Avaliação de complexos de inclusão na inibição do aço carbono em meio ácido

A indústria de petróleo e gás apresenta sérios problemas relacionados à corrosão. Nas petroquímicas e nas instalações de refino de petróleo, as falhas em materiais estão relacionadas com a corrosão, além disso, os processos de corrosão de metais são problemas no mundo, causando ônus em processos industriais e gerando situações de risco como a corrosão de pilares metálicos em pontes ou em fuselagens de aviões. Dentre os meios corrosivos, um muito comum é o meio ácido, que será o meio estudado neste trabalho. Com todos os problemas citados, se faz necessário o estudo de inibidores de corrosão com alta eficiência, estabilidade e que, preferencialmente, não agridam o meio ambiente. Alguns inibidores de corrosão apresentam solubilidade limitada em água, sendo necessária a utilização de alguns solventes não tão amigáveis ao meio ambiente. Então, propôs-se formar um complexo de inclusão para tornar possível a solubilização de inibidores convencionais em solução aquosa, como algumas tioureias, que apresentam solubilidade limitada em água. Essa completa solubilização do inibidor de corrosão orgânico em meio aquoso é possível com a utilização de um aditivo (hospedeiro) capaz de encapsular tais moléculas (convidados) via interações não covalentes, de modo a alcançar o máximo desempenho de inibição. Para a formação do complexo de inclusão foi usado como molécula hospedeira, a α e a β hidroxipropilciclodextrina e como molécula convidada a dibenziltioureia. A intenção foi testar a melhora da ação inibidora da corrosão do aço carbono em meio de HCl 1mol.L-1 com ensaios de perda de massa, de impedância, polarização e microscopia eletrônica de varredura (MEV), além de evidenciar a formação destes complexos de inclusão através da espectroscopia de absorção vibracional no infravermelho, espectroscopia de RMN de 1H, espectroscopia de absorção no Ultra-violeta e análise térmica diferencial (DTA)

Assessing the potential of yield improvements, through process scrap reduction, for energy and CO2 abatement in the steel and aluminium sectors

Targets to cut 2050 CO2 emissions in the steel and aluminium sectors by 50%, whilst demand is expected to double, cannot be met by energy efficiency measures alone, so options that reduce total demand for liquid metal production must also be considered. Such reductions could occur through reduced demand for final goods (for instance by life extension), reduced demand for material use in each product (for instance by lightweight design) or reduced demand for material to make existing products. The last option, improving the yield of manufacturing processes from liquid metal to final product, is attractive in being invisible to the final customer, but has had little attention to date. Accordingly this paper aims to provide an estimate of the potential to make existing products with less liquid metal production. Yield ratios have been measured for five case study products, through a series of detailed factory visits, along each supply chain. The results of these studies, presented on graphs of cumulative energy against yield, demonstrate how the embodied energy in final products may be up to 15 times greater than the energy required to make liquid metal, due to yield losses. A top-down evaluation of the global flows of steel and aluminium showed that 26% of liquid steel and 41% of liquid aluminium produced does not make it into final products, but is diverted as process scrap and recycled. Reducing scrap substitutes production by recycling and could reduce total energy use by 17% and 6% and total CO 2 emissions by 16% and 7% for the steel and aluminium industries respectively, using forming and fabrication energy values from the case studies. The abatement potential of process scrap elimination is similar in magnitude to worldwide implementation of best available standards of energy efficiency and demonstrates how decreasing the recycled content may sometimes result in emission reductions. Evidence from the case studies suggests that whilst most companies are aware of their own yield ratios, few, if any, are fully aware of cumulative losses along their whole supply chain. Addressing yield losses requires this awareness to motivate collaborative approaches to improvement. © 2011 Elsevier B.V. All rights reserved.

