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12 pages, 3210 KiB

Open AccessArticle

Improving Ammonia Emission Model of Urea Fertilizer Fluidized Bed Granulation System Using Particle Swarm Optimization for Sustainable Fertilizer Manufacturing Practice

by Norhidayah Mohamad, Nor Azlina Ab. Aziz, Anith Khairunnisa Ghazali and Mohd Rizal Salleh

Processes 2024, 12(5), 1025; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12051025 - 18 May 2024

Viewed by 241

Abstract

Granulation is an important class of production processes in food, chemical and pharmaceutical manufacturing industries. In urea fertilizer manufacturing, fluidized beds are often used for the granulation system. However, the granulation processes release ammonia to the environment. Ammonia gas can contribute to eutrophication, [...] Read more.

Granulation is an important class of production processes in food, chemical and pharmaceutical manufacturing industries. In urea fertilizer manufacturing, fluidized beds are often used for the granulation system. However, the granulation processes release ammonia to the environment. Ammonia gas can contribute to eutrophication, which is an oversupply of nitrogen and acidification to the ecosystems. Eutrophication may cause major disruptions of aquatic ecosystems. It is estimated that global ammonia emissions from urea fertilizer processes are approximately at 10 to 12 Tg N/year, which represents 23% of overall ammonia released globally. Therefore, accurate modeling of the ammonia emission by the urea fertilizer fluidized bed granulation system is important. It allows for the system to be operated efficiently and within sustainable condition. This research attempts to optimize the model of the system using the particle swarm optimization (PSO) algorithm. The model takes pressure (Mpa), binder feed rate (rpm) and inlet temperature (°C) as the manipulated variables. The PSO searches for the model’s optimal coefficients. The accuracy of the model is measured using mean square error (MSE) between the model’s simulated value and the actual data of ammonia released which is collected from an experiment. The proposed method reduces the MSE to 0.09727, indicating that the model can accurately simulate the actual system. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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16 pages, 925 KiB

Open AccessArticle

Determinants for Supplier Selection Based on Hybrid Grey Theory: Case Study of the Vietnamese Coffee Industry

by Nguyen-Nhu-Y Ho, Phuong Mai Nguyen, Cong Thanh Tran and Huy Hung Ta

Processes 2024, 12(5), 901; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12050901 - 28 Apr 2024

Viewed by 426

Abstract

Coffee is not merely a refreshing beverage but also invigorates people, provides relaxation, contributes to human health, and fosters closer social connections. Coffee is one of the most widely consumed beverages worldwide and the most traded commercial commodity. Moreover, the rapid development of [...] Read more.

Coffee is not merely a refreshing beverage but also invigorates people, provides relaxation, contributes to human health, and fosters closer social connections. Coffee is one of the most widely consumed beverages worldwide and the most traded commercial commodity. Moreover, the rapid development of the Vietnamese coffee industry caused some concerns due to its insufficient performance and the fierce competition within the industry. It is significant to establish an efficient supply network; notwithstanding, supplier selection has always been a challenge for companies. Therefore, this paper employs a hybrid model to determine the supplier selection criteria, a vital factor for a manufacturer under practical operating conditions. Firstly, a combined model of Grey forecasting and the Grey Fourier series is applied to forecast future rainfall and temperature data for six consecutive years. Secondly, based on the criteria, strategies, and buyer requirements, the single-objective linear programming model helps identify the outperformed suppliers. The results found that prices and location change are determinants of supplier selection, and supplier shortage is an enormous barrier for the industry. In this study, these price forecasts allow supply chain management to make informed decisions about inventory levels, transportation routes, and resource allocation to ensure smooth operation and optimize coffee supply chain management. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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16 pages, 1554 KiB

Open AccessArticle

Northern Lights: Prospecting Efficiency in Europe’s Renewable Energy Sector

by Yen-Hsing Hung and Fu-Chiang Yang

Processes 2024, 12(3), 618; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12030618 - 20 Mar 2024

Viewed by 701

Abstract

Northern European nations are at the forefront of renewable energy adoption but face challenges in optimizing energy conversion efficiency. There is a lack of detailed understanding of how behavioral factors affect the efficiency of renewable energy conversion in these countries. This study aims [...] Read more.

