Optimization of Line Configuration and Balancing for Flexible Machining Lines

Line configuration and balancing is to select the type of line and allot a given set of operations as well as machines to a sequence of workstations to realize high-efficiency production. Most of the current researches for machining line configuration and balancing problems are related to dedicated transfer lines with dedicated machine workstations. With growing trends towards great product variety and fluctuations in market demand, dedicated transfer lines are being replaced with flexible machining line composed of identical CNC machines. This paper deals with the line configuration and balancing problem for flexible machining lines. The objective is to assign operations to workstations and find the sequence of execution, specify the number of machines in each workstation while minimizing the line cycle time and total number of machines. This problem is subject to precedence, clustering, accessibility and capacity constraints among the features, operations, setups and workstations. The mathematical model and heuristic algorithm based on feature group strategy and polychromatic sets theory are presented to find an optimal solution. The feature group strategy and polychromatic sets theory are used to establish constraint model. A heuristic operations sequencing and assignment algorithm is given. An industrial case study is carried out, and multiple optimal solutions in different line configurations are obtained. The case studying results show that the solutions with shorter cycle time and higher line balancing rate demonstrate the feasibility and effectiveness of the proposed algorithm. This research proposes a heuristic line configuration and balancing algorithm based on feature group strategy and polychromatic sets theory which is able to provide better solutions while achieving an improvement in computing time.

Estimating water deficit and its uncertainties in water-scarce area using integrated modeling approach

Accurate assessment of water deficit and related uncertainties in water-scarce areas is strategically important in various fields of water resources management. This study developed a hybrid approach integrating conceptual water balance model and econometric regression to estimate water shortage and its related uncertainties in water-scarce areas. This hybrid approach was used to assess the agricultural water deficit of Beijing, an extremely water-scarce area in China. A predictive model of agricultural water demand was developed using the stepwise multiple regression method, and was validated by comparing the predicted values with observed data. Scenario analysis was employed to investigate the uncertainties of agricultural water shortage and agricultural water demand. This modeling approach can assist water administration in creating sustainable water allocation strategies in water-scarce areas.

A Distributed Monthly Water Balance Model for Analyzing Impacts of Land Cover Change on Flow Regimes

The Miyun Reservoir is the most important water source for Beijing Municipality, the capital of China with a population of more than 12 million. In recent decades, the inflow to the reservoir has shown a decreasing trend, which has seriously threatened water use in Beijing. In order to analyze the influents of land use and cover change (LUCC) upon inflow to Miyun Reservoir, terrain and land use information from remote sensing were utilized with a revised evapotranspiration estimation formula; a water loss model under conditions of human impacts was introduced; and a distributed monthly water balance model was established and applied to the Chaobai River Basin controlled by the Miyun Reservoir. The model simulation suggested that not only the impact of land cover change on evapotranspiration, but also the extra water loss caused by human activities, such as the water and soil conservation development projects should be considered. Although these development projects were of great benefit to human and ecological protection, they could reallocate water resources in time and space, and in a sense thereby influence the stream flow.

Component content distribution profile control in rare earth countercurrent extraction process

Considering that the on-line measurement and automatic control of element component content(ECC) are difficult to perform in rare earth cascade extraction process, the ECC distribution profile is dynamically regulated at all stages to assess the effect of product purity control. Focusing on the theory of countercurrent extraction, the technology parameters and pre-setting flow-rates during the extract process are designed. Under varying process parameters, a novel step by step model is also proposed for each stage to analyze the impact on the distribution profile change. Combining the mass balance model and ECC changing trend at the monitoring stage, the ECC distribution profile can be automatically regulated by dynamically compensating the related extract or scrubbing liquid flow-rate. To this end, the required product purity at the two outlets is achieved. Based on Wincc and Matlab dynamic simulators, a specific Pr/Nd cascade extraction process is used to illustrate and demonstrate the application of the present approach.

Batch-to-batch Optimization of Batch Crystallization Processes

It is the fact that several process parameters are either unknown or uncertain. Therefore, an optimal control, profile calculated with developed process models with respect to such process parameters may not give an optimal performance when implemented to real processes. This study proposes a batch-to-batch optimization strategy for the estimation of uncertain kinetic.par.ameters in a batch crystallization process of potassium sulfate production. The knowledge of a crystal size distribution of the product at the end of batch operation is used in the proposed methodology. The updated kinetic parameters are applied for determining an optimal operating temperature policy for the next batch run.

CFD simulation of gas–liquid flow in a high-pressure bubble column with a modified population balance model

In this study,based on the Luo bubble coalescence model,a model correction factor C_e for pressures according to the literature experimental results was introduced in the bubble coalescence efficiency term.Then,a coupled modified population balance model(PBM) with computational fluid dynamics(CFD) was used to simulate a high-pressure bubble column.The simulation results with and without C_e were compared with the experimental data.The modified CFD-PBM coupled model was used to investigate its applicability to broader experimental conditions.These results showed that the modified CFD-PBM coupled model can predict the hydrodynamic behaviors under various operating conditions.

