In the era of rapid technological advancement and evolving industrial landscapes, embracing the concept of the factory of the future (FoF) is crucial for companies seeking to optimize efficiency, enhance productivity, and stay sustainable. This case study explores the concept of the FoF and its role in driving the energy transition and digital transformation within the automotive sector. By embracing advancements in technology and innovation, these factories aim to establish a smart, sustainable, inclusive, and resilient growth framework. The shift towards hybrid and electric vehicles necessitates significant adjustments in vehicle components and production processes. To achieve this, the adoption of lighter materials becomes imperative, and new technologies such as additive manufacturing (AM) and artificial intelligence (AI) are being adopted, facilitating enhanced efficiency and innovation within the factory environment. An important aspect of this paradigm involves the development a... [more]

This paper presents a coupled computational fluid dynamics−discrete element method (CFD−DEM) simulation to predict cuttings transport by the drilling fluid (mud) in different oil well drilling conditions. The mud rheology is expressed by the Herschel−Bulkley behaviour and modelled in a Eulerian framework (CFD), while the cuttings are modelled using the Lagrangian approach (DEM). In this work, the effects of drill string rotation, inclination angle, cutting size, mud rheology, and annular velocity on cleaning efficiency are investigated. It is found that increasing the well deviation from vertical to horizontal leads to a higher cuttings concentration. However, at low annular velocity, the cuttings concentration for the inclined (45-degree) annulus is found to be higher than the horizontal one due to the sliding motion of cuttings on the lower section of the annulus. Overall, the drill pipe rotation has little effect on decreasing the cuttings concentration, but the effect is more prono... [more]

Pillar stability is of paramount importance in ensuring the safety of underground rock engineering structures. The stability of pillars directly influences the structural integrity of the mine and mitigates the risk of collapses or accidents. Therefore, assessing pillar stability is crucial for safe, productive, reliable, and profitable underground mining engineering processes. This study developed the application of decision intelligence-based predictive modelling of hard rock pillar stability in underground engineering structures using K-Nearest Neighbour coupled with the grey wolf optimization algorithm (KNN-GWO). Initially, a substantial dataset consisting of 236 different pillar cases was collected from seven underground hard rock mining engineering projects. This dataset was gathered by considering five significant input variables, namely pillar width, pillar height, pillar width/height ratio, uniaxial compressive strength, and average pillar stress. Secondly, the original hard r... [more]

Located in the Kuqa foreland basin, Tarim Basin, the Xinkeshen gas field is a rare ultra-deep and ultra-high-pressure fractured tight sandstone gas reservoir. During the development process, the fluid in the well migrates from the bottom hole to the ground. Due to the huge temperature drop and pressure drop in the wellbore, salting-out and scale-out occur in the well to destroy the oil and gas flow channel, resulting in a decrease in gas production in the well and seriously affecting the normal production of the oil field. Aiming at the problem of wellbore scaling and blockage in the Keshen gas field, this paper takes the wellbore of the Keshen block as the research object. After analyzing the composition of produced water and scale in the wellbore, the solution of ‘fixing scale, clarifying mechanism, early prediction, and fine treatment’ is formulated, and the analysis and evaluation technology of the scale formation process and the prediction model of the gas well model are formed. T... [more]

In order to reveal the physical properties of CO2 under actual formation conditions, this paper establishes a mathematical model of the temperature field and pressure field in the wellbore under CO2 injection conditions, optimizes the state equation of CO2 physical-property parameters, calculates the change trend of CO2 density, viscosity, and compression factor along the wellbore, and obtains the influence law of CO2 corrosion on the casing and interface. The viscosity showed a downward trend along the well depth; the compression factor showed an upward trend. The surfaces of the three casings were smooth and flat without obvious defects, the cement structure was dense, and there was no obvious pore structure. After corrosion, with the increase of Cr content, the change of interfacial corrosion decreases. The morphology of the Q125 and 3Cr interface is loose after corrosion, while there is no obvious change in the 13Cr interface. With the prolongation of corrosion time, low wellbore i... [more]

The study of porous liquids (PLs) using molecular dynamics (MD) simulation is one of the most interesting and attractive research topics. The possibility of creating permanent porosity in a solvent and increasing its adsorption capacity is very practical. The purpose of the present study is to examine how an MD model can be developed to evaluate the possibility of PL formation. Additionally, the validation of the model was conducted by simulations using two metal−organic frameworks (MOFs) including zeolitic imidazolate framework-8 (ZIF-8) and Hong Kong University of Science and Technology-1 (HKUST-1) as porogens and water (H2O) and triethylene glycol (TEG) as solvents. The results revealed that H2O and TEG are incapable of penetrating the ZIF-8 pores due to their small size and unfavorable thermodynamics; however, both solvents easily penetrate through the large HKUST-1 pores. These observations aligned with findings from experimental literature studies, thus confirming the validity of... [more]

