Simulation-based support tool for operator performance in batch manufacturing

In industry, the workload and utilization of shop floor operators is often misunderstood. In this paper, we will present several real case studies, using Discrete Event Simulation (DES) models, which allow us to better understand operators in a batch manufacturing environment. The first study investigates labour in a machining plant consisting of multiple identical CNC machines that batch produce parts. The second study investigates labour in an eight station, gravity die casting rotary table. The results from these studies have shown that there can be potential improvements made by the production planners in the current labour configuration. In the first case study, a matrix is produced that estimates what the operator's utilization levels will be for various configurations. From this, the preferred operator to machine ratio over a range of cycle times is presented. In the second study, the results have shown that by reducing the casting cycle time, the operator would be overloaded. A discrete event simulation of these two cases highlighted areas that were misunderstood by plant management, and provided them with a useful decision support tool for production planning.

A decision support tool for resource allocation in batch manufacturing

A decision support tool for production planning is discussed in this paper to perform the job of machine grouping and labour allocation within a machining line. The production plans within the industrial partner have been historically inefficient because the relationship between the cycle times, the machine group size, and the operator's utilisation hasn't been properly understood. Starting with a simulation model, a rule-base has been generated to predict the operator's utilisation for a range of production settings. The resource allocation problem is then solved by breaking the problem into a series of smaller sized tasks. The objective is to minimise the number of operators and the difference between the maximum and minimum cycle times of machines within each group. The results from this decision support tool is presented for the particular case study.

Use of electrochemical impedance spectroscopy for study of CO2 corrosion prevention by batch treatment inhibitor films

Electrochemical impedance spectroscopy (EIS) was used to study and evaluate commercial batch treatment inhibitors which are used for protecting oil wells, gas wells, and pipelines from CO2 corrosion, focusing on the evaluation of inhibitor film persistency. It was found that theformation and deterioration of batch treatment inhibitor films were accompanied by typical impedance spectral changes. During the formation of inhibitor films, electrode impedance showed a rapid increase and the Bode phase angle plots also showed a sudden change. Thus, the formation of inhibitor film was a very fast process. During the deterioration of inhibitor films, electrode impedance showed a gradual decrease and the Bode phase angle plots showed changes which characterised the three stages of the inhibitor film deterioration process. The relationships between EIS and corrosion rate are discussed, including comparisons with weight loss measurements. Based on the experimental findings in the present work, a method is suggested for estimating the persistency of inhibitor films by monitoring the characteristic changes in the Bode phase angle plots and by measuring electrochemical charge transfer resistance at the second and third stages of the inhibitor film deterioration process.

Monitoring batch treatment inhibitor performance continuously using electrochemical noise analysis

Electrochemical noise analysis (ENA) was used to monitor continuously the formation and deterioration processes of a commercial batch treatment inhibitor film of the type used for protecting against CO₂ corrosion in oilfields; ENA was shown to be able to follow effectively the formation and deterioration processes of batch treatment inhibitor films. As an inhibitor film formed, the current noise amplitude decreased rapidly and the noise resistance R_n, which is deducible from the voltage and current noise records, was found to increase sharply. Conversely, as the inhibitor film deteriorated, the current noise amplitude increased rapidly and R_n decreased rapidly. In the corrosion inhibition system studied, the noise resistance was confirmed to be similar to the linear polarisation resistance. Based on the calculation of R_n on a continuous basis, a technique is proposed to study fast corrosion processes.

Investigation of process dynamics and control of polystyrene batch reactor using hybrid model

The effects of operating conditions such as initiator and monomer concentration as well as reactor temperature of polymerization reactors are studied in this work. A recently developed hybrid model for polystyrene batch reactor is utilized in simulation study. The simulation results reveal the sensitivity of polymer properties and monomer conversion to variation of process operating conditions. In the second phase of this study, the optimization problem involving minimum time optimal temperature policy is considered for control study. An advanced neural network-based model predictive controller (NN-MPC) is designed and tested online. The experimental studies reveal that the developed controller is able to track the optimal setpoint with a minor oscillation and overshoot.

Performance analysis of two advanced controllers for polystyrene polymerization in batch reactor

The performance of two advanced model based non-linear controllers is analyzed for the optimal setpoint tracking of free radical polymerization of styrene in batch reactors. Artificial neural network-based model predictive controller (NN-MPC) and generic model controller (GMC) are both applied for controlling the system. The recently developed hybrid model [1] as well as available literature models are utilized in the control study. The optimal minimum temperature profiles are determined based on Hamiltonian maximum principle. Different types of disturbances are artificially generated to examine the stability and robustness of the controllers. The experimental studies reveal that the performance of NN-MPC is superior over that of GMC.