Northern European nations are at the forefront of renewable energy adoption but face challenges in optimizing energy conversion efficiency. There is a lack of detailed understanding of how behavioral factors affect the efficiency of renewable energy conversion in these countries. This study aims to evaluate and compare the renewable energy conversion efficiency of Northern European countries, intending to inform strategic policy making and identify best practices for technology deployment in the renewable energy sector. Employing a Data Envelopment Analysis (DEA) model, the study integrates behavioral economic parameters—specifically, the aversion loss and gain significance coefficients—to assess the efficiency of renewable energy conversion, accounting for psychological factors in decision making. A comprehensive sensitivity analysis was conducted, varying the gain significance coefficient while maintaining the aversion loss coefficient at constant levels. This experiment was designed to observe the impact of behavioral parameters on the efficiency ranking of each country. The analysis revealed that Latvia consistently ranked highest in efficiency, irrespective of the gain significance valuation, whereas Iceland consistently ranked lowest. Other countries demonstrated varying efficiency rankings with changes in gain significance, indicating different behavioral economic influences on their renewable energy sectors. Theoretically, the study enhances the DEA framework by integrating behavioral economics, offering a more holistic view of efficiency in renewable energy. Practically, it provides a benchmarking perspective that can guide policy and investment in renewable energy, with sensitivity analysis underscoring the importance of considering behavioral factors. The research offers a practical tool for policymakers and energy stakeholders to align renewable energy strategies with behavioral incentives, aiming to improve the adoption and effectiveness of these initiatives. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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13 pages, 3126 KiB

Open AccessArticle

Finite Element Simulation of a Multistage Square Cup Drawing Process for Relatively Thin Sheet Metal through a Conical Die

by Walid M. Shewakh and Ibrahim M. Hassab-Allah

Processes 2024, 12(3), 525; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12030525 - 6 Mar 2024

Viewed by 630

Abstract

A new manufacturing process has been developed that involves drawing circular sheets of thin metal through a conical die to create square cups. This technique produces deep square cups with a height-to-punch-side length ratio of approximately 2, as well as high dimensional accuracy [...] Read more.

A new manufacturing process has been developed that involves drawing circular sheets of thin metal through a conical die to create square cups. This technique produces deep square cups with a height-to-punch-side length ratio of approximately 2, as well as high dimensional accuracy and a nearly uniform height. The study investigated how various factors, including the sheet material properties and process geometric parameters, affect the limiting drawing ratio (LDR). The researchers used finite element analysis to determine the optimal die design for achieving a high LDR and found that the proposed technique is advantageous for producing long square cups with high dimensional accuracy. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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Graphical abstract

17 pages, 1955 KiB

Open AccessArticle

Method of Analyzing Technological Data in Metric Space in the Context of Industry 4.0

by Karolina Czerwińska and Andrzej Pacana

Processes 2024, 12(2), 401; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12020401 - 17 Feb 2024

Viewed by 587

Abstract

The purpose of this article was to develop a method of analyzing the manufacturing process with variables indicating product competitiveness and technological capabilities in metric space as a cognitive source. The presented method will facilitate the identification of key development factors within the [...] Read more.

The purpose of this article was to develop a method of analyzing the manufacturing process with variables indicating product competitiveness and technological capabilities in metric space as a cognitive source. The presented method will facilitate the identification of key development factors within the manufacturing processes that have the greatest impact on the adaptation of the manufacturing enterprise to Industry 4.0. The presented method of manufacturing process analysis integrates a number of tools (SMART method, brainstorming, BOST analysis, 3 × 3 metrics) that enable the implementation of statistical analysis. The model developed makes it possible to apply known mathematical methods in areas new to them (adaptation in the manufacturing area), which makes it possible to use scientific information in a new way. The versatility of the method allows it to be used in manufacturing companies to identify critical factors in manufacturing processes. A test of the developed method was carried out in one of the foundry enterprises, which allowed us to build a series of importance factors affecting effective production management. The methodology is addressed to the management of manufacturing enterprises as a method to assist in analyzing data and building (on the basis of improved manufacturing processes) a competitive strategy. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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18 pages, 4046 KiB

Open AccessArticle

Optimizing Production Schedules: Balancing Worker Cooperation and Learning Dynamics in Seru Systems

by Weiguo Liu, Weizhe Dai and Xuyin Wang

Processes 2024, 12(1), 38; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12010038 - 22 Dec 2023

Viewed by 696

Abstract

This paper aims to investigate the seru scheduling problem while considering the dual effects of worker cooperation and learning behavior to minimize the makespan and order processing time. Given the complexity of this research problem, an improved shuffled frog leaping algorithm based on [...] Read more.