An evaluation of a new product data model

Engineering companies face many challenges today such as increased competition, higher expectations from consumers and decreasing product lifecycle times. This means that product development times must be reduced to meet these challenges. Concurrent engineering, reuse of engineering knowledge and the use of advanced methods and tools are among the ways of reducing product development times. Concurrent engineering is crucial in making sure that the products are designed with all issues considered simultaneously. The reuse of engineering knowledge allows existing solutions to be reused. It can also help to avoid the mistakes made in previous designs. Computer-based tools are used to store information, automate tasks, distribute work, perform simulation and so forth. This research concerns the evaluation of tools that can be used to support the design process. These tools are evaluated in terms of the capture of information generated during the design process. This information is vital to allow the reuse of knowledge. Present CAD systems store only information on the final definition of the product such as geometry, materials and manufacturing processes. Product Data Management (PDM) systems can manage all this CAD information along with other product related information. The research includes the evaluation of two PDM systems, Windchill and Metaphase, using the design of a single-handed water tap as a case study. The two PDMs were then compared to PROSUS/DDM. PROSUS is the Process-Based Support System proposed by [Blessing 94] using the same case study. The Design Data Model is the product data model that includes PROSUS. The results look promising. PROSUS/DDM is able to capture most design information and structure and present it logically. The design process and product information is related and stored within the DDM structure. The PDMs can capture most design information, but information from early stages of design is stored only as unstructured documentation. Some problems were found with PROSUS/DDM. A proposal is made that may make it possible to resolve these problems, but this will require further research.

Cost-effective 10 Gb/s polymer-based chip-to-chip optical interconnect

Board-level optical links are an attractive alternative to their electrical counterparts as they provide higher bandwidth and lower power consumption at high data rates. However, on-board optical technology has to be cost-effective to be commercially deployed. This study presents a chip-to-chip optical interconnect formed on an optoelectronic printed circuit board that uses a simple optical coupling scheme, cost-effective materials and is compatible with well-established manufacturing processes common to the electronics industry. Details of the link architecture, modelling studies of the link's frequency response, characterisation of optical coupling efficiencies and dynamic performance studies of this proof-of-concept chip-to-chip optical interconnect are reported. The fully assembled link exhibits a -3 dBe bandwidth of 9 GHz and -3 dBo tolerances to transverse component misalignments of ±25 and ±37 μm at the input and output waveguide interfaces, respectively. The link has a total insertion loss of 6 dBo and achieves error-free transmission at a 10 Gb/s data rate with a power margin of 11.6 dBo for a bit-error-rate of 10 -12. The proposed architecture demonstrates an integration approach for high-speed board-level chip-to-chip optical links that emphasises component simplicity and manufacturability crucial to the migration of such technology into real-world commercial systems. © 2012 The Institution of Engineering and Technology.

Superconducting fault current limiter design using parallel-connected YBCO thin films

Superconducting Fault Current Limiters (SFCLs) are able to reduce fault currents to an acceptable value, reducing potential mechanical and thermal damage to power system apparatus and allowing more flexibility in power system design and operation. The device can also help avoid replacing circuit breakers whose capacity has been exceeded. Due to limitations in current YBCO thin film manufacturing processes, it is not easy to obtain one large thin film that satisfies the specifications for high voltage and large current applications. The combination of standardized thin films has merit to reduce costs and maintain device quality, and it is necessary to connect these thin films in different series and parallel configurations in order to meet these specifications. In this paper, the design of a resistive type SFCL using parallel-connected YBCO thin films is discussed, including the role of a parallel resistor and the influence of individual thin film characteristics, based on both theory and experimental results. © 2009 IEEE.

Bulk forming of sheet metal

Ever increasing demands on functional integration of high strength light weight products leads to the development of a new class of manufacturing processes. The application of bulk forming processes to sheet or plate semi-finished products, sometimes in combination with conventional sheet forming processes creates new products with the requested properties. The paper defines this new class of sheet-bulk metal forming processes, gives an overview of the existing processes belonging to this class, highlights the tooling aspects as well as the resulting product properties and presents a short summary of the relevant work that has been done towards modeling and simulation. © 2012 CIRP.