Changes in oil content, lipid class and fatty acid composition of the microalga Chaetoceros calcitrans over different phases of batch culture

 Abstract
The diatom Chaetoceros calcitrans is a microalgal species used as food for larva in aquaculture for many species worldwide. Chaetoceros calcitrans is an important source of omega 3 long chain (C ≥ 20) polyunsaturated fatty acids (n-3 LC PUFA), chiefly eicosapentaenoic acid (EPA, 20:5n-3). This article reports lipid content, lipid class composition and fatty acid profiles of each lipid class during the growth cycle of batch cultures of C. calcitrans. Total lipid content and the concentration of neutral lipid were highest in the late stationary growth phase (day 12). However, the amount of EPA was highest during the logarithmic growth phase (1.24 pg/cell on day 4). EPA was initially concentrated in the glycolipid fraction, but this fraction decreased during logarithmic growth, coinciding with the increase in neutral lipid. Docosahexaenoic acid (22:6n-3, DHA) (0.91 pg/cell) was reported as a major fatty acid (>10 mg/100 g) in all lipid classes on day 1. DHA was depleted quickly from the neutral lipid and glycolipid classes, but at a slower rate from the polar lipid fraction. This work confirms that C. calcitrans is a good source of lipid, in particular EPA, for larval and adult filter feeders in aquaculture.

Control of polystyrene batch reactor using fuzzy logic controller

Control of polymerization reactors is a challenging issue for researchers due to the complex reaction mechanisms. A lot of reactions occur simultaneously during polymerization. This leads to a polymerization system that is highly nonlinear in nature. In this work, a nonlinear advanced controller, named fuzzy logic controller (FLC), is developed for monitoring the batch free radical polymerization of polystyrene (PS) reactor. Temperature is used as an intermediate control variable to control polymer quality, because the products quality and quantity of polymer are directly depends on temperature. Different FLCs are developed through changing the number of fuzzy membership functions (MFs) for inputs and output. The final tuned FLC results are compared with the results of another advanced controller, named neural network based model predictive controller (NN-MPC). The simulation results reveal that the FLC performance is better than NN-MPC in terms of quantitative and qualitative performance criterion.

Development and characterization of the 2,4,6-trichlorophenol (2,4,6-TCP) aerobic degrading granules in sequencing batch airlift reactor

2,4,6-trichlorophenol (2,4,6-TCP) aerobic degrading granules were successfully developed in the sequencing batch airlift reactor. The key strategy used in cultivation of the granules was dosing glucose and acetate as co-substrates. After granulation, average concentrations of 2,4,6-TCP and COD in the effluent were less than 8mgL-1 and 59mgL-1, respectively. The removal efficiencies of 2,4,6-TCP and COD were above 93% and 90%, respectively. The specific degradation rate of 2,4,6-TCP peaked at 61mg 2,4,6-TCP gVSS-1h-1 when inoculated at the concentration of 400mgL-1. The extracellular polymeric substance (EPS) contents of the 2,4,6-TCP aerobic degrading granules were decreased compared with the contents in seed sludge. Two peaks attributed to the protein-like fluorophores were identified by three-dimensional excitation emission matrix (EEM) fluorescence spectra. The decrease of fluorescence parameters, e.g., peak locations, intensities, indicated quenching effect of 2,4,6-TCP on the EPS fluorescence. Meanwhile, the shift of peak position indicated chemical changes of the EPS.

Enhancement of aerobic granulation by zero-valent iron in sequencing batch airlift reactor

This study elucidates the enhancement of aerobic granulation by zero-valent iron (ZVI). A reactor augmented with ZVI had a start-up time of aerobic granulation (43 days) that was notably less than that for a reactor without augmentation (64 days). The former reactor also had better removal efficiencies for chemical oxygen demand and ammonium. Moreover, the mature granules augmented with ZVI had better physical characteristics and produced more extracellular polymeric substances (especially of protein). Three-dimensional-excitation emission matrix fluorescence showed that ZVI enhanced organic material diversity. Additionally, ZVI enhanced the diversity of the microbial community. Fe(2+) dissolution from ZVI helped reduce the start-up time of aerobic granulation and increased the extracellular polymeric substance content. Conclusively, the use of ZVI effectively enhanced aerobic granulation.

Performance analysis of three advanced controllers for polymerization batch reactor: an experimental investigation

The performances of three advanced non-linear controllers are analyzed for the optimal set point tracking of styrene free radical polymerization (FRP) in batch reactors. The three controllers are the artificial neural network-based MPC (NN-MPC), the artificial fuzzy logic controller (FLC) as well as the generic model controller (GMC). A recently developed hybrid model (Hosen et al., 2011a. Asia-Pac. J. Chem. Eng. 6(2), 274) is utilized in the control study to design and tune the proposed controllers. The optimal minimum temperature profiles are determined using the Hamiltonian maximum principle. Different types of disturbances are introduced and applied to examine the stability of controller performance. The experimental studies revealed that the performance of the NN-MPC is superior to that of FLC and GMC. © 2013 The Institution of Chemical Engineers.

