Scale-up of decanter centrifuges for the particle separation and mechanical dewatering in the minerals processing industry by means of a numerical process model

Decanter centrifuges are frequently used for thickening, dewatering, classification, or degritting in the mining industry and various other sectors. Their use in an industrial process chain requires a sufficiently accurate prediction of the product and the machine behaviour. For this purpose, experiments on a smaller pilot-scale are carried out for scale-up of a decanter centrifuge, which is usually a major challenge. Predicting the process behaviour of decanter centrifuges from laboratory tests is rather difficult. Basically, there are two common ways of scale-up: First, via analytical methods and the law of similarity, which often requires an enormous experimental effort. Second, using numerical models, which demands a mathematically and physically precise description of the multiple processes running simultaneously in such machines. This article provides an overview of both methods for scale-up of a decanter centrifuge. The concept of a previous developed numerical approach is introduced. Pros and cons of both scale-up methods are compared and further discussed. Experiments on lab-scale, pilot-scale, and industrial-scale decanter centrifuges with two different finely dispersed calcium carbonate water suspensions were carried out and simulations were done to investigate and prove the scale-up capability and transferability of the numerical approach

Grey box modelling of decanter centrifuges by coupling a numerical process model with a neural network

Continuously operating decanter centrifuges are often applied for solid-liquid separation in the chemical and mining industries. Simulation tools can assist in the configuration and optimisation of separation processes by, e.g., controlling the quality characteristics of the product. Increasing computation power has led to a renewed interest in hybrid models (subsequently named grey box model), which combine parametric and non-paramteric models. In this article, a grey box model for the simulation of the mechanical dewatering of a finely dispersed product in decanter centrifuges is discussed. Here, the grey box model consists of a mechanistic model (as white box model) presented in a previous research article and a neural network (as black box model). Experimentally determined data is used to train the neural network in the area of application. The mechanistic approach considers the settling behaviour, the sediment consolidation, and the sediment transport. In conclusion, the settings of the neural network and the results of the grey box model and white box model are compared and discussed. Now, the overall grey box model is able to increase the accuracy of the simulation and physical effects that are not modelled yet are integrated by training of a neural network using experimental data

