A new idea to deal with the backmixing problem in a scaled-up multi-inlet vortex mixer is proposed in this paper. Firstly, a Reynolds-averaged Navier−Stokes−large-eddy simulation hybrid model was used to simulate the flow field in a vortex mixer, and the numerical simulation results were compared with those from a particle image velocimetry experiment in order to validate the shielded detached eddy simulation model in the rotating shear flow. Then, by adding a series of columns in the mixing chamber, the formation of wake vortexes was promoted. The flow field in the vortex mixer with different column arrangements were simulated, and the residence time distribution curves of the fluid were obtained. Meanwhile, the degree of backmixing in the vortex mixer was evaluated by means of a tanks-in-series model. In the total ten cases related with four groups of variables, it was found that increasing the diameter of the column was the most efficient for weakening the backmixing in the vortex m... [more]

Assessing oxidation−reduction potential (ORP) is of paramount importance in the efficient management of wastewater within both chemical and biological treatment processes. However, despite its critical role, insufficient information exists about how reactive chemical species generated by cold plasma (CP) in chemical treatment are associated with ORP and air flow rate. Therefore, we aim to identify the correlation between ORP and the removal of organic pollutants when using CP treatment. Additionally, we introduce a machine-learning-based operation to predict removal efficiency in the CP process. Results reveal a significant correlation of over 0.9 between real-time ORP and total organic carbon (TOC), which underscores the efficacy of ORP as a key parameter. This approach made it possible to control OH radical generation by regulating the air flow rate of the CP. This study posits that smart management facilitated by machine learning has the potential to enhance the economic viability o... [more]

In order to indirectly calculate the core temperature of a cable joint, an equivalent transient thermal circuit model of single-core cable joint by considering axial heat dissipation is proposed. Firstly, the temperature field of the middle joint of a 110 kV single-core cable is calculated by finite element method. Based on the heat dissipation path of the core, an improved equivalent thermal circuit model is proposed. The axial heat dissipation of the cable joint core is simplified to a thermal resistance and the temperature rise of the cable body core, the temperature calculation of the cable joint transient process is realized. Compared with the results of finite element simulation, the steady-state temperature errors of the thermal circuit model are within 1 °C, while the maximum temperature errors of the transient process shall not exceed 3 °C, which proves the validity of the model. This method can provide reference for temperature inversion and the dynamic current-carrying capac... [more]

In recent years, deep learning models have led to improved accuracy in industrial defect detection, often using variants of YOLO (You Only Look Once), due to its high performance at a low cost. However, the generalizability, fairness and bias of their outcomes have not been examined, which may lead to overconfident predictions. Additionally, the complexity added by co-occurring defects, single and multi-class defects, and the effect on training, is not taken into consideration. This study addresses these critical gaps by introducing new methodologies for analyzing dataset complexity and evaluating model fairness. It introduces the novel approach of co-occurrence impact analysis, examining how the co-occurrence of defects in sample images affects performance, and introducing new dimensions to dataset preparation and training. Its aim is to increase model robustness in the face of real-world scenarios where multiple defects often appear together. Our study also innovates in the evaluatio... [more]

The exploration of coal wettability is not only of paramount significance in the mitigation of coal dust and the development of coalbed methane, but it also provides crucial technical support for realizing the geological storage of CO2 within the ‘dual-carbon’ background. Molecular simulation serves as an effective means by which to investigate coal wettability at the microscopic level. This study employed a molecular dynamics simulation to investigate the wettability of coal across 13 distinct coal ranks. Through the analysis of trajectory files, and the incorporation of experimental data during the modeling process, the mechanisms governing the evolution of wettability were revealed. The results demonstrated that the contact angle on the surface of coal increases with the elevation of coal rank. The molecule relative concentration analysis revealed that, with increasing coal rank, the overlap range between water droplets and the coal slab decreases, the height increases, and the diff... [more]

