基于ISA88的批次控制技术在制丝生产线中的应用

传统的制丝生产线控制系统在处理复杂工艺过程中,由于工艺调整困难、控制模块通用性差,难于适应制丝分组加工工艺复杂多变的要求。为此,基于符合ISA88标准的批次控制技术设计了制丝线控制系统。该系统由设备控制层、集中监控层和生产管理层组成,在模型构建上分为过程模型、物理模型、程序控制模型和配方模型4个层次,通过BATCH控制软件程序设计、标准化的程序接口和系统集成技术实现了制丝线管控系统的柔性化、精细化管理和控制要求。应用效果表明,该系统符合制丝线分组加工所需要的分段化、模块化、个性化和通用化要求,缩短了系统研发周期,加快了新产品的研发速度,提高了生产效率。     

卷烟制丝生产的柔性制造初探

通过对烟草制丝线的需求和发展方向进行分析,提出了卷烟制丝线的柔性制造技术和加工模式,并对传统制丝线、半柔性制丝(分组加工技术)和柔性制丝生产系统进行了对比分析。着重探讨了柔性制丝生产系统3个子系统(加工系统,物流系统,控制与管理系统)及实现的功能,并提出卷烟制丝的柔性化加工将成为今后卷烟制丝生产的重要方式之一。     

制丝生产多维度评价体系的建立

结合制丝生产批次评价系统在长沙卷烟厂生产管理中的应用,总结了长沙卷烟厂制丝生产定量评价的经验:（1）建立产、质、耗指标评价体系;（2）根据工艺要求确定目标值,建立统一的评分规则;（3）根据各指标数据回归分析确定指标权重。最终实现从点到面对制丝生产地整体评价,从而提高生产柔性组织能力、质量控制水平、成本控制水平,促进生产总体平衡。      

复杂工艺柔性数字化制丝线的构建

为解决制丝生产采用分组加工技术后工艺路径复杂、加工柔性化等导致的生产管理和控制难度大等问题,采用建模、排程、物流等技术对制丝线进行了3步数字化建设:基于平台对制丝线进行标准化建模,在模型上建立高级排程系统实施生产计划排程,以物流技术为基础实现虚拟到现实的同步匹配,从而构建了具有等级烟叶分类预处理和模块烟叶分组加工能力的柔性数字化制丝线。应用效果表明,数字化建设应用于常德卷烟厂"芙蓉王"6000 kg/h制丝专线,每天处理片烟超过10万kg,每次排程时间均在10min以内,生产组织管理有效,物料和路径在线管理同步匹配,数据传递及时准确,有效保障了制丝生产的可靠与高效运行。     

基于批次的制丝质量检验系统的设计应用

传统的质量检验作业按业务单据内容完成,由于业务单据中存在多个牌号和多种检验项目,其主线是业务单据号,按业务单据设计的信息系统无法实现对牌号和检验项目进行分析,为此引入批次主线设计了基于批次的制丝检验作业流程.通过批次贯通制丝生产过程各工序检验项目,实现了制丝检验业务按批次进行查询、统计和分析,改变了传统的检验作业模式,解决了传统检验系统检验项目数据混杂的问题.实际应用效果表明,该系统操作简单,检验业务合理,报表清晰明确.     

卷烟厂异味处理系统控制方式的优化改进

为解决北京卷烟厂制丝生产线两套独立的异味处理系统在实际生产过程中排潮量与处理能力不匹配而引起的能源浪费问题,对车间异味处理系统的控制方式进行了优化改进。将独立运行的两套异味处理系统合二为一,通过调节异味处理系统风机频率和主、备系统切换方式,使异味处理系统处理能力与制丝线排潮量始终保持一致。应用效果表明,改进后异味处理系统可根据制丝线各生产工序的开启、排潮量进行合理的调节和控制,电耗由15000 kW.h/月左右下降到8000 kW.h/月左右,有效降低了制丝生产中的能源消耗。     

