Process Intensification of Living Cationic Polymerization of Isobutylene by a Flow Reaction System

Increasing the reaction temperature of the living cationic polymerization of isobutylene is crucial for industrial production due to the cost of refrigeration. The reaction temperature increase was achieved with an accelerated reaction rate using a flow reaction system. The polymerization conditions, including the flow reactor design, were based on the results of kinetic studies. Utilizing a milli‐scale flow reactor, polyisobutylene, which has a narrow molecular weight distribution, was obtained within a considerably short residence time at a high temperature. Furthermore, it was confirmed that the value of M_w/M_n correlates with the product of the Reynolds number and the angle of collision.     

Hybrid hydrate processes for CO2/H2 mixture purification: A techno-economic analysis

In this work, hydrate based separation technique was combined with membrane separation and amine-absorption separation technologies to design hybrid processes for separation of CO₂/H₂ mixture. Hybrid processes are designed in the presence of different types of hydrate promoters. The conceptual processes have been developed using Aspen HYSYS. Proposed processes were simulated at different flow rates for the feed stream. A comprehensive cost model was developed for economic analysis of novel processes proposed in this study. Based on the results from process simulation and equipment sizing, the amount of total energy consumption, fixed cost, variable cost, and total cost were calculated per unit weight of captured CO₂ for various flow rates of feed stream and in the presence of different hydrate promoters. Results showed that combination of hydrate formation separation technique with membrane separation technology results in a CO₂ capture process with lowest energy consumption and total cost per unit weight of captured CO₂. As split fraction and heat of hydrate formation increases, the share of hydrate formation section in total energy consumption increases. When TBAB is applied as hydrate promoter, due to its higher hydrate separation efficiency, more amount of CO₂ is captured in hydrate formation section and consequently the total cost for process decreases considerably. Hybrid hydrate-membrane process in the presence of TBAB as hydrate promoter with 29.47 US$/ton CO₂ total cost is the best scheme for hybrid hydrate CO₂ capture process. Total cost for this process is lower than total cost for single MDEA-based absorption process as the mature technology for CO₂ capture.     

稀土灼烧过程温湿度场仿真分析

影响稀土灼烧工艺的因素十分复杂,关系产品质量稳定及能耗,现行工艺存在优化空间。通过剖析灼烧窑中温度和湿度分布状况,运用κ-ε双方程湍流模型、流体传热、多孔介质传热等理论,按特定组分运输模式,建立灼烧过程质量、动量和能量耦合传递数学模型。设置不同边界导入Fluent环境对数学模型进行仿真试验,完成数据处理实现工艺参数优化。结果表明所建模型能准确反映灼烧窑中温湿度场分布及变化,且最终仿真结果与实际灼烧后的产品湿度含量相符合。     

Theoretical framework for formulating MIP scheduling models with multiple and non-uniform discrete-time grids

We present a framework for the formulation of MIP scheduling models based on multiple and nonuniform discrete time grids. In a previous work we showed that it is possible to use different (possibly non-uniform) time grids for each task, unit, and material. Here, we generalize these ideas to account for general resources, and a range of processing characteristics such as limited intermediate storage and changeovers. Each resource has its own grid based on resource consumption and availability allowing resource constraints to be modeled more accurately without increasing the number of binary variables. We develop algorithms to define the unit-, task-, material-, and resource-specific grids directly from problem data. Importantly, we prove that the multi-grid formulation is able to find a schedule with the same optimal objective as the discrete-time single-grid model with an arbitrarily fine grid. The proposed framework leads to the formulation of models with reduced number of binary variables and constraints, which are able to find good solutions faster than existing models.     

A semicontinuous approach for heterogeneous azeotropic distillation processes

The separation of azeotropes has substantial energy and investment costs, and the available methods require high capital costs for reconstruction of process plants. As an alternative, a semicontinuous configuration that utilizes an existing plant with minor modifications has been explored. In this paper, a semicontinuous, heterogeneous azeotropic distillation process is proposed and acetic acid dehydration process is used as a case study. To carry out the simulation work, Aspen HYSYS^® simulation software is used along with MATLAB^® and an interface program to handle the mode-transition of the semicontinuous process. Sensitivity analyses on operating parameters are performed to identify the process limits. Comparisons are made to conventional heterogeneous azeotropic distillation, and dividing-wall distillation column on the annual cost. The results proved that the semicontinuous system is the best setup in terms of total annual costs and energy requirements.     

