Although continuous production processes are often desired, many processing industries still work in batch mode due to technical limitations. Transitioning to continuous production requires an in-depth understanding of how each unit operation is affected by the shift. This contribution reviews the scientific understanding of similarities and differences between emulsification in turbulent rotor-stator mixers (also known as high-speed mixers) operated in batch and continuous mode. Rotor-stator mixers are found in many chemical processing industries, and are considered the standard tool for mixing and emulsification of high viscosity products. Since the same rotor-stator heads are often used in both modes of operation, it is sometimes assumed that transitioning from batch to continuous rotor-stator mixers is straight-forward. However, this is not always the case, as has been shown in comparative experimental studies. This review summarizes and critically compares the current understandin... [more]

Grafting of acrylic monomers onto the renewable feedstock starch via free radical polymerizations has been investigated for many years. Many potential applications have been studied, such as superabsorbents, flocculants, thickening agents and so forth. It is expected that size and spacing of the grafts have a large influence on the performance of such polymers. Yet, information upon the structure-property relationships is only scarcely found in literature. Moreover, there is no clear overview of how reaction variables can be used to influence the grafted structure. In this review, an assessment has been made of the relation between the architecture of the grafts and potential applications. Then, from a selection of relevant literature data it is demonstrated that reaction variables such as the relative concentrations of initiator and monomer, have a large impact on the average size and spacing of the grafts. The emergence of controlled radical polymerizations, like Atom Transfer Radica... [more]

Presented herein is a model-driven strategy for characterizing the production capability of expression host and subsequently identifying targets for strain improvement by resorting to network structural comparison with reference strain and in silico analysis of genome-scale metabolic model. The applicability of the strategy was demonstrated by exploring the capability of Zymomonas mobilis, as a succinic acid producer. Initially, the central metabolism of Z. mobilis was compared with reference producer, Mannheimia succiniciproducens, in order to identify gene deletion targets. It was followed by combinatorial gene deletion analysis. Remarkably, resultant in silico strains suggested that knocking out pdc, ldh, and pfl genes encoding pyruvate-consuming reactions as well as the cl gene leads to fifteen-fold increase in succinic acid molar yield. The current exploratory work could be a promising support to wet experiments by providing guidance for metabolic engineering strategies and loweri... [more]

A process consisting of ball milling followed by NaOH leaching was developed to selectively dissolve alumina from black dross. From the ball milling treatment, it was found that milling speed greatly affected the leaching behavior of silica and the oxides of Ca, Fe, Mg, and Ti present in dross. The leaching behavior of the mechanically activated dross was investigated by varying NaOH concentration, leaching temperature and time, and pulp density. In most of the leaching conditions, only alumina and silica were dissolved, while the leaching percentage of other oxides was negligible. The leaching percentage of silica decreased rapidly to nearly zero as pulp density increased to 100 g/L. At the optimum leaching conditions (5 M NaOH, 50 °C, 2 h, pulp density of 100 g/L), the purity of Al in the leaching solution was higher than 98%, but the leaching percentage of alumina was only 35%.

The aim of this study is to explore an innovative downstream route for microalgae processing to reduce cost production. Experiments have been carried out on cell disruption and fractionation stages to recover lipids, sugars, and proteins. Steam explosion and dynamic membrane filtration were used as unit operations. The species tested were Nannochloropsis gaditana, Chlorella sorokiniana, and Dunaliella tertiolecta with different cell wall characteristics. Acid-catalysed steam explosion permitted cell disruption, as well as the hydrolysis of carbohydrates and partial hydrolysis of proteins. This permitted a better access to non-polar solvents for lipid extraction. Dynamic filtration was used to moderate the impact of fouling. Filtration enabled two streams: A permeate containing water and monosaccharides and a low-volume retentate containing the lipids and proteins. The necessary volume of solvent to extract the lipids is thus much lower. An estimation of operational costs of both steam... [more]

In the field of chemical engineering, mathematical models have been proven to be an indispensable tool for process analysis, process design, and condition monitoring. To gain the most benefit from model-based approaches, the implemented mathematical models have to be based on sound principles, and they need to be calibrated to the process under study with suitable model parameter estimates. Often, the model parameters identified by experimental data, however, pose severe uncertainties leading to incorrect or biased inferences. This applies in particular in the field of pharmaceutical manufacturing, where usually the measurement data are limited in quantity and quality when analyzing novel active pharmaceutical ingredients. Optimally designed experiments, in turn, aim to increase the quality of the gathered data in the most efficient way. Any improvement in data quality results in more precise parameter estimates and more reliable model candidates. The applied methods for parameter sens... [more]

