Industrial Energy Management and Sustainability

Growing environmental concerns caused by increasing consumption of naturalresources and pollution need to be addressed. Manufacturing dictates the efficiencywith which resource inputs are transformed into economically valuableoutputs in the form of products and services. Consequently, it is also responsiblefor the resulting waste and pollution generated from this transformation process.As a matter of fact, about one-third of the global total energy consumption isassociated withmanufacturing activities; thus, achieving higher energy efficiencyin this sector has been the focus of research as well as of policy and industrialprogrammes in recent years. In particular, being able to effectively manageenergy and energy-related activities has proved to be a fundamental capabilityfor companies willing to improve their sustainability, as it constitutes the first,critical step to understanding their processes and to identifying and correctlyevaluating improvement opportunities.This Special Issue focuses on energy management and sustainability of bothmanufacturing processes and systems, including methods, practices, tools, applicationsand experiences

English for Study and Work: Coursebook in 4 books. Book 2 Obtaining and Processing Information for Specific Purposes

Подано всі види діяльності студентів з вивчення англійської мови, спрямовані на розвиток мовної поведінки, необхідної для ефективного спілкування в академічному та професійному середовищах. Містить завдання і вправи, типові для різноманітних академічних та професійних сфер і ситуацій. Структура організації змісту – модульна, охоплює мовні знання і мовленнєві вміння залежно від мовної поведінки. Даний модуль має на меті розвиток у студентів стратегій, умінь, навичок читання, пошуку та вилучення професійно-орієнтованої інформації, необхідної для ефективної професійної діяльності і навчання. Містить завдання і вправи, типові для академічних та професійних сфер, пов’язаних з гірництвом і розробкою родовищ корисних копалин. Зразки текстів – автентичні, різножанрові, взяті з реального життя, містять цікаву й актуальну інформацію про особливості видобутку мінеральних ресурсів в провідних країнах світу, сучасний підхід до розробки родовищ тощо. Ресурси для самостійної роботи (Частина ІІ) містять завдання та вправи для розширення словникового запасу та розвитку знань найуживанішої термінології з гірництва, що спрямовано на організацію самостійної роботи з розвитку мовленнєвих умінь, знань про корисні копалини, методи їх видобутку. За допомогою засобів діагностики студенти можуть самостійно перевірити засвоєння навчального матеріалу й оцінити свої досягнення. Призначений для студентів вищих навчальних закладів, зокрема технічних університетів. Може використовуватися для самостійного вивчення англійської мови викладачами, фахівцями і науковцями різних галузей

Development of the UMAC-based control system with application to 5-axis ultraprecision micromilling machines

This thesis was submitted for the degree of Doctor of Philosophy and awarded by Brunel University.Increasing demands from end users in the fields of optics, defence, automotive, medical, aerospace, etc. for high precision 3D miniaturized components and microstructures from a range of materials have driven the development in micro and nano machining and changed the manufacturing realm. Conventional manufacturing processes such as chemical etching and LIGA are found unfavourable or limited due to production time required and have led mechanical micro machining to grow further. Mechanical micro machining is an ideal method to produce high accuracy micro components and micro milling is the most flexible enabling process and is thus able to generate a wider variety of complex micro components and microstructures. Ultraprecision micromilling machine tools are required so as to meet the accuracy, surface finish and geometrical complexity of components and parts. Typical manufacturing requirements are high dimensional accuracy being better than 1 micron, flatness and roundness better than 50 nm and surface finish ranging between 10 and 50 nm. Manufacture of high precision components and parts require very intricate material removal procedure. There are five key components that include machine tools, cutting tools, material properties, operation variables and environmental conditions, which constitute in manufacturing high quality components and parts. End users assess the performance of a machine tool based on the dimensional accuracy and surface quality of machined parts including the machining time. In this thesis, the emphasis is on the design and development of a control system for a 5-axis bench-type ultraprecision micromilling machine- Ultra-Mill. On the one hand, the developed control system is able to offer high motion and positioning accuracy, dynamic stiffness and thermal stability for motion control, which are essential for achieving the machining accuracy and surface finish desired. On the other hand, the control system is able to undertake in-process inspection and condition monitoring of the machine tool and process. The control of multi-axis precision machines with high-speed and high-accuracy motions and positioning are desirable to manufacture components with high accuracy and complex features to increase productivity and maintain machine stability, etc. The development of the control system has focused on fast, accurate and robust positioning requirements at the machine system design stage. Apart from the mechanical design, the performance of the entire precision systems is greatly dependent on diverse electrical and electronics subsystems, controllers, drive instruments, feedback devices, inspection and monitoring system and software. There are some variables that dynamically alter the system behaviour and sensitivity to disturbance that are not ignorable in the micro and nano machining realm. In this research, a structured framework has been developed and integrated to aid the design and development of the control system. The framework includes critically reviewing the state of the art of ultraprecision machining tools, understanding the control system technologies involved, highlighting the advantages and disadvantages of various control system methods for ultraprecision machines, understanding what is required by end-users and formulating what actually makes a machine tool be an ultraprecision machine particularly from the control system perspective. In the design and development stage, the possession of mechatronic know-how is essential as the design and development of the Ultra-Mill is a multidisciplinary field. Simulation and modelling tool such as Matlab/Simulink is used to model the most suitable control system design. The developed control system was validated through machining trials to observe the achievable accuracy, experiments and testing of subsystems individually (slide system, tooling system, monitoring system, etc.). This thesis has successfully demonstrated the design and development of the control system for a 5-axis ultraprecision machine tool- Ultra-Mill, with high performance characteristics, fast, accurate, precise, etc. for motion and positioning, high dynamic stiffness, robustness and thermal stability, whereby was provided and maintained by the control system

