Category Archives: Industry

Sustainable Paper And Pulp Production: A Brief Guide

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Paper has many different uses. Receipts, paper bags, cartons, and books all use paper. That being said, the utility of paper is quite clear especially given the fact that the world is going greener by the day. However, while there has been a lot of progress in attaining a green standard in the paper and pulp industry, there’ve also been quite a few challenges.

Also, as our contemporary society has evolved over the years, the demand for paper has increased exponentially. Probably because we use a lot of it. It comes as no surprise then that the world is creating sustainable processes and innovations to increase yields to sustain the ever-increasing demand for paper globally. You’d be right in saying that the rate of innovation, as far as making paper is concerned, is quite rapid.

Unfortunately, paper and pulp production account for some of the pollutions in our society. Also, plenty of water is wasted during the process. As much as 100 liters of water can go into making a kilogram of paper. Moreover, due to poor industry practices, the polluted water that comes out as a byproduct of this process is dumped in places where it shouldn’t be e.g., the ocean. Also, on that note, a lot of energy is wasted in the process. Almost every stage of the paper-making process uses a lot of energy.

guide on sustainable paper and pulp production

Also, in the world’s bid to make the future renewable, wood will be a very important part of this transition. Therefore, sustainable forestry should be instituted as a matter of urgency otherwise it will be hard to meet our targets. Mind you if resources are used improperly, unwanted consequences may arise.

That being said, the following is a brief guide on sustainable paper and pulp production. It details some of the things you need to know about the industry seeing that it’s an industry that’s seen many advancements over the years. It also gives some vital outlooks as far as sustainable forestry is concerned.

1. Sustainable Manufacturing and Harvesting

Wood is the primary raw material in the paper-making process. Paper is made from pulp and pulp is made from fibers (cellulose) found in wood. As such, plenty of wood is required to produce more and to meet demand. Thus, the necessity of sustainable forestry. More forest is needed to harvest and produce more. The move towards sustainable paper and pulp production has to be facilitated by adopting innovative technology. Here’s why:

Since production starts in the forest, you need the machinery to harvest the wood. Sawing equipment like deck saws and saw chains are used to cut and log trees for further processing. To minimize wastage and save time, you need the help of advanced technologies. Reputable brands like Pacific Trail Manufacturing have a wide array of equipment to choose from. They have the most cutting-edge technologies in terms of sawing trees.

Moreover, if sustainability is to be attained in the paper and pulp production industry, it should start somewhere at the source (forest) e.g., if you salvage time savings, money savings, and reduce waste (water and electricity) by using advanced technology when harvesting wood, these costs, and environmental advantages will trickle down the value chain.

Machine technology is more effective and efficient compared to the human hand. Humans are not as fast as computers, robots, and machines. Since machines are more productive, they make fewer mistakes than humans. Mind you, making mistakes may not be good for a business’s bottom line. That’s why the paper and pulp production process is mostly automated. Human involvement is needed before upkeep and maintenance. From source to processing to the end product, every part of the production has some form of automation in it. A sustainable future cannot be secured apart from innovation, information and technology, and machinery.

2. Forest Biodiversity

This establishment of sustainable forests is good for the industry. It allows for the spread and diversification of plant species. Also, if done right, it contributes towards environmental equilibrium. While it is true that some people still engage in irresponsible logging activities, there’s still a concerted effort toward making the paper-making process environmentally sustainable. You certainly don’t want to produce paper at the expense of natural habitats. Also, you do not want to destroy habitats all for the sake of meeting a demand for paper. It makes a lot of economic sense, but it’s morally skewed.

Moreover, when forests are grown specifically for raising trees that will be used in the paper in paper production, we preserve the integrity of the nature reserves surrounding those areas. That’s why it’s important to have regulations in place that govern how sustainable forestry should be done. You need to work with nature lest it works against you.

Furthermore, the whole point of sustainability is to improve productivity without worsening the condition of nature. Otherwise, we will pay a heavy price for disrupting the equilibrium that’s already there. Thankfully we have experts in the field of biodiversity research. Tons of research help people to understand the dynamics of nature, what to look out for, and how we can improve production without damaging our environment.