An analysis of entropy generation and exergy efficiency can effectively explore the energy-saving potential of reheating furnaces. This paper simulated the combustion, flow, and heat transfer in a walking beam reheating furnace by establishing a half-furnace model. The entropy generation rate distribution of different thermal processes was numerically calculated. The effect of slab residence time and fuel distribution in the furnace was studied to optimize exergy efficiency. The results indicated that combustion and radiative heat transfer are the primary sources of entropy generation. Irreversible losses accounted for 26.39% of the total input exergy, in which the combustion process accounted for 16.43%, and radiative heat transfer accounted for 8.47%. Reducing the residence time by 60 min decreased irreversible exergy loss by about 2.5% but increased heat dissipation and exhaust exergy loss by 5.8%. Energy saving can only be achieved when the heat exchanger’s exergy recovery efficien... [more]

A pantograph is a key component on the tops of trains that allows them to efficiently tap electricity from power lines and propel them. This study investigates the possibility of using metal matrix composites (MMCs), specifically aluminum MMCs, as a material for making pantograph parts regarding the dynamics of the train’s movement and external meteorological conditions. In this study, a computer-aided design (CAD) model is created using PTC Creo design software and moves to detailed finite element analysis (FEA) simulations executed by the ANSYS software suite. These simulations are important in examining how the dynamic performance of pantographs can vary. The incorporation of Al MMC materials into the structure of the pantograph resulted in significant improvements in structural robustness, with equal stress reduced by up to 0.18%. Similarly, aluminum MMC materials reduced the strain energy by 0.063 millijoules. The outcomes not only give a new perspective to the implementation of m... [more]

The constitutive model refers to the mapping relationship between the stress and deformation conditions (such as strain, strain rate, and temperature) after being loaded. In this work, the hot deformation behavior of a Ni-Cr-Mo steel was investigated by conducting isothermal compression tests using a Gleeble-3800 thermal simulator with deformation temperatures ranging from 800 °C to 1200 °C, strain rates ranging from 0.01 s−1 to 10 s−1, and deformations of 55%. To analyze the constitutive relation of the Ni-Cr-Mo steel at high temperatures, five machine learning algorithms were employed to predict the flow stress, namely, back-propagation artificial neural network (BP-ANN), Random Committee, Bagging, k-nearest neighbor (k-NN), and a library for support vector machines (libSVM). A comparative study between the experimental and the predicted results was performed. The results show that correlation coefficient (R), root mean square error (RMSE), mean absolute value error (MAE), mean squar... [more]

In order to assess the stable operating duration of an ultrasonic vibration system, a reliability-based analysis method for the stability of the ultrasonic vibration system is proposed. Firstly, the failure mechanisms of the ultrasonic vibration system are analyzed, and the resonant frequency and amplitude are selected as two degradation features of the system. Subsequently, accelerated degradation experiments under different force loads were conducted, and the degradation model of the ultrasonic vibration system was established by comparing experimental data with degradation, distribution, and acceleration models. Finally, Copula functions were introduced to connect the two degradation features, resonant frequency, and amplitude, and lifetime curves were plotted under the influence of univariate and bivariate degradation factors. Through the analysis of the lifetime curves, the conclusion is drawn that the decay of amplitude is the primary indicator of system lifetime, and it is predi... [more]

Acid fracturing is an effective stimulation technology that is widely applied in carbonate reservoirs. An integrated model for acid fracturing without prepad treatment has been established. Compared with the previous models which use prepad for generating hydraulic fractures, this model can simultaneously simulate the fracture propagation and the acid etching of fracture surfaces, as well as the wormhole growth during acid fracturing. The influences of some essential factors have been studied through a series of numerical simulations, and the main conclusions are as follows. First, increasing the injected acid volume can expand the size of the formed hydraulic fractures and extend the propagation distance of the wormhole. Increasing the injected acid volume can also expand the etched width and extend the effective distance of the injected acid. Second, a high injection rate impels more acid to flow into the depth of a fracture before infiltration and reaction, resulting in the augmenta... [more]