Parametric investigation of batch adsorption of proteins onto polymeric particles

Background: Effective bimolecular adsorption of proteins onto solid matrices is characterized by in-depth understanding of the biophysical features essential to optimize the adsorption performance. Results: The adsorption of bovine serum albumin (BSA) onto anion-exchange Q-sepharose solid particulate support was investigated in batch adsorption experiments. Adsorption kinetics and isotherms were developed as a function of key industrially relevant parameters such as polymer loading, stirring speed, buffer pH, protein concentration and the state of protein dispersion (solid/aqueous) in order to optimize binding performance and adsorption capacity. Experimental results showed that the first order rate constant is higher at higher stirring speed, higher polymer loading, and under alkaline conditions, with a corresponding increase in equilibrium adsorption capacity. Increasing the stirring speed and using aqueous dispersion protein system increased the adsorption rate, but the maximum protein adsorption was unaffected. Regardless of the stirring speed, the adsorption capacity of the polymer was 2.8 mg/ml. However, doubling the polymer loading increased the adsorption capacity to 9.4 mg/ml. Conclusions: The result demonstrates that there exists a minimum amount of polymer loading required to achieve maximum protein adsorption capacity under specific process conditions.

Changes in lipid class content and composition of Isochrysis sp. (T-Iso) grown in batch culture

© 2015, Springer International Publishing Switzerland. For decades, the microalgae Isochrysis spp. have been widely utilised as a live feed in aquaculture practices. This species possesses a number of favourable characteristics, notably its long-chain omega-3 polyunsaturated fatty acid (LC n-3 PUFA) content; primarily docosahexaenoic acid (DHA, 22:6n-3). This article describes the lipid class content and composition of this microalga grown in batch culture, covering the entirety of lag, log and stationary growth phases. The total lipid was highest in the lag phase (27 pg/cell). Total lipid significantly decreased in the exponential growth (7 pg/cell), then steadily increasing for the remainder of growth. The increase in total lipid was due to the accumulation of neutral lipid in the form of triacylglycerides. The DHA content (pg/cell) of the neutral lipid remained relatively unchanged for the duration of growth, with the influx of fatty acids being primarily myristic and palmitic acids. DHA (pg/cell) was found at relatively uniform amounts across all lipid classes. However, the DHA content as a percentage differed greatly between classes. The polar lipid class had a significantly higher DHA content, which peaked at 38 % of all polar lipid in log growth. The primary PUFA species present in the glycolipid class was stearidonic acid (18:4n-3). This work gives an overview of the lipid content and composition of Isochrysis sp. (T-Iso) over the entirety of its growth under batch culture. The lipid profile for this species at different stages of culture provides a basal data set that is useful for comparative studies using this organism.

An epidemic model based temporal violation prediction strategy for large batch of parallel business cloud workflows

Temporal violations often take place during the running of large batch of parallel business cloud workflow, which have a serious impact on the on-time completion of massive concurrent user requests. Existing studies have shown that local temporal violations (namely the delays of workflow activities) occurring during cloud workflow execution are the fundamental causes for failed on-time completion. Therefore, accurate prediction of temporal violations is a very important yet challenging task for business cloud workflows. In this paper, based on an epidemic model, a novel temporal violation prediction strategy is proposed to estimate the number of local temporal violations and the number of violations that must be handled so as to achieve a certain on-time completion rate before the execution of workflows. The prediction result can be served as an important reference for temporal violation prevention and handling strategies such as static resource reservation and dynamic provision. Specifically, we first analyze the queuing process of the parallel workflow activities, then we predict the number of potential temporal violations based on a novel temporal violation transmission model inspired by an epidemic model. Comprehensive experimental results demonstrate that our strategy can achieve very high prediction accuracy under different situations.

Preemptive job scheduling policy for distributively-owned workstation clusters

Cluster computing has come to prominence as a cost-effective parallel processing tool for solving many complex computational problems. In this paper, we propose a new timesharing opportunistic scheduling policy to support remote batch job executions over networked clusters to be used in conjunction with the Condor Up-Down scheduling algorithm. We show that timesharing approaches can be used in an opportunistic setting to improve both mean job slowdowns and mean response times with little or no throughput reduction. We also show that the proposed algorithm achieves significant improvement in job response time and slowdown as compared to exiting approaches and some recently proposed new approaches.