Mitigating Emergent Safety and Security Incidents of CPS by a Protective Shell

In today's modern world, Cyber-Physical Systems (CPS) have gained widespread prevalence, offering tremendous benefits while also increasing society's dependence on them. Given the direct interaction of CPS with the physical environment, their malfunction or compromise can pose significant risks to human life, property, and the environment. However, as the complexity of CPS rises due to heightened expectations and expanded functional requirements, ensuring their trustworthy operation solely during the development process becomes increasingly challenging. This thesis introduces and delves into the novel concept of the 'Protective Shell' – a real-time safeguard actively monitoring CPS during their operational phases. The protective shell serves as a last line of defence, designed to detect abnormal behaviour, conduct thorough analyses, and initiate countermeasures promptly, thereby mitigating unforeseen risks in real-time. The primary objective of this research is to enhance the overall safety and security of CPS by refining, partly implementing, and evaluating the innovative protective shell concept. To provide context for collaborative systems working towards higher objectives — common within CPS as system-of-systems (SoS) — the thesis introduces the 'Emergence Matrix'. This matrix categorises outcomes of such collaboration into four quadrants based on their anticipated nature and desirability. Particularly concerning are outcomes that are both unexpected and undesirable, which frequently serve as the root cause of safety accidents and security incidents in CPS scenarios. The protective shell plays a critical role in mitigating these unfavourable outcomes, as conventional vulnerability elimination procedures during the CPS design phase prove insufficient due to their inability to proactively anticipate and address these unforeseen situations. Employing the design science research methodology, the thesis is structured around its iterative cycles and the research questions imposed, offering a systematic exploration of the topic. A detailed analysis of various safety accidents and security incidents involving CPS was conducted to retrieve vulnerabilities that led to dangerous outcomes. By developing specific protective shells for each affected CPS and assessing their effectiveness during these hazardous scenarios, a generic core for the protective shell concept could be retrieved, indicating general characteristics and its overall applicability. Furthermore, the research presents a generic protective shell architecture, integrating advanced anomaly detection techniques rooted in explainable artificial intelligence (XAI) and human machine teaming. While the implementation of protective shells demonstrate substantial positive impacts in ensuring CPS safety and security, the thesis also articulates potential risks associated with their deployment that require careful consideration. In conclusion, this thesis makes a significant contribution towards the safer and more secure integration of complex CPS into daily routines, critical infrastructures and other sectors by leveraging the capabilities of the generic protective shell framework.:1 Introduction 1.1 Background and Context 1.2 Research Problem 1.3 Purpose and Objectives 1.3.1 Thesis Vision 1.3.2 Thesis Mission 1.4 Thesis Outline and Structure 2 Design Science Research Methodology 2.1 Relevance-, Rigor- and Design Cycle 2.2 Research Questions 3 Cyber-Physical Systems 3.1 Explanation 3.2 Safety- and Security-Critical Aspects 3.3 Risk 3.3.1 Quantitative Risk Assessment 3.3.2 Qualitative Risk Assessment 3.3.3 Risk Reduction Mechanisms 3.3.4 Acceptable Residual Risk 3.4 Engineering Principles 3.4.1 Safety Principles 3.4.2 Security Principles 3.5 Cyber-Physical System of Systems (CPSoS) 3.5.1 Emergence 4 Protective Shell 4.1 Explanation 4.2 System Architecture 4.3 Run-Time Monitoring 4.4 Definition 4.5 Expectations / Goals 5 Specific Protective Shells 5.1 Boeing 737 Max MCAS 5.1.1 Introduction 5.1.2 Vulnerabilities within CPS 5.1.3 Specific Protective Shell Mitigation Mechanisms 5.1.4 Protective Shell Evaluation 5.2 Therac-25 5.2.1 Introduction 5.2.2 Vulnerabilities within CPS 5.2.3 Specific Protective Shell Mitigation Mechanisms 5.2.4 Protective Shell Evaluation 5.3 Stuxnet 5.3.1 Introduction 5.3.2 Exploited Vulnerabilities 5.3.3 Specific Protective Shell Mitigation Mechanisms 5.3.4 Protective Shell Evaluation 5.4 Toyota 'Unintended Acceleration' ETCS 5.4.1 Introduction 5.4.2 Vulnerabilities within CPS 5.4.3 Specific Protective Shell Mitigation Mechanisms 5.4.4 Protective Shell Evaluation 5.5 Jeep Cherokee Hack 5.5.1 Introduction 5.5.2 Vulnerabilities within CPS 5.5.3 Specific Protective Shell Mitigation Mechanisms 5.5.4 Protective Shell Evaluation 5.6 Ukrainian Power Grid Cyber-Attack 5.6.1 Introduction 5.6.2 Vulnerabilities in the critical Infrastructure 5.6.3 Specific Protective Shell Mitigation Mechanisms 5.6.4 Protective Shell Evaluation 5.7 Airbus A400M FADEC 5.7.1 Introduction 5.7.2 Vulnerabilities within CPS 5.7.3 Specific Protective Shell Mitigation Mechanisms 5.7.4 Protective Shell Evaluation 5.8 Similarities between Specific Protective Shells 5.8.1 Mitigation Mechanisms Categories 5.8.2 Explanation 5.8.3 Conclusion 6 AI 6.1 Explainable AI (XAI) for Anomaly Detection 6.1.1 Anomaly Detection 6.1.2 Explainable Artificial Intelligence 6.2 Intrinsic Explainable ML Models 6.2.1 Linear Regression 6.2.2 Decision Trees 6.2.3 K-Nearest Neighbours 6.3 Example Use Case - Predictive Maintenance 7 Generic Protective Shell 7.1 Architecture 7.1.1 MAPE-K 7.1.2 Human Machine Teaming 7.1.3 Protective Shell Plugin Catalogue 7.1.4 Architecture and Design Principles 7.1.5 Conclusion Architecture 7.2 Implementation Details 7.3 Evaluation 7.3.1 Additional Vulnerabilities introduced by the Protective Shell 7.3.2 Summary 8 Conclusion 8.1 Summary 8.2 Research Questions Evaluation 8.3 Contribution 8.4 Future Work 8.5 Recommendatio

Multi-Layer Cyber-Physical Security and Resilience for Smart Grid

The smart grid is a large-scale complex system that integrates communication technologies with the physical layer operation of the energy systems. Security and resilience mechanisms by design are important to provide guarantee operations for the system. This chapter provides a layered perspective of the smart grid security and discusses game and decision theory as a tool to model the interactions among system components and the interaction between attackers and the system. We discuss game-theoretic applications and challenges in the design of cross-layer robust and resilient controller, secure network routing protocol at the data communication and networking layers, and the challenges of the information security at the management layer of the grid. The chapter will discuss the future directions of using game-theoretic tools in addressing multi-layer security issues in the smart grid.Comment: 16 page

Energy balance and techno-economic assessment of algal biofuel production systems