Reliability of complex chemical engineering processes

This paper presents a stochastic performance modelling approach that can be used to optimise design and operational reliability of complex chemical engineering processes. The framework can be applied to processes comprising multiple units, including the cases where closed form process performance functions are unavailable or difficult to derive from first principles, which is often the case in practice. An interface that facilitates automated two-way communication between Matlab^® and process simulation environment is used to generate large process responses. The resulting constrained optimisation problem is solved using both Monte Carlo Simulation (MCS) and First Order Reliability Method (FORM); providing a wide range of stochastic process performance measures. Adding such capabilities to traditional deterministic process simulators provides a more informed basis for selecting optimum design factors; giving a simple way of enhancing overall process reliability and cost-efficiency. Two case study systems are considered to highlight the applicability and benefits of the approach.     

川北某黑色页岩型铼矿工艺矿物学研究

通过矿相显微镜、扫描电镜、电子探针、X射线能谱元素面分析等多种手段综合研究了川北某黑色页岩型铼矿中铼的赋存状态。样品为黑色页岩,有机碳含量较高。粘土矿物总量为14.6%,黄铁矿含量16.2%,石英含量37.7%。样品具典型的粘土结构,矿物粒度微细。铼有两种赋存状态,一种呈类质同象形式赋存于黄铁矿内,另一种则以分散形式存在。典型黄铁矿测点Re平均含量为0.024%。黄铁矿是Re的重要载体矿物。建议通过浮选分离黄铁矿,从而实现Re的富集。      

Sensor network design based on system-wide reliability criteria. Part I: Objectives

Reliability based criteria are quite popular for optimal sensor network design. We present a modified definition of system reliability for sensor network design for two applications: reliable estimation of variables in a steady state linear flow process, and reliable fault detection and diagnosis for any process. Unlike the weakest-link based definition of system reliability in the literature, the proposed definition considers the entire system and is consistent with the reliability concept used in classical reliability literature. For each application, dual approaches for defining system reliability are proposed, and their analogy with the reliability problem in the classical reliability literature is established. Using examples and stochastic simulations, the advantage of using the proposed system reliability in contrast to the existing definition is illustrated. Part II of this series of articles presents methods for efficient generation of the system reliability function and its use in optimization-based approaches for designing optimal sensor networks.     

Spray coating process variable and property analysis of UV-curable polyurethane acrylate coating on polycarbonate substrate

A series of spray coating experiments were conducted on an UV-curable, polyurethane-modified, acrylate-based coating formulation with the aim to control defects, coating thickness, and thickness variation. Statistical approaches including design of experiment, residual examination, analysis of variance, and t-test were used in designing the experiments and analyzing data. Viscosity of formulation, atomizing pressure, liquid feeding pressure, distance between nozzle and substrate, and travel speed of substrate were the process variables studied. The ranges of process variables that gave defect-free coating were identified and used in the subsequent experiments to determine process variables and interactions that had significant contribution to the changes in coating thickness and thickness variation. All process variables studied were found to have contribution to the change in coating thickness, but they showed no significant contribution to the variation of coating thickness. No interaction displayed significant contribution. Confirmation tests performed on extra samples prepared with varying coating thicknesses indicated a good agreement with the experimental results. Additional samples were tested for total transmittance, transmission haze, adhesion, surface roughness, hardness, scratch hardness, abrasion resistance, and durability to attack of car wash chemicals. Spray coated samples showed slight improvement in the total transmittance over the uncoated samples, while maintaining the transmission haze and exhibiting rougher surfaces. Only samples with thin coatings were found to possess sufficient adhesion to the substrate. These thin coatings gave improved hardness, scratch hardness, and durability to car wash attack to the level comparable to commercial coated polycarbonate headlamp lenses, whilst giving better abrasion resistance.     

An investigation into the cause of loss of containment from the supply of mini-bulk lubricants

An Intermediate Bulk Container (IBC) was punctured during its handling, releasing oil onto soil at an environmentally-sensitive region of Australia. The telehandler did not pierce the plastic of the IBC directly (as was expected) but rather one of the tynes had caught on the underside of the metal base plate, despite numerous controls being in place at time of spill, revealing a previously unreported mechanism for a fluid spill from handling of petroleum hydrocarbons. The diverse investigation team used a root cause analysis (RCA) technique to identify the underlying cause: the inspection process was inadequate with contributing factors of not using a spotter and design of IBC did not anticipate conditions. Engineering controls were put in place as part of the change management process to help prevent spills from occurring from piercing from telehandler tynes on the current project site.