a closed high-pressure cycle is the accumulation of low-boiling components, in particular, nitrogen in the circulating gas stream, as a result of which the throttle effect decreases and, accordingly, the specific energy consumption of the liquefaction plant increases. The nitrogen concentration influence on the liquefaction plant operation in the throttle cycle of high-pressure natural gas with a nitrogen content of 0 to 6 % was studied using the GazCondNafta software system for computer simulation of technological processes. To solve the problem of liquefaction of nitrogen-containing gases, a liquefaction scheme with two stages of throttling and intermediate separation with nitrogen vapor stripping is proposed. The effect of gas pressure in the nitrogen separator was determined from the point of view of minimizing losses of the main component of natural gas — methane — with stripping gas with a relatively small decrease in energy efficiency. Bibl. 14, Fig. 6, Tab. 4.

ОБ УЧЕТЕ ЕДИНИЦ ИЗМЕРЕНИЯ ФИЗИЧЕСКИХ ВЕЛИЧИН ПРИ СОСТАВЛЕНИИ МАТЕМАТИЧЕСКИХ МОДЕЛЕЙ НА ЯЗЫКЕ ПРОГРАММИРОВАНИЯ PYTHON

The thesis reveals the problem of units of measurement of physical quantities in mathematical simulation of technological processes using the Python programming language. General information about the purpose and capabilities of the “Pint” module is given. It is shown the module allows you to perform mathematical calculations with taking control of units of measurement

An Automatic Assembly SMT Production Line Operation Technological Process Simulation Model Development

This article describes an automatic assembly SMT production line operation technological process simulation model development within the framework of modern cyber-physical production systems. In the course of the research, the authors conduct an analysis of modern publications on the topic of research, and the need to find new approaches for modeling the work of a production line at the initial stages of design. This makes it possible to assess the load on each element of the system at the design stage, and identify disadvantages at the early stages of production planning. The authors give an example of the task solution for modeling a fragment of an automated production line of SMT assembly, based on the use of typical mathematical schemes of mass service systems (MSS). A description of the functioning of the technological link of the process is carried out, and a Q-diagram of the technological process of SMT assembly is developed. Using the simulation modeling language GPSS and the technological parameters of the selected equipment, a block diagram was developed, on the basis of which the program was written and the work of the SMT assembly production line was simulated. The obtained results further allow us to estimate the production capacity, the loading of each equipment, the functioning processes of both the selected fragment, and the developed model and they can be applied to the simulation of large production lines within the framework of PCB production.

MODELING OF PROCESSES OF INDUSTRIAL PREPARATION, PROCESSING AND LIQUEFACTION OF NATURAL GAS

The article presents the results of the development of the modernization of the complex gas preparation installation, namely the modeling of the processes of removing heavy hydrocarbons at the stage of preparing natural gas for transportation. Heavy hydrocarbons, which are removed at this stage, become a separate commodity product in the process of processing. With the use of software systems for computer simulation of technological processes of GazCondNafta and HYSYS, a variant of the modernization of the existing installation of complex gas preparation of the gas condensate field was developed. Options for modeling technological schemes for obtaining target fractions of methane, ethane, propane, butane from natural gas, gas synthesis and pyrolysis gas are given. Bibl. 9, Fig. 5, Tab. 8.

Experience of virtual commissioning of a process control system for the production of high-paraffin oil

This work describes the experience in developing and testing software for oil industry automation control systems based on the simulation of technological processes and control systems combined in virtual reality, this approach is called virtual commissioning and is widely used in the world both to create automated process control systems and to simulate interactions between different systems.

