Efficient Engineering and Production Concepts for Products in Regulated Environments – Dream or Nightmare?

Manufacturing of chemical‐pharmaceutical products is moving increasingly fast on a global scale. Therefore, developing and starting up production facilities fast, with high quality, and at reasonable costs has become extremely challenging. Engineering concepts like modularization, standardization and simultaneous/parallel engineering are discussed as methods for speeding up process design and filing for regulatory approval. Transfer from batch to continuous operation mode of production is pointed out as the key‐issue in such strategies.     

Low-cost direct writing lithography system for the sub-micron range

Abstract

We have developed a fixed beam direct writing laser lithography system with a minimum feature size of 400nm at 457nm wavelength and a writing speed of 4·2mm/s with total system costs of less than 100 000 US$.     

Comparison of filter media,plant communities and microbiology within constructed wetlands treating wastewater containing heavy metals

The aim of this study was to investigate the treatment efficiency of passive vertical‐flow wetland filters containing Phragmites australis and/or Typha latifolia and granular media of different adsorption capacities. A cost–benefit analysis was performed on the characteristics of constructed wetlands. Cheap gravel and sand as well as expensive granular activated carbon, charcoal and Filtralite (light expanded clay) were used as filter media. Different concentrations of lead and copper sulfate were added to polluted urban beck inflow water in order to simulate pre‐treated mine wastewater, landfill leachate or highway runoff. The relationships between growth media, microbial and plant communities as well as the reduction of lead, copper, five‐day biochemical oxygen demand (BOD) in particular, and potentially pathogenic bacteria were investigated. A breakthrough of copper within the first 9 weeks was only recorded for filters containing media with limited adsorption capacities. The breakthrough was independent of the presence of plants. However, after maturation of the biomass, which dominated the schmutzdecke and litter zone, lead and copper concentrations were reduced by 97–99% and BOD by 41–60% in all wetlands. There appears to be no additional benefit in using macrophytes and expensive adsorption media in constructed wetlands to enhance metal reduction during the set‐up period of 5 months. © 2001 Society of Chemical Industry     

Recrystallization kinetics of ultrafine-grained Ni studied by dilatometry

The release of excess volume upon recrystallization of ultrafine-grained Ni deformed by high-pressure torsion was measured with a high-precision difference-dilatometer employing constant heating rates in the range from 0.3 to 10 K min^?1. The kinetics of the recrystallization process was analyzed according to the Johnson–Mehl–Avrami–Kolmogorov theory adapted to the case of constant heating rates. An effective Avrami exponent of 2 and a value of 1.20 eV for the activation energy of recrystallization was determined. Analysis by the Kissinger method yielded the same result for the activation energy.     

Drying quality of rubberwood: an industrial perspective

In this study, the kiln drying yield of 30 mm Rubberwood (Hevea brasiliensis) used for the furniture manufacturing industry in South East Asia was evaluated. The results showed that the average yield loss was 10%, and end-checks, splits and warping were the most common drying defects. It was found that sawn timber from older trees (> 21 years) were less prone to drying defects, and the use of stress relieving treatments significantly reduced the incidence of drying defects.     

The virtual production simulation platform: from collaborative distributed simulation to integrated visual analysis

Computational simulations are used for the optimization of production processes in order to significantly reduce the need for costly experimental optimization approaches. Yet individual simulations can rarely describe more than a single production step. A set of simulations has to be coupled to each other to form a contiguous representation of a process chain. Eventually, simulated results have to be analyzed by domain experts to gather insight from the preformed computations. In this paper, we propose an IT infrastructure and software tools that aim at a rather non-intrusive way of coupling resources and domain expert’s knowledge to enable the collaborative setup, execution and analysis of distributed simulation chains. We illustrate the approach in the domain of materials processing. Beyond means originating from the domain of GRID computing for resource management, a data integration component assures semantic data integrity between the simulation steps and stores simulation data in an application independent way. Thus, we can transform this data into native formats for each simulation tool, and finally into a format that allows for contiguous visualizations and an intuitive, comprehensive analysis of complete simulated process chains.     

Particle Size Distribution of Wood Dust in Rubberwood (Hevea Brasiliensis) Furniture Manufacturing

The study evaluated the concentration and particle size distribution of air-borne wood dust in the Rubberwood furniture manufacturing industry. Air quality samples were measured at routing and hand-sanding work stations in furniture factories using the micro-orifice uniform deposit impactor (MOUDI) air-quality measuring instrument. It was found that less than 25% of the air-borne wood dust particles at the two work stations were less than 10 μm in size, which in turn did not pose major respiratory health hazards. However, the high wood dust concentrations at the two work stations is a matter of concern, and efforts must be taken to minimize the air-borne wood dust exposure levels workers are subjected to in the Rubberwood furniture manufacturing industry.     

Verklebung von wachsimprägnierter Buche unter Variation der Klebesysteme und Durchführung einer Plasmabehandlung

Beech wood was impregnated with two hot melting waxes. Contact angle measurement followed to determine hydrophobizing of such treated wood. Tensile shear tests were carried out to test the adhesion properties with three different glues under varying environmental conditions. Furthermore, wax impregnated beech was subjected to plasma treatment prior to glueing. The results demonstrate that wood treated with polar paraffin shows lower adhesion properties compared to montan wax. Therefore, montan wax was investigated more intensely. Beech impregnated with such wax can be used for constructive building elements in the interior sector. D3 Glues for non-constructive applications were realized by using PVAc and phenol-resorcinol resin under permanent influence of humidity. Plasma treatment improves this quality to obtain D4 glue. Back-drying of the water stored specimens proves the suitability of isocyanate glue and also that of PVAc after plasma treatment for 120 s.