Air DTH (Down-The-Hole) hammer percussion drilling (vibration percussion drilling) has proven to be a highly efficient geothermal drilling technique, and percussion fractures near the wellbore benefit geothermal energy development in many ways (such as hydraulic fracturing, perforation, etc.). However, no research has been done on the mechanism of fracture-increasing and permeation-increasing in granite pore walls by air DTH hammer percussion drilling. This article: (1) using an air drilling test device, an air DTH hammer whole bit impact rock fragmentation test was conducted on granite in an atmospheric environment; (2) dyeing experiments, CT scanning, and 3D reconstruction modeling were used to characterize and identify wellbore cracks; (3) research the strength, porosity, and permeability changes of granite wellbore through mechanical and permeability testing experiments; and (4) numerical simulation of impact stress waves using particle flow code (PFC) 6.0 software to demonstrate t... [more]

With the notable achievements attained through the implementation of steam-assisted gravity drainage (SAGD), the vertical−horizontal steam drive (VHSD) emerges as a pivotal technological advancement aimed at significantly enhancing the efficiency of thin reservoir heavy oil recovery subsequent to steam cyclic stimulation. The inclusion of nitrogen assistance has proven effective in enhancing the efficacy of gravity drainage techniques in reservoir development. However, it is noteworthy that this method has only led to improvements in approximately 50% of the well groups within the observed field. The comprehensive evaluation index of VHSD was proposed, and as the objective function, it was determined that the greatest contribution to the VHSD technique lies in oil saturation, accounting for 40% of the overall evaluations. This differs from conventional SAGD operations, where reservoir thickness serves as the primary determinant. Building upon an enhanced physical simulation similarity... [more]

Wildfire is one of the most critical natural disasters that poses a serious threat to human lives as well as ecosystems. One issue hindering a high accuracy of computer vision-based wildfire detection is the potential for water mists and clouds to be marked as wildfire smoke due to the similar appearance in images, leading to an unacceptable high false alarm rate in real-world wildfire early warning cases. This paper proposes a novel hybrid wildfire smoke detection approach by combining the multi-layer ResNet architecture with SVM to extract the smoke image dynamic and static characteristics, respectively. The ResNet model is improved via the SE attention mechanism and fully convolutional network as SE-ResNet. A fusion decision procedure is proposed for wildfire early warning. The proposed detection method was tested on open datasets and achieved an accuracy of 98.99%. The comparisons with AlexNet, VGG-16, GoogleNet, SE-ResNet-50 and SVM further illustrate the improvements.

One of the main trends in the development of the modern electronics industry is the miniaturization of electronic devices and components. Miniature electronic devices require compact cooling systems that can dissipate large amounts of heat in a small space. Researchers are exploring ways to improve the design of the heat sink of the cooling system in such a way that it increases the heat flow while at the same time reducing the size of the heat sink. Researchers have previously proposed different designs for heat sinks with altered fin shapes, perforations, and configurations. However, this approach to optimizing the design of the heat sink results in an increase in the labor intensity of its production. Our goal is to optimize the heat sink design to reduce its size, reduce metal consumption, and increase heat flow. This goal is achieved by changing the number of fins and the distance between them. In this case, there is no significant difference in the geometry of a conventional plat... [more]

Due to their high porosity and permeability characteristics, reservoirs of loose sandstone have great development potential. Under weak dynamic conditions, the vertical migration and mass exchange of oil−water two-phase fluids in loose sandstone reservoirs occur very easily. The phenomenon of vertical seepage flow equilibrium has a significant impact on the distribution of oil−water two-phase fluids in the reservoir. However, existing mainstream numerical simulators cannot accurately describe the phenomenon of vertical migration of oil−water two-phase fluids under weak dynamic conditions. In this study, using 3D printing technology, multiple transparent rock core holders were constructed to conduct experiments on the vertical seepage flow equilibrium time of different viscosities and contents of crude oil under different permeabilities of rock cores. Through the analysis and regression of experimental results, a predictive formula for the vertical seepage flow equilibrium time of loose... [more]

The gas−water relative permeability curve plays a crucial role in reservoir simulation and development for condensate gas reservoirs. This paper conducted a series of high-temperature and high-pressure analysis experiments on real gas cores from Wells A and B in Block L of the Yinggehai Basin to investigate the effects of temperature, pressure, and different types of gas media on gas−water seepage. The gas−water relative permeability was simulated in this experiment through variations in temperature, pressure, and gas composition. Temperature has a significant impact on both gas and water relative permeability, particularly on gas relative permeability. As temperature increases, gas relative permeability shows a substantial increase, while water relative permeability remains relatively unchanged. Under the same effective stress, increasing pressure causes downward shifts in both the gas and water relative permeability curves; however, there is a more pronounced decrease in gas relative... [more]

Pyrolytic conversion is the only biomass exploitation route capable of providing solid and liquid biofuels, as well as platform biomolecules for sustainable energy sources and raw materials for bio-based products [...]