Low-cost PCB-integrated 10-Gb/s optical transceiver built with a novel integration method

A novel integration method for the production of cost-effective optoelectronic printed circuit boards (OE PCBs) is presented. The proposed integration method allows fabrication of OE PCBs with manufacturing processes common to the electronics industry while enabling direct attachment of electronic components onto the board with solder reflow processes as well as board assembly with automated pick-and-place tools. The OE PCB design is based on the use of polymer multimode waveguides, end-fired optical coupling schemes, and simple electro-optic connectors, eliminating the need for additional optical components in the optical layer, such as micro-mirrors and micro-lenses. A proof-of-concept low-cost optical transceiver produced with the proposed integration method is presented. This transceiver is fabricated on a low-cost FR4 substrate, comprises a polymer Y-splitter together with the electronic circuitry of the transmitter and receiver modules and achieves error-free 10-Gb/s bidirectional data transmission. Theoretical studies on the optical coupling efficiencies and alignment tolerances achieved with the employed end-fired coupling schemes are presented while experimental results on the optical transmission characteristics, frequency response, and data transmission performance of the integrated optical links are reported. The demonstrated optoelectronic unit can be used as a front-end optical network unit in short-reach datacommunication links. © 2011-2012 IEEE.

Characterisation of different commercial reactive magnesia

Reactive magnesia (MgO) has emerged as an essential component in a new family of cements with significantly superior technical and environmental performance over Portland cement. The physical characteristics of different reactive magnesia, which are likely to affect their engineering performance, vary considerably depending on their origin and manufacturing processes. To appropriately utilise such a material, it is essential to develop a better understanding of the characteristics of different magnesia from various sources. In this study, the detailed characterisation of 14 commercial magnesia in terms of reactivity, textural properties, X-ray diffraction pattern, pH value and hydration behaviour and morphology is presented and correlation between them is developed. Relationships were developed between the reactivity, specific surface area, agglomeration ratio and hydration rate based on the experimental observations. As a result, the reactive magnesia used in this study were grouped into three categories and their characteristics and anticipated performances in different applications were discussed.

具有随机机器故障的制造过程建模与性能分析

为研究机器故障和维修活动对制造过程性能的影响,提出一种基于广义随机Petri网的制造过程建模与性能分析方法。分析了随机机器故障特征;定义了两种故障发现模式和两种中断作业处理策略;给出具有随机机器故障的制造过程的不同模型方法;通过对模型结构特征的分析,证明了其有效性。针对不同策略和参数设置进行了性能仿真。分别以平均产量和平均过程流时间等性能指标,分析了单个工作站的性能;采用平均产量,分析了具有两个工作站的流水线的性能。仿真结果表明,故障率、平均维修时间、缓存数量配置、维修工人数量、故障发现模式和中断作业处理策略是影响具有随机机器故障的制造过程性能的主要因素。

基于时间Petri网的制造过程模型研究

分析了时间Petri网的激发规则、托肯可用时间和抑制弧等特性,以及制造过程中随机故障的特征。提出不同的时间关联方式对应的多种建模方法,考虑不同的故障发现模式、不同的作业处理策略,建立相应的单机制造过程模型。在此基础上采用模块化和层次化方法可以构建复杂制造过程的时间着色Petri网模型,并可以转换成仿真模型,进一步分析随机机器故障对制造过程性能的影响。

基于多Agent制造过程的建模方法

分析了制造系统与制造过程之间的关系;论证了从过程的角度对制造进行建模更恰当;结合Agent和π演算的特点,给出Agent制造系统描述模型及基于π演算的单个Agent的BDI模型,并指出Agent和π演算结合的制造过程模型有利于进行优化目标在不同制造过程层次的分解,不论从方法的角度还是实现的角度,都适合复杂系统建模。Agent和π演算相结合可以有效分析并解决离散事件的建模与仿真中的问题。