Emerging Research Trend in Chemical Technology Towards Sustainable Development

The rapid industrialization and urbanization as well as rising global transportation have induced numerous challenges regarding energy security, environmental protection, waste management, and greenhouse gas emissions across the world. Addressing these current issues is crucial to guarantee the sustainable development, green environment, and circular economy. The implementation of advanced chemical technology in industrial production, worldwide transportation, and environmental treatment could contribute to efficiently solve these global challenges. This special issue of Chemical Engineering & Technology highlights the recent research trends in chemical technology towards sustainable development such as advanced material synthesis from various waste sources, biological and thermochemical processes for alternative biofuels and chemicals production. In particular, the synthesis of polysulfide from waste cooking palm oil and the production of hybrid films reinforced with cellulose nanofibers used as packaging materials are thoroughly discussed. Additionally, a comprehensive review regarding waste biomasses transformation to value-added biofuels and biochemicals via thermochemical processes, namely, liquefaction, gasification, torrefaction, and pyrolysis, is presented in this special issue. The environmental benefits associated with these approaches are also underlined. Computer-aided methods including simulation, modeling, and optimization of different chemical engineering processes for energy and environmental applications are offered as well. The contribution from authors across the world to this thematic issue is highly appreciated. The guest editors also acknowledge the valuable effort and constructive comments from reviewers for manuscript assessment. Lastly, we would like to appreciate the Editor in Chief Dr. Barbara Böck and the entire editorial office for their valuable support and guidance during the completion of this topical issue. Dr. Dai-Viet N. Vo, Institute of Applied Technology and Sustainable Development, Nguyen Tat Thanh University, Vietnam Dr. Sumaiya Zainal Abidin, Department of Chemical Engineering, College of Engineering, Universiti Malaysia Pahang, Malaysia Dr. P. Senthil Kumar, Department of Chemical Engineering, Sri Sivasubramaniya Nadar College of Engineering, India Dr. Muthusamy Govarthanan, Department of Environmental Engineering, Kyungpook National University, South Korea Dai-Viet N. Vo Sumaiya Zainal Abidin P. Senthil Kumar Muthusamy Govarthanan

Verification of analytical antiderivatives forms using correlation analysis for mechanical problems

An analytical search for antiderivative functions (indefinite integrals) is widely used in the mathematical simulation of various engineering, economic, ecological, biological, social, and other processes. In their turn, mechanical problems have many subproblems whose solution involves analytical integration methods. Among these problems is the problem of development of analytical models for navigation and ballistics support and control theory models in space rocket engineering. The advantage of this approach to mathematical simulation is a fast analysis of the state of dynamic systems on different time intervals without calculating all previous states. In their turn, for some classes of functions, antiderivatives may be found in several different ways, as a result of which there exist several different forms of antiderivatives that are hard to verify by the classical method in standard form. This is mainly due to the choice of various combinations of integration methods used in the development of analytical models, in particular in problems of applied mechanics. Taking into consideration these difficulties in the verification of the set of antiderivative functions, this paper proposes a method to check their analytical forms for correspondence with the use of correlation analysis. In doing so, the arrays of the values of each antiderivative form at certain nodal points are represented as a set of random variables. With this in mind, it is suggested that the verification process be conducted with the use of the standard approach based on correlation analysis (using Pearson’s correlation coefficient). The efficiency of the method is shown by the example of verifying the antiderivatives of the reciprocal of a squared quadratic trinomial. This approach will make it possible to check the adequacy of the i-th candidate antiderivative and to adapt the problem to the standard form.

A review of the contributions of P. Raj Bishnoi to chemical engineering

AbstractThis paper provides a review of Professor Bishnoi's research contributions in the broad discipline of chemical engineering. Prof. Bishnoi has been a dedicated mentor, collaborator, innovator, and outstanding researcher. He has had a most productive and illustrious career, spanning more than four decades in both academia and industry. He is among the top 50 most‐published authors of the The Canadian Journal of Chemical Engineering. He initiated a most successful and renowned research group at the University of Calgary, which was dedicated to the understanding of thermodynamics and kinetics related to the formation and decomposition of gas hydrates as well as the chemical engineering process design and simulation. As a tribute to Prof. Bishnoi's numerous scientific and engineering contributions and innovations, this review highlights his academic and research accomplishments, which included the training of several doctoral degree students, master's degree students, and postdoctoral scholars and research associates. In this paper, we have divided Prof. Bishnoi's research contributions into three broad areas, namely, chemical thermodynamics of hydrocarbon systems, process development and simulation, and thermodynamics and kinetics of the formation and decomposition of gas hydrates.