This study is conducted to investigate the characteristics of outflow wastewater of the 1 m³ on-site wastewater treatment unit on the basis of the testing and measurement data of the samples that were taken during the study monitored period (August 2017 to January 2018). For this purpose, samples were taken on a weekly basis from the treated wastewater effluent and five quality parameters (biochemical oxygen demand (BOD), chemical oxygen demand (COD), total suspended solids (TSS), pH, E-coli counts) were monitored and measured. The average values of the five parameters were compared with the Jordanian standard maximum values, and water reuse in irrigation of plants classifications have been assessed and investigated. Average values of BOD, COD, TSS, pH, and E-coli in treated wastewater were 11 mg/L, 104 mg/L, 15 mg/L, 7.51, and 387 counts, respectively. The installation of in-line ultraviolet (UV) unit in recirculating delivery system played a vital role in the reduction of counts far... [more]

Energy saving is an important issue for any industrial sector; in particular, for the process industry, it can help to minimize both energy costs and environmental impact. Maintenance optimization and operational procedures can offer margins to increase energy efficiency in process plants, even if they are seldom explicitly taken into account in the predictive models guiding the energy saving policies. To ensure that the plant achieves the desired performance, maintenance operations and maintenance results should be monitored, and the connection between the inputs and the outcomes of the maintenance process, in terms of total contribution to manufacturing performance, should be explicit. In this study, a model for the energy efficiency analysis was developed, based on cost and benefits balance. It is aimed at supporting the decision making in terms of technical and operational solutions for energy efficiency, through the optimization of maintenance interventions and operational procedu... [more]

This Special Issue (SI) of Processes, “Combined Scheduling and Control,” includes approaches to formulating combined objective functions, multi-scale approaches to integration, mixed discrete and continuous formulations, estimation of uncertain control and scheduling states, mixed integer and nonlinear programming advances, benchmark development, comparison of centralized and decentralized methods, and software that facilitates the creation of new applications and long-term sustainment of benefits.[...]

Fuel gas network (FGN) synthesis is a systematic method for reducing fresh fuel consumption in a chemical plant. In this work, we address FGN synthesis problems using a block superstructure representation that was originally proposed for process design and intensification. The blocks interact with each other through direct flows that connect a block with its adjacent blocks and through jump flows that connect a block with all nonadjacent blocks. The blocks with external feed streams are viewed as fuel sources and the blocks with product streams are regarded as fuel sinks. An additional layer of blocks are added as pools when there exists intermediate operations among source and sink blocks. These blocks can be arranged in a I × J two-dimensional grid with I = 1 for problems without pools, or I = 2 for problems with pools. J is determined by the maximum number of pools/sinks. With this representation, we formulate FGN synthesis problem as a mixed-integer nonlinear... [more]

In the processing of cotton and neem seeds to obtain oil for diverse uses, enormous quantities of seed husk are generated as waste, which when not properly disposed of, poses environmental problems. One way of reducing this waste is to use it for the production of activated carbon (AC) for its multiple applications. In this work, activated carbon was produced from cotton and neem seed husks by carbonization followed by acid activation. The prepared ACs were characterized for its porosity and surface properties as well as for its ability to bleach neutral cotton seed oil. The prepared ACs are very efficient in the decoloration process, as they removed about 96⁻98% of the pigments compared to 98.4% removal with commercial bleaching earth. Temperature had a pronounced effect on the bleaching of neutral cotton seed oil. Maximum adsorption was observed at 60 °C for a contact time of 45 min. The adsorption kinetics were modelled by the intra-particle and the pseudo-second order equations whi... [more]

Due to the intrinsic stochasticity, the signaling dynamics in a clonal population of cells exhibit cell-to-cell variability at the single-cell level, which is distinct from the population-average dynamics. Frequently, flow cytometry is widely used to acquire the single-cell level measurements by blocking cytokine secretion with reagents such as Golgiplug™. However, Golgiplug™ can alter the signaling dynamics, causing measurements to be misleading. Hence, we developed a mathematical model to infer the average single-cell dynamics based on the flow cytometry measurements in the presence of Golgiplug™ with lipopolysaccharide (LPS)-induced NF κ B signaling as an example. First, a mathematical model was developed based on the prior knowledge. Then, average single-cell dynamics of two key molecules (TNF α and I κ B α ) in the NF κ B signaling pathway were measured through flow cytometry in the presence of Golgiplug™ to validate the model and maximize its prediction accur... [more]