面向复杂制造过程质量的模糊Petri网预测及诊断方法研究

在复杂制造过程中，存在质量异常预测及诊断能力弱、智能化程度低、效率低等问题。如何针对制造过程质量问题特点采用合适的预测与诊断方法，满足日益提高的过程自动化水平的要求，是该领域研究人员面临重要的亟待解决的问题。 由于模糊Petri网是模糊集理论与Petri网理论有机结合的一种网络理论，其突出优势在于知识表示、推理和处理模糊信息的能力; 目前，尽管模糊Petri网已有成功的应用案例，但仍存在某些不足，需不断地改进与完善。因此，对模糊Petri网理论方法的研究，有利于提高其知识表示能力、模糊动态推理能力、推理结果可靠性与准确性等，对模糊Petri网理论的广泛应用具有推动作用。 本文以制造过程质量问题的预测与诊断为研究和应用背景，对模糊Petri网预测与诊断方法的研究为主线，以研发的系统为辅助分析工具，重点从方法的层面上对模糊Petri网理论进行了研究和探讨。旨在进一步完善模糊Petri网相关理论，并应用于制造过程质量问题的解决，提高过程的质量监控能力、事故预防能力、缩短故障原因查找周期、提高定位准确性及可靠性奠定方法基础。 针对制造过程质量预测与诊断问题特点，在广泛阅读相关文献并深入探索的基础上，对模糊Petri网理论方法进行了较深入的研究和探讨，重点解决了以下问题： 1）模糊Petri网自动建模方法：对模糊Petri网理论研究的基础和前提是建立模糊Petri网模型。为解决当前模糊Petri网建模效率低、工作量大、易出错等问题，本文提出了模糊Petri网的自动建模方法。该方法的提出，易于保证知识库与模型库更新的同步和一致，提高了建模效率，避免了建模的人为失误。 2) 模糊Petri网参数确定：模型建立后，为实现可靠有效地推理，需进行相关参数的确定。提出了确定模糊Petri网的初始库所token的方法。通过模糊统计的方法来获得模糊token，减少确定token时的主观臆断性和不一致性，为物理量与模糊token的实时转换提供了技术支持。由于构建符合客观实际的、连续的隶属函数是确定模糊token的前提条件，本文提出采用最小二乘拟合来构造模糊隶属函数方法。该方法简单，拟合能力强，人工干预少。由于变迁阈值影响推理的正确性及可靠性，这里对阈值设定进行了初步探讨。阈值设定越高，预测及诊断的漏报率越高；反之，误报率越高。给出了阈值设定的总代价计算式，阈值选择的目标是使总代价最小。 在建立了模糊Petri网模型、确定了相关参数后，便可对异常事件进行预测及诊断推理。 3）模糊Petri网预测方法：对预测模式进行了分类与定义，便于对不同模式下进行预测分析。提出了改进的FPN四种基本推理模型，通过禁止弧的引入，避免了激发过的变迁反复被激发，减少不必要的计算，实现了推理与模型结构的一致性。从而提高了推理效率和基于规则系统的响应能力。 4）模糊Petri网诊断方法：给出了一种模糊Petri网诊断推理方法。该方法充分利用模糊Petri网自身的结构与数学特性这一突出优势，实现了并行推理。以矢量计算方式获得中间库所能力，取代了常规的搜索方式，提高了推理效率。通过引入人机交互的处理策略，减少了模糊Petri网的复杂性及规模。指出在实践中，推理方法的效率、成本及实际的应用效果， 在重要性方面，要远大于方法自身的运算效率。 5）模糊着色Petri网推理方法：在建模复杂大型系统时，为解决模糊Petri网存在模型空间过大，模型数据结构松散等问题，提出了FCPN并行推理方法及FPR与FCPN模型转换算法。提出的FCPN与现有方法的主要区别在以下方面：首先，算法实现变迁的单次激发，避免推理激发变迁的重复计算。其次，某个使能变迁前集库所中token在该变迁激发后并不移除，符合实际推理情况。此外，通过输入/输出关联矩阵计算迭代，实现了并行推理。 最后，以一典型制造过程—埋弧自动焊接过程质量问题的预测和诊断为例，来说明模糊Petri网方法的实际应用。通过系统的实现，验证了相应方法是可行的。通过模糊Petri网的预测及诊断推理，便于实现质量异常的分析、预警、处理、过程控制及数字化管理，为生产策略的调整、纠正措施的采取提供了决策依据，加快了系统响应速度。 本文研究工作重点围绕模糊Petri网理论方法展开，虽以制造过程质量问题的预测与诊断为研究和应用背景，但并不局限于该领域，是属于具有一般性的共性方法。因此，所开展的方法研究工作具有良好的科研价值和广泛的应用前景。

Exploring alternatives for milk quality improvement and more efficient dairy production in a smallholder farming context – case study: Mantaro Valley (Peru)