Applications of Dynamic Modeling in Crushing Plants

Modeling is a tool to describe phenomena in a simplified way, and the models can then be used to simulate these phenomena. Models of equipment used in the mining and aggregate industries can be used for process simulations of the processes in those industries to improve the operations. To study processes and the operation of processes, time dynamic models are a great tool. This thesis focuses on applications of time dynamic modeling in crushing plants. The time dynamic models predict the output of the equipment as a function of time. The work presented within this thesis focuses on three areas; Unit modeling, process modeling, and control modeling.Unit modeling refers to developing models of single processing units, which could be a comminution unit, classification unit, or materials handling unit. The new models presented in this thesis are for jaw crushers, high pressure grinding rolls (HPGR), and storage units (e.g., bin, silo, or stockpile). The developed models are based on the fundamental insight of the physics that happens within the unit. The validity of the models is aimed to be broad and cover many operating points and uses. The models are intended for high fidelity process simulation applications.Process modeling refers to the modeling of many interconnected units, and the modeling presented in this thesis has been done with both high-fidelity unit models and with simplified models. Both high fidelity and simple simulations are demonstrated within the thesis. The simpler models are used to try new concepts of plant design or control and study plant robustness or ability to handle variations. Meanwhile, the high-fidelity models can be used to study topics such as particle size distribution, debottlenecking and specific control issues.Control modeling refers to developing controller models to control plants like those modeled within the process modeling section. Optimal control, such as model predictive control (MPC), relies on models to steer processes optimally relative to some objective. The models within those controllers have been discussed in this thesis. Additionally, being able to move between the various fidelity domains of models is beneficial for this application. In this thesis, multiple new models and methods are presented, along with how they can be applied within the minerals processing and aggregate industry, ultimately improving the efficiency and performance of the industries

Different perspectives of dynamics in comminution processes

The performance of a comminution and classification process depends on the design and configuration of each process unit, the configuration of the plant, the design of the control and physical properties of the incoming feed. Comminution processes should be designed to have a stable and efficient production over a wide range of conditions. However, demands from the management, operational cost, investment, maintenance or any other related field can result in process alterations that are not beneficial for the stability of the circuit and, therefore, utilization and efficiency of the production. Furthermore, advanced process control and optimization rely heavily on understanding the dynamic behaviour of the process in achieving a more stable and consequently efficient process. This review aims to explore different dynamic aspects from particle, bulk, unit and process perspectives, their origin, and what consequences they may have on the operation. The aim is to illustrate a holistic view of process dynamics that should be considered when evaluating circuit performances and identifying risk zones that affect the process, considering the state-state performance and dynamic behaviour. Based on that, several dynamic related issues were formulated and ranked by experts within the field to get a subjective perspective. Issues such as process control design and configuration, ore variability, segregation and upstream disturbances ranked high in possible gains for comminution processes