There has been considerable discussion in recent years about the potential of micro-algae for the production of sustainable and renewable biofuels. Unfortunately the scientific studies are accompanied by a multitude of semi-technical and commercial literature in which the claims made are difficult to substantiate or validate on the basis of theoretical considerations.To determine whether biofuel from micro-algae is a viable source of renewable energy three questions must be answered:a. How much energy can be produced by the micro-algae?b. How much energy is used in the production of micro-algae?c. Is more energy produced than used?A simple approach has been developed that allows calculation of maximum theoretical dry algal biomass and oil yields which can be used to counter some of the extreme yield values suggested in the 'grey' literature. No ready made platform was found that was capable of producing an energy balance model for micro-algal biofuel. A mechanistic energy balance model was successfully developed for the production of biogas from the anaerobic digestion of micro-algal biomass from raceways. Preliminary calculations had suggested this was the most promising approach. The energy balance model was used to consider the energetic viability of a number of production scenarios, and to identify the most critical parameters affecting net energy production. These were:a. Favourable climatic conditions. The production of micro-algal biofuel in UK would be energetically challenging at best.b. Achievement of ‘reasonable yields’ equivalent to ~3 % photosynthetic efficiency (25 g m-2 day-1)c. Low or no cost and embodied energy sources of CO2 and nutrients from flue gas and wastewaterd. Mesophilic rather than thermophilic digestione. Adequate conversion of the organic carbon to biogas (? 60 %)f. A low dose and low embodied energy organic flocculant that is readily digested, or micro-algal communities that settle readilyg. Additional concentration after flocculation or sedimentationh. Exploitation of the heat produced from parasitic combustion of micro-algal biogas in CHP unitsi. Minimisation of pumping of dilute micro-algal suspensionIt was concluded that the production of only biodiesel from micro-algae is not economically or energetically viable using current commercial technology, however, the production of micro-algal biogas is energetically viable, but is dependent on the exploitation of the heat generated by the combustion of biogas in combined heat and power units to show a positive balance.Two novel concepts are briefly examined and proposed for further research:a. The co-production of Dunaliella in open pan salt pans.b. A 'Horizontal biorefinery' where micro-algae species and useful products vary with salt concentration driven by solar evaporation.<br/

Ultra scale-down approaches to study the centrifugal harvest for viral vaccine production

Large scale continuous cell‐line cultures promise greater reproducibility and efficacy for the production of influenza vaccines, and adenovirus for gene therapy. This paper seeks to use an existing validated ultra scale‐down tool, which is designed to mimic the commercial scale process environment using only milliliters of material, to provide some initial insight into the performance of the harvest step for these processes. The performance of industrial scale centrifugation and subsequent downstream process units is significantly affected by shear. The properties of these cells, in particular their shear sensitivity, may be changed considerably by production of a viral product, but literature on this is limited to date. In addition, the scale‐down tool used here has not previously been applied to the clarification of virus production processes. The results indicate that virus infected cells do not actually show any increase in sensitivity to shear, and may indeed become less shear sensitive, in a similar manner to that previously observed in old or dead cell cultures. Clarification may be most significantly dependent on the virus release mechanism, with the budding influenza virus producing a much greater decrease in clarification than the lytic, non‐enveloped adenovirus. A good match was also demonstrated to the industrial scale performance in terms of clarification, protein release, and impurity profile.UK Engineering and Physical Sciences Research Council, EPSRC. Grant Number: EP/G034656/1Published versio

Conceptual design of deoiling processes : business process reengineering (BPR) and computer support tools

Deoiling of petroleum wastewater is a major concern in petroleum process engineering. The conventional design procedure for deoiling systems consists of nine consecutive stages involving different people or groups. This thesis considers reengineering the conventional procedure, with the aim of increasing the efficiency of the process and productivity of people involved. The thesis then investigates the development of the appropriate computer support tools for the new procedure. The reengineering of the procedure is based on concepts proposed by Hammer (1990). The resulting procedure consists of four stages, where parallelism of the different tasks in the conventional procedure is explicitly considered. A model of the new procedure is described in UML (Unified Modelling Language). The advantage of using UML instead of using just natural language description is that UML uses graphical representation that is easy to use and less prone to ambiguity. Based on the new procedure, a decision support system called CODES (Conceptual DEsign of deoiling Systems) was designed and implemented. CODES supports the stages of wastewater assessment, equipment options at different locations, treatment disposal options and recommendations for final process configuration. Two Case Studies using operating field data are reported. The Case Studies using CODES proved to be straightforward to use and produced appropriate comments on the performance of the existing designs and proposed alternatives to satisfy the design requirements. CODES results agreed with knowledge from previous plant trials. The contribution of this thesis to the deoiling design process is twofold. Firstly, a critical review of the conventional procedure has resulted in a new one, which has potential benefits of improving a company's efficiency by reducing the number of people and activities involved, and shortening the design time. Secondly, the feasibility of applying the new procedure and CODES is successfully demonstrated through the case studies. Limitations and areas of extensions are also identified

Implementation of virtual manufacturing by a technology licensing company

NoThe paper considers the implementation of a virtual manufacturing system as an alternative to outward technology licensing in a high technology industrial sector. Brief theoretical definition and description of the two strategy options is provided to give background and context. This is followed by empirical material from a longitudinal case study of a company that has developed a virtual manufacturing system in addition to its pre-existing outward technology licensing business stream. A summary account of the company history and development is followed by description of the virtual manufacturing proposal. Analysis of this identified a number of competencies that would be required in order to succeed. The final part of the paper describes the company's response to this analysis and discusses early implementation of the virtual system. It is shown that implementation of the proposal has represented a positive response to the business challenges facing the company