Consumer demand is revolutionizing the way products are being produced, distributed and marketed. In relation to the dairy sector in developing countries, aspects of milk quality are receiving more attention from both society and the government. However, milk quality management needs to be better addressed in dairy production systems to guarantee the access of stakeholders, mainly small-holders, into dairy markets. The present study is focused on an analysis of the interaction of the upstream part of the dairy supply chain (farmers and dairies) in the Mantaro Valley (Peruvian central Andes), in order to understand possible constraints both stakeholders face implementing milk quality controls and practices; and evaluate “ex-ante” how different strategies suggested to improve milk quality could affect farmers and processors’ profits. The analysis is based on three complementary field studies conducted between 2012 and 2013. Our work has shown that the presence of a dual supply chain combining both formal and informal markets has a direct impact on dairy production at the technical and organizational levels, affecting small formal dairy processors’ possibilities to implement contracts, including agreements on milk quality standards. The analysis of milk quality management from farms to dairy plants highlighted the poor hygiene in the study area, even when average values of milk composition were usually high. Some husbandry practices evaluated at farm level demonstrated cost effectiveness and a big impact on hygienic quality; however, regular application of these practices was limited, since small-scale farmers do not receive a bonus for producing hygienic milk. On the basis of these two results, we co-designed with formal small-scale dairy processors a simulation tool to show prospective scenarios, in which they could select their best product portfolio but also design milk payment systems to reward farmers’ with high milk quality performances. This type of approach allowed dairy processors to realize the importance of including milk quality management in their collection and manufacturing processes, especially in a context of high competition for milk supply. We concluded that the improvement of milk quality in a smallholder farming context requires a more coordinated effort among stakeholders. Successful implementation of strategies will depend on the willingness of small-scale dairy processors to reward farmers producing high milk quality; but also on the support from the State to provide incentives to the stakeholders in the formal sector.

Infant milk formula manufacture: process and compositional interactions in high dry matter wet-mixes

Infant milk formula (IMF) is fortified milk with composition based on the nutrient content in human mother's milk, 0 to 6 months postpartum. Extensive medical and clinical research has led to advances in the nutritional quality of infant formula; however, relatively few studies have focused on interactions between nutrients and the manufacturing process. The objective of this research was to investigate the impact of composition and processing parameters on physical behaviour of high dry matter (DM) IMF systems with a view to designing more sustainable manufacturing processes. The study showed that commercial IMF, with similar compositions, manufactured by different processes, had markedly different physical properties in dehydrated or reconstituted state. Commercial products made with hydrolysed protein were more heat stable compared to products made with intact protein, however, emulsion quality was compromised. Heat-induced denaturation of whey proteins resulted in increased viscosity of wet-mixes, an effect that was dependant on both whey concentration and interactions with lactose and caseins. Expanding on fundamental laboratory studies, a novel high velocity steam injection process was developed whereby high DM (60%) wet-mixes with lower denaturation/viscosity compared to conventional processes could be achieved; powders produced using this process were of similar quality to those manufactured conventionally. Hydrolysed proteins were also shown to be an effective way of reducing viscosity in heat-treated high DM wet-mixes. In particular, using a whey protein concentrate whereby β-Lactoglobulin was selectively hydrolysed, i.e., α-Lactalbumin remained intact, reduced viscosity of wet-mixes during processing while still providing good emulsification. The thesis provides new insights into interactions between nutrients and/or processing which influence physical stability of IMF both in concentrated liquid and powdered form. The outcomes of the work have applications in such areas as; increasing the DM content of spray drier feeds in order to save energy, and, controlling final powder quality.

Risk mitigation framework for a robust design process

The increasing complexity of new manufacturing processes and the continuously growing range of fabrication options mean that critical decisions about the insertion of new technologies must be made as early as possible in the design process. Mitigating the technology risks under limited knowledge is a key factor and major requirement to secure a successful development of the new technologies. In order to address this challenge, a risk mitigation methodology that incorporates both qualitative and quantitative analysis is required. This paper outlines the methodology being developed under a major UK grand challenge project - 3D-Mintegration. The main focus is on identifying the risks through identification of the product key characteristics using a product breakdown approach. The assessment of the identified risks uses quantification and prioritisation techniques to evaluate and rank the risks. Traditional statistical process control based on process capability and six sigma concepts are applied to measure the process capability as a result of the risks that have been identified. This paper also details a numerical approach that can be used to undertake risk analysis. This methodology is based on computational framework where modelling and statistical techniques are integrated. Also, an example of modeling and simulation technique is given using focused ion beam which is among the investigated in the project manufacturing processes.