Method of analytical modeling and simulation of technological processes subject to the influence of external factors

The method of analytical modeling and simulation of technological processes is presented, which makes it possible to assess the influence of external factors on the operation of information and control systems. The application of this method to study the process of detecting pipeline defects by vibroacoustic control systems is considered. A mathematical model with automatic selection of the parameters of autocorrelation functions of random disturbances is proposed, which makes it possible to take into account the influence of natural and man-made noises on the detection process. The possibility of modeling the influence of random disturbances on the working processes of technological machines is also considered. The proposed simulation models are of practical value, since they allow one to study virtual prototypes of construction and road-building machinery in various modes and reduce the cost of performing expensive field experiments.

Influence of thermal piston insulation on the indicated efficiency of SI-engines

High efficiency gasoline combustion engines with up to 50 % indicated efficiency are the target of current research work. To reach this goal, it’s essential to reduce all the combustion engine losses as much as possible. One major loss, with about 30 % of the total fuel energy, is the wall heat transfer loss. To reduce this loss, one solution is a temperature swing insulation, which is characterized by a low thermal conductivity and at the same time a low volumetric heat capacity. In order to analyze the thermal efficiency potential of different insulation materials, a thermal insulation model for one-dimensional engine process simulations has been developed and is presented in this paper. The insulation is discretized by a thermal node model and is coupled to an engine process simulation using the simulation tool GT-Power. The heat transfer and temperature swing behavior of the thermal insulation model is validated against 3D-CFD engine cycle simulations. A predictive detailed chemistry combustion model is used in 3D-CFD simulations to evaluate the influence of thermal insulations on the knocking tendency. Two different thermal insulation materials are investigated using the developed simulation model. One is yttria stabilized zirconia (YSZ) as a common thermal sprayed coating. The second material is produced by an electrolytic oxidation of the piston surface (anodizing). With thermal piston insulation, there is only a small increase in thermal efficiency in the range of 0.2 % to 0.6 % possible with both materials, whereby the potential increases at low speeds and medium loads. The reason can be found in the relative heat losses, which increases with a constant center of combustion and increasing load. An efficiency loss analysis shows that the exhaust losses increase by about two third of the reduced heat losses. Due to its lower volumetric heat capacity and similar heat conductivity, the anodized piston surface shows a thermal efficiency advantage compared to YSZ. The simulation results are finally validated by measurements conducted with a single-cylinder research engine for an YSZ coated piston surface as well as a hard anodized piston surface.

Дослідження лабораторного прокатного стана 150 як об'єкта автоматизації

The purpose of the work is to study the laboratory rolling mill 150 as an object of automation to establish the relationship between rolling parameters and the dimensions of the rolled products, as well as the implementation of the system of automated regulation of the thickness of the rolled products (SAR). The work is intended for further application in the educational process for the formation of students' competencies in the study of automation objects and the synthesis of SAR. Teaching students with the help of computer equipment and technological process simulation packages definitely made progress in education, allowed to quickly explore different modes of processes and obtain the necessary solutions to problems. But the lack of studies of real processes with real sensors and executive mechanisms and in the conditions of obstacles creates a feeling of ease in research and decision-making. The conducted experimental studies made it possible to establish the dependence between the thickness of the finished rolled product and the rolling force, the change in the thickness of the roll and the change in the gap between the rolls. The stiffnesses of the rolling mill and rolled metall were determined. The stiffness of the rolling mill is equal to 26801 N/mm and is much higher than the stiffness of rolled steel. It is shown that the line of plastic deformation of the rolled product has a significantly nonlinear character, the stiffness of the rolled product varies in the range of 618 - 7093 N/mm. It is shown that changing the inter-roll gap does not provide full compensation for the effect of changing the thickness of the roll. Research has also shown that to determine the necessary parameters, it is enough to have a limited number of lead samples, which allows you to apply experimental research in the educational process. The conducted experimental studies determined that it is possible to conduct them in the conditions of laboratory work performed by students, they allow students to gain the necessary experience in the study of the rolling state as an object of automation and the operation of the system for regulating the thickness of the rolled metal.

