A bi-layer optimization approach for a hybrid flow shop scheduling problem involving controllable processing times in the steelmaking industry

A steelmaking-continuous casting (SCC) scheduling problem is an example of complex hybrid flow shop scheduling problem (HFSSP) with a strong industrial background. This paper investigates the SCC scheduling problem that involves controllable processing times (CPT) with multiple objectives concerning the total waiting time, earliness/tardiness and adjusting cost. The SCC scheduling problem with CPT is seldom discussed in the existing literature. This study is motivated by the practical situation of a large integrated steel company in which the just-in-time (JIT) and cost-cutting production strategy have become a significant concern. To address this complex HFSSP, the scheduling problem is decomposed into two subproblems: a parallel machine scheduling problem (PMSP) in the last stage and an HFSSP in the upstream stages. First, a hybrid differential evolution (HDE) algorithm combined with a variable neighborhood decomposition search (VNDS) is proposed for the former subproblem. Second, an iterative backward list scheduling (IBLS) algorithm is presented to solve the latter subproblem. The effectiveness of this bi-layer optimization approach is verified by computational experiments on well-designed and real-world scheduling instances. This study provides a new perspective on modeling and solving practical SCC scheduling problems.     

A Complexing Agent to Enable a Wide-Temperature Range Bromine-Based Flow Battery for Stationary Energy Storage

Bromine-based flow batteries (Br-FBs) are considered one of the most promising energy storage systems due to their features of high energy density and low cost. However, they generally suffer from uncontrolled diffusion of corrosive bromine particularly at high temperatures. That is because the interaction between polybromide anions and the commonly used complexing agent (N–methyl–N–ethyl–pyrrolidinium bromide [MEP]) decreases with increasing temperatures, which causes serious self-discharge and capacity fade. Herein, a novel bromine complexing agent, 1–ethyl–2–methyl–pyridinium bromide (BCA), is introduced in Br-FBs to solve the above problems. It is proven that BCA can combine with polybromide anions very well even at a high temperature of 60 °C. Moreover, the BCA contributes to decreasing the electrochemical polarization of Br⁻/Br₂ couple, which in turn improves their power density. As a result, a zinc–bromine flow battery with BCA as the complexing agent can achieve a high energy efficiency of 84% at 40 mA cm⁻², even at high temperature of 60 °C and it can stably run for more than 400 cycles without obvious performance decay. This paper provides an effective complexing agent to enable a wide temperature range Br-FB.     

Flow state monitoring of gas-water two-phase flow using multi-Gaussian mixture model based on canonical variate analysis

As a highly complex and time-varying process, gas-water two-phase flow is commonly encountered in industries. It has a variety of typical flow states and transition flow states. Accurate identification and monitoring of flow states is not only beneficial to further study of two-phase flow but also helpful for stable operation and economic efficiency of process industry. Combining canonical variate analysis (CVA) and Gaussian mixture model (GMM), a strategy called multi-CVA-GMM is proposed for flow state monitoring in gas-water two-phase flow. CVA is used to extract flow state features from the perspective of correlation between historical data and future data, which solves the cross correlation and temporal correlation of multi-sensor measurement data. GMM calculates the possibility that the current flow state belongs to each typical flow pattern and judges the current flow state by probability indicators. It is conducive to follow-up use of Bayesian inference probability and Mahalanobis distance-based (BID) indicator for flow state monitoring, which avoids repeated traversal of multiple CVA-GMM models and improves the efficiency of the monitoring process. The probability indicators can also be used to analyze transition flow states. The method combining the probabilistic idea of GMM with the deterministic idea of multimodal modeling can accurately identify the current flow state and effectively monitor the evolution of flow state. The multi-CVA-GMM method is validated by using the measured data of the horizontal flow loop of gas-water two-phase flow experimental facility, and its effectiveness is proved.     

Comments on “Study and application of discharge calibration for submerged radial gates” by Guo X., Guo Y., Wang T., Fu H., Li J. Flow Meas. Instrum. 78 (2021) 101912, https://doi.org/10.1016/j.flowmeasinst.2021.101912

This paper discusses the capability of Guo et al.'s (2021) equations to determine the discharge of radial gates under submerged flow conditions. It was concluded that Guo et al.'s (2021) equations are associated with error reduction compared to the Incomplete Self-Similarity (ISS) theory and the calibration method. However, it does not have a significant advantage over Energy-Momentum (E-M) approach. Employing E-M principles, new equations were proposed to determine the discharge of radial gates, which has some advantages compared to Guo et al. (2021), such as (1) error reduction under partially and fully submerged flow conditions, (2) least dependence on the empirical constants, (3) uniformity of form over the entire submerged condition, and (4) no need to classify the submerged flow. Field calibration showed that the proposed equations in the present study for a single gate predict the discharge of parallel radial gates with a mean absolute error of less than 4.5% subject to the submerged operation of all open gates.     