Investigation of flue gas water-alternating gas (flue gas–WAG) injection for enhanced oil recovery and multicomponent flue gas storage in the post-waterflooding reservoir

Flue gas fooding is one of the important technologies to improve oil recovery and achieve greenhouse gas storage.In order to study multicomponent fue gas storage capacity and enhanced oil recovery(EOR)performance of fue gas water-alternating gas(fue gas-WAG)injection after continuous waterfooding in an oil reservoir,a long core fooding system was built.The experimental results showed that the oil recovery factor of fue gas-WAG fooding was increased by 21.25%after continuous waterfooding and fue gas-WAG fooding could further enhance oil recovery and reduce water cut signifcantly.A novel material balance model based on storage mechanism was developed to estimate the multicomponent fue gas storage capacity and storage capacity of each component of fue gas in reservoir oil,water and as free gas in the post-waterfooding reservoir.The ultimate storage ratio of fue gas is 16%in the fue gas-WAG fooding process.The calculation results of fue gas storage capacity showed that the injection gas storage capacity mainly consists of N_(2) and CO_(2),only N_(2) exists as free gas phase in cores,and other components of injection gas are dissolved in oil and water.Finally,injection strategies from three perspectives for fue gas storage,EOR,and combination of fue gas storage and EOR were proposed,respectively.

Characteristics of land-atmosphere energy and turbulentfluxes over the plateau steppe in central Tibetan Plateau

The land-atmosphere energy and turbulence exchange is key to understanding land surface processes on the Tibetan Plateau(TP). Using observed data for Aug. 4 to Dec. 3, 2012 from the Bujiao observation point(BJ) of the Nagqu Plateau Climate and Environment Station(NPCE-BJ), different characteristics of the energy flux during the Asian summer monsoon(ASM) season and post-monsoon period were analyzed. This study outlines the impact of the ASM on energy fluxes in the central TP. It also demonstrates that the surface energy closure rate during the ASM season is higher than that of the post-monsoon period. Footprint modeling shows the distribution of data quality assessments(QA) and quality controls(QC) surrounding the observation point. The measured turbulent flux data at the NPCE-BJ site were highly representative of the target land-use type. The target surface contributed more to the fluxes under unstable conditions than under stable conditions. The main wind directions(180° and 210°) with the highest data density showed flux contributions reaching 100%, even under stable conditions. The lowest flux contributions were found in sectors with low data density, e.g., 90.4% in the 360° sector under stable conditions during the ASM season. Lastly, a surface energy water balance(SEWAB) model was used to gap-fill any absent or corrected turbulence data. The potential simulation error was also explored in this study. The Nash-Sutcliffe model efficiency coefficients(NSEs) of the observed fluxes with the SEWAB model runs were 0.78 for sensible heat flux and 0.63 for latent heat flux during the ASM season, but unrealistic values of-0.9 for latent heat flux during the post-monsoon period.

Effect of reforestation on annual water yield in a large watershed in northeast China

A simplified water balance model in conjunc- tion with an evapotranspiration （ET） model and cumulative forest cover data were used to quantify the changes in annual water yield in response to reforestation in a large watershed, northeast China. Cumulative forest cover increased by 22 %, leading to a significant decrease in estimated annual water yield. Reforestation increased ET （P = 0.0144）, resulting in a remarkable decrease （P = 0.0001） in estimated annual water yield according to the water balance model. Reforestation increased ET by 33 mm and decreased annual water yield by 38 mm per decade. The effect of reforestation on annual water yield can be quantified using a simplified water balance model in a large watershed, although our reforestation area was small （about 20 %） in relation to the total watershed area.

Numerical simulation of flocculation and settling behavior of whole-tailings particles in deep-cone thickener

Rapid dewatering and thickening of whole-tailings with ultrafine particles is one of the most important processes for the whole-tailings paste preparation. Deep-cone thickener, a kind of such process for the flocculation and settling of whole-tailings, is particularly necessary to study. However, there exist many problems in observing the flocculation and settling process of whole-tailings, as well as the particle size distribution(PSD) of whole-tailings floccules in deep-cone thickener. Population balance model(PBM) is applied to predict the PSD in deep-cone thickener, and LUO model and GHADIRI model are employed to study the aggregation and fragmentation mechanism of the whole-tailings particles, respectively. Through three-dimensional numerical simulation on the whole-tailings flocculation and settling in deep-cone thickener using computational fluid dynamics(CFD)-PBM, the distribution of density and turbulent kinetic energy in deep-cone thickener were obtained, at the same time the spatio-temporal changes of whole-tailings floccules particle size distribution are analyzed. Finally, the major flocculation position in deep-cone thickener is found and the flocculation settling rules of whole-tailings are achieved.