3. Certification

The objective of certification procedures in forestry is to legitimize the paper and pulp production process. It’s no secret that healthy forests are essential in building a sustainable production process. The paper production industry accounts for a lot of waste as mentioned before. So, if sustainable production is to be attained, regulation is required.

In North America, there are three notable programs in place to help validate processes of harvest and production namely the American Tree Farming System (ATTS), Forest Stewardship Council (FSC), and the Sustainable Forest Initiative (SFI). They are all different regarding the key focus areas they intend to address. But the end goal is more or less the same, to instill credibility accountability in forestry.

These programs can elaborate on the practices which are supposed to be followed by all landowners as far as growing trees and sustainably harvesting them is concerned. Those landowners who can prove their certification automatically improve their credibility. They will also have greater access to other markets. The more landowners that partner with such endeavors, the more sustainable the value chain will be. Remember, if any sustainable future is to be secured, it has to start from the source.

An additional benefit of managing forests is that the paper and pulp industry accounts for a lot of jobs globally. Establishing regulations that protect forests can contribute to protecting the jobs of the many people who are employed in the industry. Throughout the value chain, you will find that there are a lot of people who are employed from the tree cutting to the final product (paper).

4. Renewable Energy

Paper is perhaps one of the most renewable substances on this planet. Paper recycling is quite popular nowadays and it accounts for much of the paper that we use. The fact that paper is recyclable means that it’s a better substitute for non-renewable substances like plastic. The more that our world gravitates towards a pro-paper society, the more inventive people have to be to extract more volumes of paper from waste and landfills.

paper-recycling

Demand is and will most likely stay high. Recycling is going to be a part of the renewable future that the world is aiming towards. A lot of energy is lost in processing and extracting paper. Therefore, innovation will be a constant feature insofar as attaining sustainable paper and pulp induction is concerned.

Also, relying too much on energy can be deleterious because it means that if a power cut occurs, the whole process will be affected. Using renewable energy sources to facilitate production can help. Renewable sources of energy like biomass and solar energy are alternatives to electrical energy.

Although the energy from renewables is hard to harness, it’s possible to create hybrid systems that utilize both renewable and non-renewable energy. If the production process is transformed into a renewable machine as much as possible, less energy is wasted and fewer emissions are produced. A renewable energy cycle can be created wherein most parts of the system are powered by green energy.

5. The Problem of Deforestation

Deforestation is a big problem. Agriculture, mining, and construction projects are the main causes of deforestation. It’s a practice that marks the epitome of unsustainable forestry. Harvesting trees without replacing them will lead to all kinds of problems in the long run.

sustainable forestry

If people make the habit of cutting forests illegally and not replacing them, it could lead to desertification and habitat loss. This also ties in with biodiversity loss which is devastating to maintaining the equilibrium of the environment. Destruction of food chains can have far-reaching effects on the entire ecosystem. That’s why deforestation must be shunned. Also, that’s why forests are being regulated more diligently.

Moreover, deforestation is a barrier to sustainable paper and pulp production. If deforestation is allowed to continue, the hope for building a sustainable paper and pulp production system is futile. It’s like moving forward-backward. That’s why most authorities around the world put punishments in place for people who cut trees without permits or some form of authorization legitimizing their activity. Trees are an important natural resource and they must be protected. If trees are harvested improperly, the effects will be felt across the whole production chain and in the environment.

Conclusion

Sustainability is much sought after in today’s contemporary society. Thus, the drive for efficiency and innovation in production. The pulp and paper industry is no different. There is no determining what the ceiling is when it comes to technological innovation. All that can be ascertained is that any form of progress is welcome. Because if the future is to be green, every opportunity for growth needs to be utilized. All things considered, sustainability is and will always be a worthwhile goal.

Why Fossil Fuels are Preferred Over Biomass by Industries?