In this research, an ANOVA analysis and a response surface methodology are applied to analyze the equilibrium of methanol reaction from pure carbon dioxide and hydrogen. In the ANOVA analysis, carbon monoxide composition in the feed, reaction temperature, recycle and water removal through a zeolite membrane are the analyzed factors. Carbon conversion, methanol yield, methanol productivity and methanol selectivity are the analyzed responses. Results show that main factors have the same effect on responses and a common significant interaction is not present. Carbon monoxide composition and water removal have a positive effect, while temperature and recycle have a negative effect on the system. From central composite design, an optimal solution is found in order to overcome thermodynamic limit: the reactor works with a membrane at lower temperature with carbon monoxide composition in the feed equal to 10 mol % and without recycle. In these conditions, carbon conversion, methanol yield, me... [more]

This paper discusses the techno-economic assessment of hydrogen production from biogas with conventional systems. The work is part of the European project BIONICO, whose purpose is to develop and test a membrane reactor (MR) for hydrogen production from biogas. Within the BIONICO project, steam reforming (SR) and autothermal reforming (ATR), have been identified as well-known technologies for hydrogen production from biogas. Two biogases were examined: one produced by landfill and the other one by anaerobic digester. The purification unit required in the conventional plants has been studied and modeled in detail, using Aspen Adsorption. A pressure swing adsorption system (PSA) with two and four beds and a vacuum PSA (VPSA) made of four beds are compared. VPSA operates at sub-atmospheric pressure, thus increasing the recovery: results of the simulations show that the performances strongly depend on the design choices and on the gas feeding the purification unit. The best purity and reco... [more]

Centrifugal pumps are widely used in the industry, especially in the oil and gas sector for fluids transport. Classically, these are designed to transfer single phase fluids (e.g., water) at high flow rates and relatively low pressures when compared with other pump types. As part of their constructive feature, centrifugal pumps rely on seals to prevent air entrapment into the rotor during its normal operation. Although this is a constructive feature, water should pass through the pump inlet even when the inlet manifold is damaged. Modern pumps are integrated in pumping units which consist of a drive (normally electric motor), a transmission (when needed), an electronic package (for monitoring and control), and the pump itself. The unit also has intake and outlet manifolds equipped with valves. Modern systems also include electronic components to measure and monitor pump working parameters such as pressure, temperature, etc. Equipment monitoring devices (vibration sensors, microphones)... [more]

Grinding circuits typically contribute disproportionately to the overall cost of ore beneficiation and their optimal operation is therefore of critical importance in the cost-effective operation of mineral processing plants. This can be challenging, as these circuits can also exhibit complex, nonlinear behavior that can be difficult to model. In this paper, it is shown that key time series variables of grinding circuits can be recast into sets of descriptor variables that can be used in advanced modelling and control of the mill. Two real-world case studies are considered. In the first, it is shown that the controller states of an autogenous mill can be identified from the load measurements of the mill by using a support vector machine and the abovementioned descriptor variables as predictors. In the second case study, it is shown that power and temperature measurements in a horizontally stirred mill can be used for online estimation of the particle size of the mill product.

Equipment throughput is one of the most critical parameters for production planning and scheduling, which is often derived by optimization techniques to achieve business goals. However, in semiconductor manufacturing, up-to-date and reliable equipment throughput is not easy to estimate and maintain because of the high complexity and extreme amount of data in the production systems. This article concerns the development and implementation of a throughput management system tailored for a semiconductor wafer fabrication plant (Fab). A brief overview of the semiconductor manufacturing and an introduction of the case Fab are presented first. Then, we focus on the system architecture and some concepts of crucial modules. This study also describes the project timescales and difficulties and discusses both tangible and intangible benefits from this project.

A process improvement in a tablet manufacturing process within a pharmaceutical industry was carried out based on an eco-efficiency approach. As it is one of the most energy consuming processes in the production line, the tablet manufacturing process was considered. It has the highest production volume with a complicated and long manufacturing product life cycle. Data were collected on energy inputs and emissions data for the stages of powder direct mixing, particle size reduction, and tableting. A straightforward approach was then used to analyze environmental impacts in terms of GHG emissions. Non- added value steps were removed from the product life cycle process, which has led to significant time and cost savings, as well as to a reduction in the emission. Annual economic savings have been achieved, a time reduction of approximately 71% was attained, and the reduction in GHG emissions and energy cost were 73.2%. The g CO₂eq per tablet reduction has been calculated within the proces... [more]