基于ANP的卷烟制丝质量评价方法

针对传统制丝质量评价体系以主观因素为主、缺乏科学依据因而难以定量分析的问题,提出了基于网络分析法ANP的制丝质量评价方法.为考察制丝工艺关键工序对制丝质量的影响权重,构建了ANP网状模型和比较判断矩阵,再根据加权超矩阵的计算排序结果进行质量评价.结果表明,滚筒烘丝工序对制丝质量影响最为显著,生产中着重强化该环节的参数优化和稳定性控制,制丝质量明显提高.这表明基于ANP的制丝质量评价方法能够有效提高制丝工艺控制精度和过程质量控制能力,可为制丝工艺确定最佳的工艺条件和准确的工艺参数提供理论依据.     

基于有向图的卷烟生产批次跟踪谱系的建立

随着分组加工技术在卷烟企业中的应用,全配方加工中的树型结构已无法表征制丝线生产批次之间的多对多关系并建立批次跟踪谱系。为此,通过对分组加工中批次管理的技术特点进行分析和研究,提出了采用有向图法建立卷烟生产批次跟踪谱系的方法。结果表明,该方法可以有效地表征分组加工中批次之间的相互关系,进而建立起分组加工中复杂混合批次跟踪谱系,从而为卷烟生产MES系统质量追溯和生产性能分析等提供数据依据。     

SPC质量统计过程控制系统在复烤生产线中的应用

对SPC技术原理在烟叶加工质量保障中的应用进行了研究,根据复烤工艺要求和SPC原理,采用C#开发了基于B/S的SPC质量统计过程控制系统,该系统将生产控制监控网、现场总线网及质量管理信息系统有机集成在一起,通过Intranet和共享数据库使数采、存储、质量分析控制一体化,实现了烟叶批次数据的自动生成、故障时间段记录等。利用控制图、直方图对烟叶批内/批间数据、装箱抽检数据进行了统计分析、质量判定及异常报警,并对复烤生产线SPC质量控制系统的系统配置,以及OPC数据采集、业务流程分析、实时关系数据库、烟叶批次生成、程序分析流程、面向对象的SPC图形界面开发等技术进行了分析。系统投入使用后,运行稳定,分析准确,通过对生产工序指标进行质量监控分析、判定,以减少烤烟生产过程中的异常波动,实现了复烤生产线质量统计过程控制的信息化、自动化,提高了打叶复烤生产的过程控制能力。     

基于加权TOPSIS的制丝综合质量评价方法

针对当前制丝质量评价方法存在的重结果轻过程、结论不直观、缺乏可比性等不足,提出了基于加权TOPSIS(Technique for Order Preference by Similarity to an Ideal Solution)的卷烟制丝过程质量评价方法。按照工段、工序、工艺参数的层次结构建立制丝过程质量评价指标体系,并采用层次分析法进行权重分配,基于加权TOPSIS法形成对工序、工段及整体制丝过程的批次质量评价方法。以D牌号一个月的制丝生产过程为例,验证该方法综合评价能力,结果表明：该方法适用于制丝过程质量与历史水平的纵向比对,能够快速发现批次弱项指标,有利于促进制丝质量持续改进。     

溶氧控制和pH控制在赖氨酸分批发酵过程中的应用

研究了溶氧和ｐＨ值对赖氨酸产生菌ＦＢ４２发酵的影响，结合发酵过程的动力学分析，得出了分批发酵操作的溶氧和ｐＨ控制模式。结果表明两种控制都使发酵水平得到提高，但以溶氧控制更有效，在溶氧控制模式下，发酵的转化率从３３．６％提高到３８．１％。     

采用鼓泡柱式光生物反应器培养螺旋藻的研究

鼓泡柱式光生物反应器是一类简单、高效的光生物反应器。本文对鼓泡柱式光生物反应器中影响螺旋藻生长的因素：光强、温度、二氧化碳、气泡、通气速度等以及分批培养生长模型进行了研究。采用有气泡分布器的１．２ｌ，鼓泡柱式光生物反应器分批培养螺旋藻，在光强Ｅ＝１６ｋｌｘ，温度Ｔ＝３０～３３℃，以通气速度Ｖｇ＝４６ｌ／ｈ通入纯净空气时，第５ｄ可达最大细胞干重：３．３ｇ／ｌ。     