Humanity is facing the challenge of reducing its environmental impact. For this reason, many specialists worldwide have been studying the processes of production and efficient use of energy. In this way, developing cleaner and more efficient energy systems is fundamental for sustainable development. The present work analyzed the technical feasibility of a solar-driven power-cooling system operating in a particular location in Mexico. The theoretical system integrates organic Rankine and single-stage absorption cooling cycles. A parabolic trough collector and a storage system integrated the solar system. Its performance was modeled for a typical meteorological year using the SAM software by NREL. The analyzed working fluids for the organic cycle include benzene, cyclohexane, toluene, and R123, while the working fluid of the absorption system is the ammonia-water mixture. The cycle’s first and second-law performances are determined in a wide range of operating conditions. Parameters such... [more]

To characterize the failure of rock mass surrounding underground tunnels, biaxial compression tests were conducted on a real sandstone model with a straight-walled arched hole. The acoustic emission (AE) system and digital image correlation (DIC) optical inspection equipment were used to investigate the crack evolution process and failure precursors of the tunnel. A two-dimensional particle flow code (PFC2D) was used to conduct numerical simulations on the sample, so as to investigate the mesoscopic failure mechanism of rock mass. The results show that the failure of the single tunnel constructed in sandstone occurs mainly in the walls on both sides (between the spandrels and arch feet), showing slabbing failure characteristics and a certain abruptness. The crack initiation in sandstone in early stage is not obvious, and the crack propagation in rock mass is rapid when acoustic emissions are enhanced. The small increments in the AE count and amplitude and the continuous reduction in th... [more]

It is of great significance to investigate the flow rate and stress distribution of multi-fracture propagation for the optimization of perforation parameters and fracture parameters. Considering the coupling of rock deformation, fracture direction and fluid flow in multi-fracture scenarios, a mathematical model and solution program for the flow and stress distribution of multiple fractures are established, and the analytical model is used for comparison and verification. The effects of perforation cluster number, cluster spacing, perforation diameter on fracture extension trajectory, fracture width, flow rate of each fracture and stress field are studied by the model. The results show that, as the number of perforating clusters increases, the inner fracture is inhibited more severely with less width, length and flow distribution, as well as lower bottom hole pressure. With the increase in cluster spacing, the stress interference between whole fractures is weakened and the flow distribu... [more]

The primary function of a mine hoist is the transportation of personnel and equipment, serving as a crucial link between underground and surface systems. The proper functioning of key components such as work braking and safety braking is essential for ensuring the safety of both personnel and equipment, thereby playing a critical role in the safe operation of coal mines. As coal mining operations extend to greater depths, they introduce heightened challenges for safe transportation, compounded by increased equipment loss. Consequently, there is a pressing need to enhance safety protocols to safeguard personnel and materials. Traditional maintenance and repair methods, characterized by routine equipment inspections and scheduled downtime, often fall short in addressing emerging issues promptly, leading to production delays and heightened risks for maintenance personnel. This underscores the necessity of adopting predictive maintenance strategies, leveraging digital twin models to antici... [more]

Autostrainer is used for the purpose of debris removal in order to increase the efficiency of the heat exchanger by taking the required raw water as a heat source for the pre-cooling hydrothermal system. During the operation of the autostrainer, a pressure drop occurs due to the blockage of the screen in the autostrainer. As a result, the resistance of the pipe network for the intake system is changed, and the operating efficiency point of the pump, valve, heat exchanger, etc., is altered. By calculating the system resistance taking into account the pressure drop caused by the blockage rate of the screen in the autostrainer, the optimum operating efficiency can be expected when the intake system such as a pump, valve or heat exchanger, etc. is constructed. In this study, Computational Fluid Dynamics (CFD) was used to construct a scenario in which screen blockage may occur, predicting pressure drop for the slot cross-section of the screen in the autostrainer to derive a resistance coeff... [more]