When a sluice gate is arranged in parallel with pumping station units, biased flow occurs in the forebay when the units are operating. The transverse flow velocity in front of the channel inlet is relatively high, and, in severe cases, it may lead to the formation of suction vortices, impacting the stable operation of pump units. Taking the Liushan Pumping Station project of the Eastern Route of the South-to-North Water Diversion Project as a case study, this paper investigates the effect of the partition wall length on the inlet flow regime of pumping station units arranged in parallel with the sluice gate to reduce the transverse flow velocity in front of the channel inlet. Using numerical simulations, the inlet flow regimes for different partition wall lengths were compared. Moreover, the flow field distributions in the forebay under different operating conditions were analyzed alongside the transverse flow velocity in front of the channel inlet and the uniformity of flow velocity d... [more]

Digital twins are an emerging technology that can be harnessed for the digitalization of the industry. Steel industry systems contain a large number of electro-hydraulic components as proportional valves. An input−output model for a water proportional cartridge valve was derived from physical modeling based on fluid mechanics, dynamics, and electrical principles. The valve is a two-stage valve with two two/two-way water proportional valves as the pilot stage and a marginally stable poppet-type cartridge valve as the main valve. To our knowledge, this is the first time that an input−output model was derived for a two-stage proportional cartridge valve with a marginally stable main valve. The orifice equation, which is based on Bernoulli principles, was approximated by a polynomial, which made the parameter estimation easier and modeling possible without measuring the pressure of the varying control volume, in contrast with previous studies of similar types of valves situated in the pilo... [more]

The 1515 mining face in Yongming Coal Mine was upward mined across half of the goaf along the panel direction. In this paper, the methods of field measurement, theoretical analysis, and numerical simulation were used to study the overlying rock fracture structure, support load characteristics, and the mechanism of mine pressure behavior across half of the goaf. The results indicate that the support load of the 1515 upward mining face across half of the goaf along the panel direction exhibits distinct zoning characteristics. The maximum support load is 1.37 times the minimum support load. The development height of the roof separation in the up-mining area is 1.74 times that in the entity coal area, at 9.1 m and 5.22 m respectively. The height of separation and hanging roof length increase and decrease, respectively, along the initial rock fracture area, tensile fracture area, structural fracture area, and compacted fracture area. Based on the definition of the variation coefficient “m”... [more]

Based on the Box−Behnken design (BBD) methodology, an experimental study of the preparation of graphene using ultrasonication was conducted. The yield of graphene served as the response variable, with ultrasonication process time, ultrasonic power, the graphite initial weight, and their interactive effects acting as the independent variables influencing the yield. A multivariate nonlinear regression model was established to describe the ultrasonic production of graphene. Verification of the experiments suggests that the developed multivariate nonlinear regression model is highly significant and provides a good fit, enabling an effective prediction of the graphene yield. The yield of graphene was found to increase with higher ultrasonic power but decrease with longer ultrasonication times and the initial weight of the graphite. The optimal process parameters according to the regression model were determined to be 30 min of ultrasonication time, an ultrasonic power of 1500 W, and a graph... [more]

The distribution law of the ground stress field is of great significance in guiding the design of coal mine roadway alignment, determining the parameters of roadway support, and preventing and controlling the impact of ground pressure in coal mines. A geostress inversion method combining Rhino surface modeling and FLAC3D 6.0 numerical simulation software is proposed. Based on the geological data of the coal mine and the results of on-site measurements, a three-dimensional geological model of Yingcheng Coal Mine is established for the geostress inversion, and the distribution law of the geostress field in Yingcheng Coal Mine is obtained. Research shows the following: (1) The horizontal maximum principal stress values of the Yingcheng Mine are between 33.9 and 35.3 MPa, the horizontal minimum principal stress values are between 23.6 and 25.4 MPa, and the direction of the horizontal maximum principal stress is roughly in the southwest to west direction; (2) the three-way principal stress... [more]

Chemical process control relies on a tightly controlled, narrow range of margins for critical variables, ensuring process stability and safeguarding equipment from potential accidents. The availability of historical process data is limited to a specific setpoint of operation. This challenge raises issues for process monitoring in predicting and adjusting to deviations outside of the range of operational parameters. Therefore, this paper proposes simulation-assisted deep transfer learning for predicting and optimizing the final purity and production capacity of the glycerin purification process. The proposed network is trained by the simulation domain to generate a base feature extractor, which is then fine-tuned using few-shot learning techniques on the target learner to extend the working domain of the model beyond historical practice. The result shows that the proposed model improved prediction performance by 24.22% in predicting water content and 79.72% in glycerin prediction over t... [more]