冷轧堆前处理加工在民丰厂的实践

介绍了冷轧堆前处理加工大生产的经验,包括设备组成;助剂及工艺条件优选;技术关键及有待改进的方面等等。     

Optimisation of bacteriocin production of Lactococcus lactis subsp. lactis MA23, a strain isolated from Boza

Lactococcus lactis subsp. lactis MA23 produces a bacteriocin (6400 AU/mL) that inhibits the growth of many Gram‐positive bacteria but is not active against Gram‐negative bacteria. This bacteriocin inhibits growth of lactococcal strains that are producing nisin, lacticin or lactococcin suggesting it to be different from these bacteriocins. The nutritional requirements and optimal growth conditions for MA23 bacteriocin production were studied with fed‐batch fermentations. The optimal pH, carbon source and nitrogen source for bacteriocin production were pH 6.5, sucrose (0.5%) and yeast extract (1%), respectively.     

灯芯绒活性染料冷轧堆染色工艺

本文介绍了活性染料冷轧堆染色工艺优越性及一般工艺介绍，并说明了生产中应注意问题。     

Effects of low pressure and a rectification column on the volatile composition of fermented grape distillate

Fermented crushed Prosecco grapes were distilled using a batch still under normal (100.9 kPa) and reduced pressure (40 or 47 kPa) with and without the rectifying column of the distillation equipment. To improve insight into the behaviour of ethanol and the partitioning of some volatile compounds, each distillate was collected in fractions and analysed for lower volatile alcohols and esters. The results show that the behaviour of ethanol under reduced pressure was more consistent, the proof level higher than at normal pressure and there was a stripping effect on the volatile compounds considered at low pressure. This effect is enhanced when the rectifying column is included. It was concluded that it could be advantageous to use 'vacuum distillation' because it simplifies the operation of the equipment and leads to an overall reduction of the heating required, although there are problems of losses of desirable aromatic compounds.     

An improved model of the seeded batch crystallization of glucose monohydrate from aqueous solutions

The current research has produced an accurate model of the non-nucleating seeded batch crystallization of glucose monohydrate which includes complex phenomena including crystal growth rate dispersion and the effect of the mutarotation reaction. The model is able to predict the population density of crystals in the batch as a function of particle size and batch time, n=n(L,t) as well as total glucose concentration in the mother liquor and the fraction of glucose in the α-d-glucopyranose form. A previous model of similar systems was limited by considering only systems with monosize seed crystals, and where growth rate dispersion had a negligible effect on the particle size distribution. Because of the nature of the ‘common history’ crystals that are produced by the growth of glucose monohydrate, the modifications required to the model to account for these additions to the model are remarkably simple. By predicting the full population density the model produces an accurate mass balance for the crystallization process, since the second moment of the crystal size distribution (CSD) may be calculated analytically at every point in the simulation. This enables the competitive kinetics between the rate of crystal mass deposition of α-glucose and the rate of production of α-glucose via the mutarotation reaction to be more accurately accounted for, and hence the significance of the mutarotation reaction on the crystal growth to be more accurately predicted.     

The role of distillation on the quality of tequila

The role of a batch rectification on the quality of tequila, a traditional Mexican beverage, was studied. It was shown that the official tequila standard composition, particularly the size of the slop cuts and the correct balance of flavour constituents, can be determined by monitoring the concentration of the regulated compounds (ethanol, methanol, higher alcohols, ethyl acetate, acetaldehyde and furfural) throughout the rectification process. It was found that these regulated compounds are produced over the same time scales when either stainless steel or copper alembics are used. When distillations were done in copper alembics, however, it was found that the copper content of the rectified product exceeded the amount permitted in the official tequila standards. Finally, we report a comparison of sensory properties of tequila distillates obtained in both copper and stainless steel alembics.