Synthesis of mass exchange network for batch processes—Part I: Utility targeting

Synthesis of optimal mass exchange network (MEN) for continuous processes based on Pinch Analysis has been rather well established. In contrast, very little work has been done on mass exchange network synthesis (MENS) for batch process systems. The batch process systems referred to in this work can be defined as processes which operate discontinuously and deliver the products in discrete amounts, with frequent starts and stops. There is a clear need to develop a MENS procedure for batch process systems which are industrially very common as well as important. Techniques developed in this paper for the batch MENS involved the first key steps in the synthesis task, i.e. setting the utility targets ahead of batch MEN design. The utility-targeting approach employs the vertical and horizontal cascading approaches in a newly developed tool, i.e. time-dependent composition interval table that has been adapted from heat exchange network synthesis for batch processes. Prior to MEN design, the targeting procedure establishes the minimum utility (solvent) and mass storage targets for a maximum mass recovery network. These targets are essential for network design and batch process rescheduling.     

Networked LQG control over unreliable channels

In this article, the linear quadratic Gaussian (LQG) optimal control problem for networked control systems when data is transmitted through a transmission control protocol (TCP)‐like network and both measurement and control packets are subject to random packet dropouts, is addressed for two cases. In the ?rst case, it is assumed that the control acknowledgment packets in TCP‐like protocols are always available, that is, they always reach the ?lter‐controller unit on time and without fail, and we propose how to design a linear optimal ‘hold‐input’ control law for this case. In the second problem, we assume the acknowledgement packets may go missing with a known probability. This case is known to be di?cult and the optimal control law would be nonlinear. Hence, we derive a suboptimal linear estimation‐control law instead. Simulation results are presented to demonstrate the effectiveness of the proposed approaches. Copyright © 2011 John Wiley & Sons, Ltd.     

Development,implementation, and analysis of direct integration offline programming method

Wire bond programming (WBP) consists of information required to drive a wire bond machine’s movement during the wire bonding process. Wire bond programs consist of three key components: material handling, bonding parameter, and bonding path instructions. Of the three components, the bonding path component requires effort and time the most to prepare, as the preparation of bond path is currently being carried out manually. The manual process is tedious and error prone. In comparison to a manual process, offline programming (OLP) of bonding path creation provides a much more reliable and a less tedious method as it is error proof. OLP can be categorized into two versions, mainly vendor specific OLP and direct integration offline programming (Di-OLP), which is presented in this paper. Vendor specific OLP utilizes bonding diagrams created by a computer-aided design program to generate wire bonding paths. Di-OLP on the other hand utilizes the numeric coordinate data extracted from the bonding diagram creation software to generate the bonding path component of the wire bond program. Di-OLP is a more flexible method as it has the potential to be adapted to different machine platforms. This paper explains the challenges in the implementation of Di-OLP. The effectiveness and efficiency of the program created by Di-OLP are evaluated as compared to a manual programming method. Final results indicate that the offline programming is more efficient as it greatly reduces the time required to create the bonding paths for wire bond programs as compared to the manual methodology.     

The application of virtual reality to tasks in manufacturing and assembly engineering

Virtual Reality is a developing technology for which a range of applications are heing explored by different international research groups. This paper describes recent research in the application of Virtual Reality to two important manufacturing and assembly tasks which have a direct influence on the speed of introduction of new products. The tasks are the production of planning documentation for assembled products and the design and planning of the cable harnesses which form part of all electro-mechanical assemblies. The research completed so far demonstrates the potential of Virtual Reality, even at its current stage of technological development, to make a significant contribution in both these cases.     

A machine vision approach to detect and categorize hydrocarbonfires in aircraft dry bays and engine compartments

In this paper, a machine approach is applied to detect hydrocarbon fires in aircraft dry bays and engine compartments. The inputs to the machine vision system consist of a set of statistical measures derived from the histogram and image subtraction analyses of successive image frames. Specifically, heuristic rules based on the median, standard deviation and normalized first-order moment statistical measures of histogram data and the mean statistical measure of image subtraction data of successive frames are used to compute the likelihood of a fire event. This machine vision system is also tested for false alarms such as those due to flashlights and high-power halogen lights     

An integrated approach for water minimisation in a PVC manufacturing process

This paper presents a water minimisation study carried out for a polyvinyl chloride (PVC) resins manufacturing plant. Due to the complexity of the mixed batch and continuous polymerisation process, an integrated process integration approach, which consists of process synthesis, analysis and optimisation was used for this work. A simulation model was first developed in a batch process simulation software, SuperPro Designer V6.0, based on the operating condition of a PVC manufacturing process. The batch simulation model captured the essential information needed for a water minimisation study, e.g. process duration, water mass flow, etc. Data extracted from the simulation model was later used in the water minimisation study, utilising the widely established process synthesis technique of water pinch analysis. Two water saving scenarios were presented. Scenario 1 reports a fresh water and wastewater reduction of 28.5 and 90.1% respectively, for the maximum water recovery scheme without water storage system. In Scenario 2, higher fresh water and wastewater reduction are reported at 31.7 and 100% respectively, when water storage tank is installed in the water network.     

Streamlined life cycle assessment of residue utilization options in <Emphasis Type="Italic">Tongkat Ali </Emphasis>(<Emphasis Type="Italic">Eurycoma longifolia</Emphasis>) water extract manufacturing process

Life cycle assessment (LCA) is often used to compare alternative process options in terms of their overall impact on the environment to easily identify the most environmentally friendly alternative. In this work, a streamlined LCA study was conducted to assess three different residue utilization schemes for Tongkat Ali (Eurycoma longifolia) extract production. The case study was firstly simulated using a batch process simulation software. The results of mass and energy balances obtained from the simulation software were then subjected to life cycle analysis. By evaluating the different schemes for using the fibrous residue from the extraction process, the potential for environmental process improvement was identified. Overall, use of the residue as process fuel was found to be the most environmentally friendly option. It produces the least emissions and reduces resource usage per unit of product than the other options evaluated.     

Targeting and design for batch regeneration and total networks

Resource conservation for batch processes is gaining good attention in recent years. This is mainly due to the recent trend in chemical engineering that focuses on product engineering, as well as in the rise of various low volume and high value-added products (e.g. pharmaceutical, specialty chemicals, etc.) in the market. In this study, a systematic procedure to perform targeting and design of a batch resource conservation network (RCN) involving material regeneration and waste treatment (also known as a total RCN) is proposed. The procedure is applicable for all fixed-schedule-type batch RCNs with mass storage facilities. Literature examples are used to elucidate the proposed procedure.     

A new addition to the family of polyesters—Synthesis and characterization of novel (alternating) poly(ether ester)s, poly(butylene 3-/4-hydoxy benzoate)s

Novel, predominantly alternating poly(ether ester)s, poly(butylene-3/4-hydroxy benzoate)s (PBHB)s were synthesized by the hydrogenation of the corresponding unsaturated polymers obtained by forming ether and ester linkages under one pot conditions. The ether substitution caused a reduction in glass transition temperature, T_g. The melting transition was also lowered by more than 100°C compared to poly(butylene terephthalate) as studied by the differential scanning calorimetry (DSC). Crystallization was observed during heating as well as cooling in the DSC studies. Wide angle X-ray diffraction (WAXRD) analysis also indicated that PB-4-HB was semi-crystalline in nature. The thermal stability of hydrogenated polymer was better than that of the unsaturated polymer.