Energy Efficiency Improvement and Cost Saving Opportunities for Cement Making. An ENERGY STAR Guide for Energy and Plant Managers

The cost of energy as part of the total production costs in the cement industry is significant, warranting attention for energy efficiency to improve the bottom line. Historically, energy intensity has declined, although more recently energy intensity seems to have stabilized with the gains. Coal and coke are currently the primary fuels for the sector, supplanting the dominance of natural gas in the 1970s. Most recently, there is a slight increase in the use of waste fuels, including tires. Between 1970 and 1999, primary physical energy intensity for cement production dropped 1 percent/year from 7.3 MBtu/short ton to 5.3 MBtu/short ton. Carbon dioxide intensity due to fuel consumption and raw material calcination dropped 16 percent, from 609 lb. C/ton of cement (0.31 tC/tonne) to 510 lb. C/ton cement (0.26 tC/tonne). Despite the historic progress, there is ample room for energy efficiency improvement. The relatively high share of wet-process plants (25 percent of clinker production in 1999 in the U.S.) suggests the existence of a considerable potential, when compared to other industrialized countries. We examined over 40 energy efficient technologies and measures and estimated energy savings, carbon dioxide savings, investment costs, and operation and maintenance costs for each of the measures. The report describes the measures and experiences of cement plants around the wold with these practices and technologies. Substantial potential for energy efficiency improvement exists in the cement industry and in individual plants. A portion of this potential will be achieved as part of (natural) modernization and expansion of existing facilities, as well as construction of new plants in particular regions. Still, a relatively large potential for improved energy management practices exists

Maintenance Performance Optimization for Critical Subsystems in Cement Pre-Grinding Section: A Case Study Approach

This paper aims to develop a simulation-based framework to identify critical equipment, critical maintenance and operational factors (e.g., maintenance actions, spare sourcing lead times and fill rate) affecting plant performance (availability and maintenance cost). The study develops a framework that utilizes empirical maintenance data. Pareto analysis is employed to identify critical subsystems, while expert input is incorporated to derive model variables. A full factorial Design of Experiment (DOE) is employed to establish the variables with significant main and interaction effects on the plant availability and maintenance cost. The framework is applied to a real case study of a cement-manufacturing firm, where a simula- tion model is developed based on the empirical maintenance and operational data while considering the availability and maintenance cost as the performance measures. Simulation results highlight the bucket elevator as the critical subsystem. At the same time, spare parts importation probability, among other parameters like the preventive maintenance interval and utilization of adjust maintenance action, significantly affects the performance (availability and maintenance cost) as main and interaction effects. The research was applied to only one case study, in this case, a cement grinding plant. The study provides a pragmatic reference model framework to practitioners that enhances maintenance decision-making by identifying critical equipment, maintenance and operational parameters and disclosing their effect (main and interaction) on the plant performance (availability and maintenance cost). This study is one of the first to (i) investigate the maintenance and operational factors’ main and interac- tion effects on maintenance cost and (ii) integrate the spare parts importation probability as a factor affecting plant performance. The developed framework assists in determining critical systems to be optimized, considers various maintenance strategies simultaneously, the stochasticity of spare parts availability and replenishment and ultimately discovers the interactions for decision support

Effect of VRM on a polymetallic sulfide ore and the flotation response as compared to conventional wet and dry rod milling