Fractured-vuggy reservoirs are crucial for increasing unconventional oil storage and production, but the controlling mechanism of this dominant flow channel remains vague, and the jamming mechanism of modulator particles is unclear. This study explores the filling and jamming processes of particles in the fractures by conducting a computational fluid dynamics−discrete element method (CFD−DEM) coupled simulation, considering the variation of fracture width, fluid velocity, particle size, and concentration. Results suggest that four sealing modes are proposed: normal filling, local jamming, complete sealing, and sealing in the main fracture. The ratio of particle size to the main fracture width exerts the primary role, with the ratio having a range of 0.625 < D/W ≤ 0.77 revealing complete jamming. Furthermore, an optimal particle size for achieving stable sealing is observed when the particle size varies from 2 to 2.5 mm. A higher concentration of particles yields better results in th... [more]

Blast furnace slag, a by-product of the iron and steel production process, contains a significant amount of untapped heat resources. Currently, China is entering a period of rapid growth in scrap production, making efficient scrap utilization a new research focus. One approach to improving scrap utilization is preheating. This study proposes a new method of preheating scrap using high-temperature slag in a drum. The discrete element method is employed for numerical simulation, which involves constructing a three-dimensional model. The study explores three influencing factors: the mass ratio of high-temperature slag to scrap, the shape of the scrap, and the drum rotational speed. The main objective is to investigate the heat transfer situation between the high-temperature slag and the scrap. The results indicate that the optimal heat transfer effect in the drum is achieved when the mass ratio of high-temperature slag to scrap is 2:1, the scrap is spherical in shape, and the drum rotatio... [more]

A cascaded pseudo-potential lattice Boltzmann model and refilling algorithms for moving boundary treatment were used to simulate the large density ratio cavitating flow in a two-dimensional nozzle with the periodic motion of the needle valve. The relationships between density variation at the cavitation zone, the evolution of force acting on the lower boundary of the sack wall region, and the surface of the needle valve with time under different needle valve motion frequencies were obtained. The results indicate that the inception and evolution of cavitation mainly exist in the vicinity of the lower boundary of the sack wall region. The density at cavitation decreases by approximately three orders of magnitude, while the force on the lower boundary of the sack wall region decreases by about one order of magnitude. Since cavitation does not exist in the vicinity of the needle valve, the forces are mainly influenced by the periodic motion of the needle valve and do not change significant... [more]

Traditional coiled tubing radial drilling with the same diameter cannot support deep and ultra-deep wells for high-pressure hydraulic jet drilling due to small diameter and sizeable hydraulic loss over long distances. The novel downhole movable pipe radial hydraulic drilling technique extracts a small diameter high-pressure injection pipe from the (tubing pipe) oil pipe and then drills it horizontally into the formation to form a radial hole. Dynamic sealing is the core of this technology, which achieves high-pressure fluid sealing while ensuring the injection pipe smoothly slides out of the oil pipe. A sealing tool is designed between the tubing and the injection pipe to prevent the leakage of high-pressure fluid. In this paper, the finite element model of the sealing tool was established, and the deformation and stress of the sealing tool under different interference and fluid pressure were simulated and analyzed. The relationship between stress distribution and contact pressure unde... [more]

Vacuum arc remelting is the main production method of titanium alloy ingots at present. In order to obtain good quality ingots, it is of great significance to study the formation of the solidification structure of ingots via vacuum arc remelting. In order to select and optimize the nucleation parameters for the solidification microstructure simulation of an ingot, a 3D CAFE model for microstructure evolution during vacuum arc remelting was established, taking into account heat transfer, flow, and solute diffusion. The Gaussian distribution continuous nucleation model and extended KGT model were used to describe the grain nucleation and dendrite tip growth rates, respectively. The multi-point mass source and moving boundary method were used to simulate the ingot growth. The results show that there are three typical crystal regions in the solidification structure of vacuum arc remelting titanium alloy ingots, namely the surface fine crystal region, columnar crystal region, and central eq... [more]

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]