Emulsion polymerization process provides a unique polymerization locus that has a confined tiny space with a higher polymer concentration, compared with the corresponding bulk polymerization, especially for the ab initio emulsion polymerization. Assuming the ideal polymerization kinetics and a constant polymer/monomer ratio, the effect of such a unique reaction environment is explored for both conventional and living free-radical polymerization (FRP), which involves chain transfer to the polymer, forming polymers with long-chain branches. Monte Carlo simulation is applied to investigate detailed branched polymer architecture, including the mean-square radius of gyration of each polymer molecule, ₀. The conventional FRP shows a very broad molecular weight distribution (MWD), with the high molecular weight region conforming to the power law distribution. The MWD is much broader than the random branched polymers, having the same primary chain length distribution. The expected ₀ for a give... [more]

The separation of small molecule gases by membrane technologies can help performance enhancement and process intensification for emerging advanced fossil energy systems with CO₂ capture capacity. This paper reports the demonstration of controlled modification of zeolitic channel size for the MFI-type zeolite membranes to enhance the separation of small molecule gases such as O₂ and N₂. Pure-silica MFI-type zeolite membranes were synthesized on porous α-alumina disc substrates with and without an aluminum-containing thin skin on the outer surface of zeolite membrane. The membranes were subsequently modified by on-stream catalytic cracking deposition (CCD) of molecular silica to reduce the effective openings of the zeolitic channels. Such a pore modification caused the transition of gas permeation from the N₂-selective gaseous diffusion mechanism in the pristine membrane to the O₂-selective activated diffusion mechanism in the modified membrane. The experimental results indicated that th... [more]

The application of a multivariable predictive controller to the mixing process for the production of a non-Newtonian fluid is discussed in this work. A data-driven model has been developed to describe the dynamic behaviour of the rheological properties of the fluid as a function of the operating conditions using experimental data collected in a pilot plant. The developed model provides a realistic process representation and it is used to test and verify the multivariable controller, which has been designed to maintain viscosity curves of the non-Newtonian fluid within a given region of the viscosity-vs-shear rate plane in presence of process disturbances occurring in the mixing process.

Urban lakes mitigate the negative impacts on the hydrological cycle and improve the quality of life in cities. Worldwide, the concern increases for the protection and management of urban water bodies. Since the physical-chemical and biological conditions of a small aquatic ecosystem can vary rapidly over time, traditional low frequency measurement approaches (weekly or monthly sampling) limits the knowledge and the transfer of research outcomes to management decision-making. In this context, this paper presents an automatic monitoring system including a full-scale experimental site and a data transfer platform for high-frequency observations (every 5 min) in a small and shallow urban lake (Lake Champs-sur-Marne, Paris, France, 10.3 ha). Lake stratification and mixing periods can be clearly observed, these periods are compared with the dynamic patterns of chlorophyll-a, phycocyanin, dissolved oxygen and pH. The results indicate that the phytoplankton growth corresponds with dissolved ox... [more]

Density Functional Theory (DFT) studies were conducted to evaluate the sensing mechanism between benzene and a polymeric sensing material, referred to as SXFA, which contains trifluoro-groups and OH-groups. These studies were undertaken to improve the understanding of how benzene and SXFA mechanistically interact based on their chemistry, information which can be used to more efficiently design polymeric sensing materials. We find that benzene adsorbed onto the OH-groups in SXFA rather than the trifluoro-groups as previously proposed. Specifically, we find that sorption results from electrostatic attraction between the negative benzene ring and the positive hydrogens of the OH-groups of SXFA.

Studies performed at single-cell resolution have demonstrated the physiological significance of cell-to-cell variability. Various types of mathematical models and systems analyses of biological networks have further been used to gain a better understanding of the sources and regulatory mechanisms of such variability. In this work, we present a novel sensitivity analysis method, called molecular density function perturbation (MDFP), for the dynamical analysis of cellular heterogeneity. The proposed analysis is based on introducing perturbations to the density or distribution function of the cellular state variables at specific time points, and quantifying how such perturbations affect the state distribution at later time points. We applied the MDFP analysis to a model of a signal transduction pathway involving TRAIL (tumor necrosis factor-related apoptosis-inducing ligand)-induced apoptosis in HeLa cells. The MDFP analysis shows that caspase-8 activation regulates the timing of the swit... [more]

The error-in-variables-model (EVM) is the most statistically correct non-linear parameter estimation technique for reactivity ratio estimation. However, many polymer researchers are unaware of the advantages of EVM and therefore still choose to use rather erroneous or approximate methods. The procedure is straightforward but it is often avoided because it is seen as mathematically and computationally intensive. Therefore, the goal of this work is to make EVM more accessible to all researchers through a series of focused case studies. All analyses employ a MATLAB-based computational package for copolymerization reactivity ratio estimation. The basis of the package is previous work in our group over many years. This version is an improvement, as it ensures wider compatibility and enhanced flexibility with respect to copolymerization parameter estimation scenarios that can be considered.