A Simulator for Educating the Digital Technologies Skills in Industry. Part One. Dynamic Simulation of Technological Processes

Digital technology is being introduced into all areas of human activity. However, there are a number of challenges in implementing these technologies. These include the delayed return on investment, the lack of visibility for decision-makers and, most importantly, the lack of human capacity to develop and implement digital technologies. Therefore, creating a digital training simulator for the industry is an actual task. This paper focuses on the first step in creating a digital training simulator for the industry: developing a dynamic process model. The process chosen is flotation, as it is one of the most common mineral processing methods. The simulation was performed in AVEVA Dynamic Simulation software. The model is based on a determination of reaction rate constants, for which, experiments were conducted on a laboratory pneumomechanical flotation machine with a bottom drive. The resulting model was scaled up to industrial size and its dynamic properties were investigated. In addition, the basic scheme of a computer simulator was considered, and the testing of the communication channels of a dynamic model with systems, equipment and software for digitalizing was conducted. The developed model showed acceptable results for its intended purpose, namely, an exact match to the technological process in terms of time. This helps to account for inertia and a fast response on all tested communication channels, as well as being acceptable for the real-time simulation speed of the solver.

Моделювання радіаційної обстановки при поводженні з відпрацьованим ядерним паливом

We have developed a model of the technological process for handling spent nuclear fuel in the reception building of the Centralized Storage Facility for Spent Nuclear Fuel using the ChNPP VRdose Planner Pro v. 2.2DEV-0. The results of the technological process simulation proved the reliability of the virtual models for scenarios of radiation-hazardous work for the optimization of the dose loads of personnel.

Study of isothermal decomposition of austenite using methods of mathematical modeling

The capabilities of the numerical simulation of technological processes are limited by the accuracy and efficiency of determining the properties of materials which continuously change with repeated heating and cooling. The parameters of structural transformations are the principal factors affecting the properties of alloyed steels. We present a method for determining the parameters of formulas describing C-shaped curves of experimental diagrams of isothermal decomposition of austenite. The proposed approach makes it possible to reconstruct the entire C-shaped curve using a relatively small fragment near the «nose» (by three points). Joint processing of a series of curves provided determination of the parameters of ferritic, pearlitic and bainitic transformation kinetics. However, it is important to take into account the features of the diffusion decomposition of austenite. For example, ferrite and pearlite are formed in overlapping temperature ranges and have similar mechanical properties, but their combining into a single ferrite-pearlite structure complicates the construction of a mathematical model of transformation. The bainitic transformation has a transient character from diffusion to diffusionless one. As for the transformation temperature range, the limiting degree is a function of temperature (as in the case of martensitic transformation). It was shown that for ferrite-pearlite transformation the best results are obtained by the Kolmogorov – Avrami equation, and for the bainitic one — by the Austin – Rickett equation modified with allowance for an incomplete transformation.

Analysis of IoT security issues used in Higher Education Institutions

The holistic analysis conducted in this article aimed to identify vulnerabilities, cyber-attacks and ways to mitigate them in IoT systems, which are increasingly implemented in Higher Education Institutions (HEIs). Industry 4.0 is gaining ground in academia, which governs with a large volume of sensitive data, and the growing use of IoT systems brings a number of undeniable benefits and growing challenges. The creation of smart university campuses, of innovative laboratories that allow the simulation of technological processes but also of smart classes that use a mix of technologies for the education of professionals in Industry 4.0, represents the future of education. That is why the security analysis of IoT systems is very important to ensure the confidentiality, integrity and availability of academic data.