Comminution is an energy intensive, size reduction and mineral dressing process which consumes up to 50% of concentrator energy consumption. Conventional methods use mainly a combination of crushers and tumbling mills in comminution circuits. Energy consumption in these circuits has been found to be relatively high. To reduce the energy requirements, compression grinding equipment, Vertical Roller Mills (VRMs) and High-Pressure Grinding Rolls (HPGRs) have been identified as potential solutions, and they have been adopted in the cement industry. Reports from plants where these technologies have been installed in circuits indicate they are more energy efficient than the conventional comminution circuits. Studies have also suggested that the use of VRMs results in comminution products with relatively higher mineral liberation degrees. Unlike in the cement industry, comminution equipment in mineral processing circuits are also required to produce particles that can be separated and recovered in downstream processes. Froth flotation is a selective separation process that utilises differences in surface properties to separate value minerals from unwanted gangue. The success of flotation is dependent on chemistry, operational and equipment factors. The chemistry factors consider the interaction between flotation reagents and solids particles surface. The operational factors consider the effect of particle size distribution, mineralogy, feed rate, pulp density, pulp potential (Eh), bubble size, temperature and circuit design on flotation. The use of different comminution procedures may result in flotation feeds of different particle size distributions (PSDs), mineral liberation characteristics and pulp potential. Due to these differences, the resultant flotation response may differ. The present study was aimed at assessing the particle size distribution, mineral liberation profiles and the flotation response from material comminuted using the VRM floated under batch flotation conditions in a 3 litre Barker flotation cell. A complex polymetallic sulfide ore containing chalcopyrite (1.3 %), galena (2.4 %) and sphalerite (1.8 %) as the main value minerals and magnetite (68.0 %) and quartz (15.7 %) as dominant gangue minerals was used for the study. The ore was milled to target grinds of 55 %, 60 %, 65 %, 70 % and 75 % passing 75 µm respectively, at a grinding pressure of 600 kPa, air temperature of 300 K. For the benchmarking grind of 65 % passing 75 µm, the ore was also milled using heated air of temperature of 373 K and at elevated grinding pressures of 800 kPa and 1000 kPa. Further work was performed to evaluate if the VRM results are comparable to conventional dry and wet rod milling products floated under the same batch flotation conditions. An increase in grinding pressure was observed to result in an increase in throughput and a general decrease in specific energy consumption without a change in product particle size distribution nor the recovery of chalcopyrite, galena and sphalerite. Using heated air (373 K) resulted in the production of slightly less fines in the comminution products. The recovery of chalcopyrite, galena and sphalerite were not affected by the change in operating temperature. However, concentrate grade (selectivity) was compromised at elevated temperatures of comminution probably due to surface oxidation. The results indicated that the grind range to achieve the best flotation performance when using the VRM as a comminution device is between 60 % and 70 % passing 75 µm. The results also indicated that at the benchmarking grind of 65 % passing 75 µm, the specific energy consumption for comminution using the VRM was 54.3 % lower than that of the conventional tumbling mill circuit. The grind of 55 % passing 75 µm resulted in lower flotation efficiencies as the minerals were unlikely liberated enough whereas the grind of 75 % passing 75 µm resulted in poor performances due to low water recovery. Comparing VRM with wet and rod milling, the different comminution procedures resulted in flotation feed of similar PSDs for all grinds compared. The wet and dry rod milling products of grinds 55 % and 75 % passing 75 µm achieved better recoveries of chalcopyrite, galena and sphalerite as compared to the VRM performance mainly due to high water recoveries achieved. While mineral recoveries were above 90 % for the grinds of 60 % and 70 % passing 75 µm, the rod milling products had statistically better flotation recoveries at 95 % confidence compared to the VRM products. The mineral recoveries after dry rod milling were marginally better than after wet rod milling due to the minimisation of galvanic interactions during dry rod milling. For the benchmarking grind of 65 % passing 75 µm, VRM grinding resulted in 84 %, 84 % and 90 % liberated chalcopyrite, galena and sphalerite respectively. The liberation of chalcopyrite, galena and sphalerite after wet and dry rod milling were 80 %, 78 % and 90 % respectively. Chalcopyrite recovery was 96.7 %, 96.3 % and 96.7 % for the VRM, dry rod mill (RD) and wet rod mill (RW) products respectively. Galena recovery was 94.3 %, 94.3 % and 92.9 % for the VRM, RD and RW products respectively. Sphalerite recovery was 96.6 %, 97.4 % and 97.4 % for the VRM, RD and RW products respectively. The differences in recovery were statistically insignificant at 95 % confidence. Liberation differences did not translate to differences in recoveries as the ore was coarse grained. The recovery kinetics were very fast and independent of comminution procedure. Reference to the benchmarking grind therefore, the VRM can be retrofitted into existing plant installations as it is more energy efficient and the flotation performance was similar when using the flotation procedure tailored for tumbling mill-flotation systems

The growth of textile factories in Derbyshire during the eighteenth century

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