CFD-PBE simulation of gas-phase hydrodynamics in a gas-liquid-solid combined loop reactor

The computational fluid dynamics （CFD）-population balance equations （PBE） coupled model is employed to investigate the hydrodynamics in a gas-slurry internal loop reactor with external slurry circulation. The predicted radial profiles of local gas holdup and bubble diameter are in good agreement with the corresponding experimental data. The spatio-temporal velocity profile of the gas phase reveals that the upward movement of gas is slowed down and the residence time of gas is prolonged by the downward momentum of the slurry, introduction of the external slurry can greatly improve the uniformity of gas holdup distribution in the reactor, especially in the downcomer-tube action region. Moreover, the interaction between the downward slurry and upward gas can lead to small bubble size and high interfacial area as well as good mass and heat transfer. The above results suggest the function of external slurry circulation for the internal loop reactor and would be helpful for optimizing the design and scale up of reactors.

Analysis of hohlraum energetics of the SG series and the NIF experiments with energy balance model

The basic energy balance model is applied to analyze the hohlraum energetics data from the Shenguang(SG)series laser facilities and the National Ignition Facility(NIF)experiments published in the past few years.The analysis shows that the overall hohlraum energetics data are in agreement with the energy balance model within 20%deviation.The 20%deviation might be caused by the diversity in hohlraum parameters,such as material,laser pulse,gas filling density,etc.In addition,the NIF's ignition target designs and our ignition target designs given by simulations are also in accordance with the energy balance model.This work confirms the value of the energy balance model for ignition target design and experimental data assessment,and demonstrates that the NIF energy is enough to achieve ignition if a 1D spherical radiation drive could be created,meanwhile both the laser plasma instabilities and hydrodynamic instabilities could be suppressed.

Simulation of a semi-industrial pilot plant thickener using CFD approach

Thickeners are important units for water recovery in various industries. In this study, a semi-industrial pilot plant thickener similar to the tailing thickener of the Sarcheshmeh Copper Mine was simulated by CFD modeling. The population balance was used to describe the particle aggregation and breakup. In this population balance, 15 particle sizes categories were considered. The Eulerian-Eulerian approach with standard k-e turbulence model was applied to describe two phases of slurry flow in the thickener under steady-state condition. The simulation results have been compared with the experimental measurements to validate the accuracy of the CFD modeling. After checking the numerical results, the effect of important parameters such as, feed flow rate, solid percentage in the feed, and solid particle size on the thickener performance was studied. The thickener residence time distribution were obtained by the modeling and also compared with the experimental data. Finally, the effects of feedwell feeding on the average diameter of aggregate and turbulent intensity were evaluated.

Estimating submarine groundwater discharge at a subtropical river estuary along the Beibu Gulf,China

In certain regions,submarine groundwater discharge(SGD)into the ocean plays a significant role in coastal material fluxes and their biogeochemical cycle;therefore,the impact of SGD on the ecosystem cannot be ignored.In this study,SGD was estimated using naturally occurring radium isotopes(^(223)Ra and ^(224)Ra)in a subtropical estuary along the Beibu Gulf,China.The results showed that the Ra activities of submarine groundwater were approximately 10 times higher than those of surface water.By assuming a steady state and using an Ra mass balance model,the SGD flux in May 2018 was estimated to be 5.98×10^(6) m^(3)/d and 3.60×10^(6) m^(3)/d based on 224Ra and 223Ra,respectively.At the same time,the activities of Ra isotopes fluctuated within a tidal cycle;that is,a lower activity was observed at high tide and a higher activity was seen at low tide.Based on these variations,the average tidal pumping fluxes of SGD were 1.15×10^(6) m^(3)/d and 2.44×10^(6) m^(3)/d with 224Ra and 223Ra,respectively.Tidaldriven SGD accounts for 24%-51%of the total SGD.Therefore,tidal pumping is an important driving force of the SGD in the Dafengjiang River(DFJR)Estuary.Furthermore,the SGD of the DFJR Estuary in the coastal zone contributes significantly to the seawater composition of the Beibu Gulf and the material exchange between land and sea.