This paper aims to investigate the seru scheduling problem while considering the dual effects of worker cooperation and learning behavior to minimize the makespan and order processing time. Given the complexity of this research problem, an improved shuffled frog leaping algorithm based on a genetic algorithm is proposed. We design a double-layer encoding based on the problem, introduce a single point and uniform crossover operator, and select the crossover method in probability form to complete the evolution of the meme group. To avoid damaging grouping information, the individual encoding structure is transformed into unit form. Finally, numerical experiments were conducted using numerical examples of large and small sizes for verification. The experimental results demonstrate the feasibility of the proposed model and algorithm, as well as the necessity of considering worker dual behavior in the seru scheduling problem. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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16 pages, 6227 KiB

Open AccessArticle

Structural Design and Analysis of a 100 kW Radial Turbine for an Ocean Thermal Energy Conversion–Organic Rankine Cycle Power Plant

by Xin Feng, Haoyang Li, Jie Huang, Qingfen Ma, Mao Lin, Jingru Li and Zhongye Wu

Processes 2023, 11(12), 3341; https://0-doi-org.brum.beds.ac.uk/10.3390/pr11123341 - 30 Nov 2023

Viewed by 704

Abstract

In this paper, a 100 kW radial inflow turbine is designed for an ocean thermal energy conversion (OTEC) power plant based on the organic Rankine cycle (ORC) with ammonia as the working fluid. Based on one-dimensional (1D) and three-dimensional computational fluid dynamics (3D-CFD) [...] Read more.

In this paper, a 100 kW radial inflow turbine is designed for an ocean thermal energy conversion (OTEC) power plant based on the organic Rankine cycle (ORC) with ammonia as the working fluid. Based on one-dimensional (1D) and three-dimensional computational fluid dynamics (3D-CFD) modeling, the mechanical structure design, static and modal analyses of the turbine and its components are carried out to investigate its mechanical performance. The results show the stress and strain distribution in the volute, stator and rotor, and their maximum values appear, respectively, at the inlet cutout, the tip of the stator outlet and the connection position between the rotor and the shaft. After optimization, all the stresses in the above components are below the allowable values. The frequencies from the first order to the sixth order of the rotor and whole turbine were obtained through modal analysis without prestress and under prestress. The maximum frequency of the rotor and whole turbine is 707.75 Hz and 40.22 Hz, both of which are far away from the resonance frequency range that can avoid resonance. Therefore, the structure of the designed turbine is safe, feasible and reliable so as to better guide actual production. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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Review

Jump to: Research

17 pages, 3676 KiB

Open AccessReview

What Role Does Simulation Play in Sustainable Industrial Development?

by Julia Nazarejova and Vladimir Modrak

Processes 2024, 12(5), 1007; https://0-doi-org.brum.beds.ac.uk/10.3390/pr12051007 - 15 May 2024

Viewed by 258

Abstract

Sustainability as a concept is present in most aspects of our everyday life, and industry is no exception. Likewise, there is no doubt that the necessity to produce goods in a sustainable way and to ensure that products are sustainable is gaining more [...] Read more.

Sustainability as a concept is present in most aspects of our everyday life, and industry is no exception. Likewise, there is no doubt that the necessity to produce goods in a sustainable way and to ensure that products are sustainable is gaining more and more attention from producers, customers, governments, and various organizations. Understandably, there are several ways to increase the sustainable development of industrial production. One effective tool is simulation, which can have a significant impact on improving environmental, economic, and social sustainability. This paper explores the role of simulation as a powerful scientific and engineering solution in advancing sustainability within industrial ecosystems. Its main scope is to map the existing literature on the usage of simulation as a supportive tool for achieving this goal. For this purpose, a bibliometric analysis was conducted, allowing for tailored insights into the use of simulation in sustainable production. Full article

(This article belongs to the Special Issue Simulation, Modeling, and Decision-Making Processes in Manufacturing Systems and Industrial Engineering)

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