Computational modelling of water flow inside laboratory Knelson concentrator bowl

Enhanced gravity concentrators such as Knelson concentrator (KC) are extensively used in the mineral processing industry. The complexities of KC bowl geometry and variation of feed characteristics have forced process engineers to design empirically new units using laboratory and pilot-scale Knelson concentrators. However, numerical modelling methods such as computational fluid dynamics (CFD) and discrete element method (DEM) provide a better insight of flow behaviour of fluid and particulate solid phases inside these processing units. This article reports findings of CFD simulations for single-phase water flow inside the laboratory KC. An available standard 7.5-cm laboratory KC bowl was numerically simulated using realisable k-ε turbulence model to resolve the turbulence dispersion of existing transitional flow regime. The effects of relative centrifugal force (RCF) intensity and bed fluidisation water flow rate on the water velocity and pressure distributions were studied. Simulations confirmed the swirling flow pattern governing inside the bowl. The results revealed that the impact of RCF intensity on the water field values is greater than that of bed fluidisation water flow rate. Both velocity and pressure variations inside the bowl rings followed a linear trend.     

A modified cross-correlation algorithm for PIV image processing of particle-fluid two-phase flow

PIV (Particle Image Velocimetry) technique for flow field measurement has achieved popular self-identify through over ten years development, and its application range is becoming wider and wider. PIV post-processing techniques have a great influence on the success of particle-fluid two-phase flow field measurement and thus become a hot and difficult topic. In the present study, a Phase Respective Identification Algorithm (PRIA) is introduced to separate low-density solid particles or bubbles and high-density tracer particles from the PIV image of particle-fluid two-phase flow. PTV (Particle Tracking Velocimetry) technique is employed to calculate the velocity fields of low-density solid particles or bubbles. For the velocity fields of high-density solid particles or bubble phase and continuous phase traced by high-density smaller particles, based on the thought of wavelet transform and multi-resolution analysis and the theory of cross-correlation of image, a delaminated processing algorithm (MCCWM) is presented to conquer the limitation of conventional Fourier transform. The algorithm is firstly testified on synthetic two-phase flows, such as uniform steady flow, shearing flow and rotating flow, and the computational results from the simulated particle images are in reasonable agreement with the given simulated data. The algorithm is then applied to images of actual bubble-liquid two-phase flow and jet flow, and the results also confirmed that the algorithm proposed in the present study has good performance and reliability for post-processing PIV images of particle-fluid two-phase flow.     

Influences of chip serration on micro-topography of machined surface in high-speed cutting

Saw-tooth chip changes from macroscopically continuous ribbon to separated segments with the increase of cutting speed. The aim of this study is to find the correlations between chip morphology and machined surface micro-topography at different chip serration stages encountered in high speed cutting. High strength alloy steel AerMet100 was employed in orthogonal cutting experiments to obtain chips at different serration stages and corresponding machined surfaces. The chips and machined surfaces obtained were then examined with optical microscope (OM), scanning electron microscope (SEM), and white light interferometer (WLI). The result shows that chip serration causes micro-waves on machined surface, which increases machined surface roughness. However, wave amplitudes (surface roughness) at different serration stages are different. The principal factor influencing wave amplitude is the thickness of the sawed segment (tooth) of saw-tooth chip. With cutting parameters in this study, surface roughness contributed by chip serration ranges from 0.39 μm to 1.85 μm. This may bring on serious problems in the case of trying to replace grinding with high-speed cutting in rough machining. Some suggestions have been proposed to control the chip serration-caused surface roughness in high-speed cutting based on the results of the current study.     

The use of bio-diesel based additive as rheology improver and pour point depressant of Nigerian waxy crude

The chemical method has proved to be the most effective mitigating method of wax deposition in petroleum system as it deals with the root cause of wax formation. Most of the commercial chemicals in the industry are very expensive and toxic. This paper aims the use of biodiesel based additives for improving the rheological behavior and pour points of waxy crude from Nigeria field. The biodiesels derived additives gave better performance than the commercial chemical and the seed oils as greatly improvement in rheology and pour point values of the waxy crude were observed     

Flow pattern identification and measurement techniques in gas-liquid-liquid three-phase flow: A review

The simultaneous flow of gas, oil, and water forms various flow patterns due to the complex interfacial relationships. Three-phase flow patterns are classified as the gas-liquid and liquid-liquid flow patterns. Pressure drop, void fraction, liquid holdup, and phase distribution are important characteristics of the three-phase flow. These characteristics are generally associated with the three-phase flow patterns. Hence, the knowledge about flow patterns can help to predict the overall behavior of the three-phase flow. Studies have been conducted to identify three-phase flow pattern and their characteristics at various superficial velocities of gas, oil, and water. The major purpose of the studies is to gather information about the three-phase co-current flow and use it for improvement of the efficiency of the flow systems. Therefore, the accuracy of the measurement technique is critical. Several types of flow pattern identification and measurement techniques have been developed to improve accuracy and provide high-quality results. In this article, classical and advanced techniques used for the three-phase flow identification and measurement have been reviewed. The survey will help the researchers working in the area of multiphase flow to choose the right technique based on the objectives of the studies.