Despite renewable energy source integration being a well-established requirement in international policies, energy systems still face some unresolved issues, including the intermittence of production. To tackle this problem, a viable solution could comprise the off-peak storage of electricity production excess, to be consumed later during peak-load hours. The transition from the diffuse pattern of centralized generation to the distributed model, involving energy communities, suggests an additional aspect to manage: the spatial constraints of systems for domestic applications. Compressed-air energy storage represents a promising Power-to-Power technology for small-scale energy integration. This study proposes the application of a gas−liquid energy storage system (GLES) in a residential building, using renewable energy excess from a photovoltaic (PV) array. The performance of the proposed system, whose operation involves the compression of the gaseous mass through a piston operated by mi... [more]

The cement industry is regarded as one of the primary producers of world carbon emissions; hence, lowering its carbon emissions is vital for fostering the development of a low-carbon economy. Carbon capture, utilization, and storage (CCUS) technologies play significant roles in sectors dominated by fossil energy. This study aimed to address issues such as high exhaust gas volume, low CO2 concentration, high pollutant content, and difficulty in carbon capture during cement production by combining traditional cement production processes with cryogenic air separation technology and CO2 purification and compression technology. Aspen Plus® was used to create the production model in its entirety, and a sensitivity analysis was conducted on pertinent production parameters. The findings demonstrate that linking the oxygen-enriched combustion process with the cement manufacturing process may decrease the exhaust gas flow by 54.62%, raise the CO2 mass fraction to 94.83%, cut coal usage by 30%, a... [more]

This study introduces a novel method to enhance numerical simulation accuracy for high-speed flows by refining the weighted essentially non-oscillatory (WENO) flux with higher-order corrections like the modified weighted compact scheme (MWCS). Numerical experiments demonstrate improved sharpness in capturing shock waves and stability in complex conditions like two interacting blast waves. Key highlights include simultaneous capture of small-scale smooth fluctuations and shock waves with precision surpassing the original WENO and MWCS methods. Despite the significantly improved accuracy, the extra computational cost brought by the new method is only marginally increased compared to the original WENO, and it outperforms MWCS in both accuracy and efficiency. Overall, this method enhances simulation fidelity and effectively balances accuracy and computational efficiency across various problems.

The CFD/DEM approach was used for investigating the forces playing a role in a furnace raceway formation and stability. The configuration is an actual pilot-scale hot blast furnace filled only with coke particles. In such a system, the raceway was unstable, with successively a growing phase and a collapse. The CFD/DEM numerical simulations were coupled with a core-shrinking model to mimic coke particle combustion. However, the kinetic reactions and heat transfers were not numerically predicted. Instead, the characteristic combustion timescale of one coke particle was imposed, and the combustion zone was adjusted to match the global combustion measured in the pilot-scale experiment. The results showed that the standard contact model was not enough to resist the pressure exerted by the granular weight on the raceway. However, the addition of a cohesive force, through the Johnson-Kendall-Roberts (JKR) model, allowed the qualitative reproduction of the gas pressure fluctuations and the col... [more]

This study examines the connections between various fracture indicators and production data with an example from one of the giant fields in the Middle East producing complex fractured carbonate lithologies. The field under study hosts two reservoirs with a long development and production history, including carbonates from the Asmari and Bangestan Formations. A fracture intensity map was generated based on the interpretation of image logs from 28 wells drilled within the field. Mud loss data were collected and mapped based on the geostatistical Gaussian Random Function Simulation (GRFS) algorithm. Maximum curvature maps were generated based on Asmari structural surface maps. Comparing the results shows a good agreement between the curvature map, fault distribution model, mud loss map, fracture intensity map, and productivity index. The results of image log interpretations led to the identification of four classes of open fractures, including major open fractures, medium open fractures,... [more]

This study presents a numerical simulation of a pump’s performance during a power-cut event and connected hazards resulting from the failure of non-return flap valves. The vertical mixed-flow pumps with suction bells were mounted inside the suction basins of a pumping station. Different regimes of the pump operation during the time were analyzed based on the pump’s 4-quadrant characteristics and the dynamics of rotating parts in the pump, gearbox and electric engine. The resulting development of flow rates, rotor speed and forces in the course of time were used to analyze the hazards of failure of any pumping system component and the flooding of the suction object and its surroundings. The presented results show a deep insight into the flow phenomena in vertical mixed-flow pumps with suction bells during the runaway process and confirm that the developed methodology can be successfully applied to monitor the critical regimes in a pumping station in real time. The simulations were verif... [more]