Kinetic parameter estimation for cooling crystallization process based on cell average technique and automatic differentiation

In this paper,a cell average technique(CAT)based parameter estimation method is proposed for cooling crystallization involved with particle growth,aggregation and breakage,by establishing a more efficient and accurate solution in terms of the automatic differentiation(AD)algorithm.To overcome the deficiency of CAT that demands high computation cost for implementation,a set of ordinary differential equations(ODEs)entailed from CAT based discretized population balance equation(PBE)are solved by using the AD based high-order Taylor expansion.Moreover,an AD based trust-region reflective(TRR)algorithm and another interior-point(IP)algorithm are established for estimating the kinetic parameters associated with particle growth,aggregation and breakage.As a result,the estimation accuracy can be further improved while the computation cost can be significantly reduced,compared to the existing algorithms.Benchmark examples from the literature are used to illustrate the accuracy and efficiency of the AD-based CAT,TRR and IP algorithms in comparison with the existing algorithms.Moreover,seeded batch cooling crystallization experiments ofβform L-glutamic acid are performed to validate the proposed method.

A Population Balance Model for Disperse Systems:Particle Size Distribution in Suspension Polymerization

On the basis of population balance a mathematical model is developed to describe the formation of polymer particle in styrene suspension polymerization. The characteristics of coalescence and breakage of droplets and the gel effect are analyzed in particular. Parameters of the models are estimated by experimental data on reaction conversion and particle size distribution. The results show that the model is suitable for predicting polymerization processes.

Test of newly developed conceptual hydrological model for simulation of rain-on-snow events in forested watershed

A conceptual hydrological model that links the Xin＇anjiang hydrological model and a physically based snow energy and mass balance model, described as the XINSNOBAL model, was developed in this study for simulating rain-on-snow events that commonly occur in the Pacific Northwest of the United States. The resultant model was applied to the Lookout Creek Watershed in the H. J. Andrews Experimental Forest in the western Cascade Mountains of Oregon, and its ability to simulate streamflow was evaluated. The simulation was conducted at 24-hour and one-hour time scales for the period of 1996 to 2005. The results indicated that runoffand peak discharge could be underestimated if snowpack accumulation and snowmelt under rain-on-snow conditions were not taken into account. The average deterministic coefficient of the hourly model in streamflow simulation in the calibration stage was 0.837, which was significantly improved over the value of 0.762 when the Xin＇anjiang model was used alone. Good simulation performance of the XINSNOBAL model in the WS 10 catchment, using the calibrated parameter of the Lookout Creek Watershed for proxy-basin testing, demonstrates that transplanting model parameters between similar watersheds can orovide a useful tool for discharge forecastin~, in un^au^ed basins.

Numerical simulation of land subsidence and verification of its character for an iron mine using sublevel caving

Combined with a digital bored photography system and in-situ statistics concerning the joints and fissures of both ore-body and surrounding rock,a 2D discrete model was constructed using UDEC.The stress field and displacement field changes of different sublevel stoping systems were also studied.Changes in the overlying rock strata settlement pattern has been analyzed and validated by in-situ monitoring data.The results show that:in the caving process,there exists an obvious delay and jump for the overlying rock strata displacement over time,and a stable arch can be formed in the process of caving,which leads to hidden goafs.Disturbed by the mining activity,a stress increase occurred in both the hanging wall and the foot wall,demonstrating a hump-shaped distribution pattern.From the comparison between simulation results and in-situ monitoring results,land subsidence shows a slow-development,suddenfailure,slow-development cycle pattern,which leads eventually to a stable state.This pattern validates the existence of balanced arch and hidden goafs.

BALANCED TRUNCATED MODELS OF C INTERCONNECT CIRCUITS AND THEIR SIMULATION

The Balanced Truncation Method (BTM) is applied to an even distributed RC interconnect case by using Wang's closed-forms of even distributed RC interconnect models. The results show that extremely high order RC interconnect can be high-accurately approximated by only third order balanced model. Related simulations are executed in both time domain and frequency domain. The results may be applied to VLSI interconnect model reduction and design.

Source Apportionment of Ambient PM_(10) in the Urban Area of Longyan City,China:a Comparative Study Based on Chemical Mass Balance Model and Factor Analysis Method

In order to identify the day and night pollution sources of PM10 in ambient air in Longyan City,the authors analyzed the elemental composition of respirable particulate matters in the day and night ambient air samples and various pollution sources which were collected in January 2010 in Longyan with inductivity coupled plasma-mass spectrometry（ICP-MS）.Then chemical mass balance（CMB） model and factor analysis（FA） method were applied to comparatively study the inorganic components in the sources and receptor samples.The results of factor analysis show that the major sources were road dust,waste incineration and mixed sources which contained automobile exhaust,soil dust/secondary dust and coal dust during the daytime in Longyan City,China.There are two major sources of pollution which are soil dust and mixture sources of automobile exhaust and secondary dust during the night in Longyan.The results of CMB show that the major sources are secondary dust,automobile exhaust and road dust during the daytime in Longyan.The major sources are secondary dust,soil dust and automobile exhaust during the night in Longyan.The results of the two methods are similar to each other and the results will guide us to plan to control the PM10 pollution sources in Longyan.