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Biomass can play a key role in economic development and emerge as a significant alternative to fossil fuels. In this article, we will discuss why fossil fuels are preferred over biomass fuel by the industrial sector.

biomass collection

 

Pyrolysis and the Promise of Biochar

The end application of biomass mostly depends on the feedstock type and the char conversion process. When processed under controlled conditions, biomass converts to char (or biochar). With the presence of high carbon content in biochar, they are highly dependent on the processing conditions of biomass (or fuel), e.g. wood char produced from pyrolysis at low or no air flow can expect to have high carbon and hydrogen with minimal minerals/inorganic presence.

Gas produced under same condition will have a high presence of heavy aromatic carbon and nitrogen gas. However, under the same conditions, if physical structure of biomass varies, the output results can fluctuate to a significant level.

The temperature, pressure, elemental composition, particle size, physical structure (e.g. density, moisture presence, molecular structure, pore size), heating rate, the maximum temperature of process, retention time during the conversion process can change the composition of biochar produced.

Biomass when converted to char has multiple applications with minimal effect on the environment. It has applications in toxic metal remediation and can remove harmful contaminants from soil which can damage plant growth and soil nutrients.

uses of char

Char has potential to stabilise cadmium, lead, chromium, zinc, but they are found to be most effective in stabilisation of lead and copper.  Researchers have found the potential application of biochar in a range of applications, viz. carbon sequestration, solid waste management, green electricity production, wastewater treatment, iron making process and building construction.

Why Fossil Fuel is Preferred Over Biomass Fuel?

Despite the significant contrast of applications and proven to have minimal effect on the environment, why is biomass not preferred or unsuccessful to attract the commercial sector? The answer relies on biomass processing technologies that still need to develop economically feasible. Besides fuel cost, the initial setup of biomass-based technologies need high capital cost, operation and maintenance cost, which eventually lead to a significantly higher cost of end application when compared with fossil fuels.

In most FMCG, sugarcane and fruit-based industries, biomass is produced as their waste, and legal compliances expect them to dispose of their waste sustainably. Industries spend substantial money to dispose of their waste in agreement with legal and environmental regulations. Researchers termed it a negative cost, which means that industries intend to pay to take this biomass off from their facility.

bagasse cogeneration

This could bring a possible opportunity to biomass processing plants to get paid or acquire fuel at no or negative cost. But most processing facilities are far from fuel (or biomass waste) sources, and cost of transportation are significant enough to compare the economics of fuel acquirement with fossil fuel costs. Moreover, processing technologies need cleaning and maintenance which further add up to the cost.

The overall economics of biomass-based electricity and any other end-use process cost higher than fossil fuels, making it very difficult to attract industries to invest in biomass over fossil fuels. Research suggests that biomass processing facilities that are available within the periphery of 200km from the fuel source will cost biomass (or fuel) at zero to negative value, improving the overall economics to a significantly comparable level to fossil fuels.

The Way Forward

To address this issue, small-scale plants must be installed in nearby areas and critical focus is vital on economically small scale biomass processing plants. Considerable research work is going on with small scale gasification plants capable of producing electricity at a small scale, but that is still under pilot project and no large-scale implementation has been found so far. Pyrolysis plants are also under the research zone, producing biochar, but this method is still under research development.

To reach targets of global temperature and carbon emissions into the atmosphere set by the UN at Climate Summit 2015, this area of research is a potentially critical area that can play a significant role in overtaking biomass over fossil fuels.

Sand Control Screens: Why Are They Essential In Oil And Gas Sector?

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As the name suggests, sand control is the method for controlling sand production into a wellbore. Around the world, for different gas and oil-producing wells, this is a common requirement.

Sand production can bring several issues, for example, production impairment as a result of the erosion to completion string, sand plugging, and downhole tools. For avoiding sand production, two main methods are used in oil production are as follows.

Types Of Sand Control Screens

Active Sand Control

The active sand control technique is all about utilizing the filters in order to control sand production. It is also known as an intrusive measure. Below are the techniques of active and control methods in the oil and gas industry.

  • Chemical consolidation.
  • Gravel pack and Frack Pack.
  • Expandable sand screen.
  • Stand Alone screen.

Passive Sand Control

Passive sand control always utilizes non-intrusive measures for controlling, reducing, or avoiding sand production from the reservoir. Here are the techniques of following sand control methods.

  • Sand management.
  • Selective perforation.
  • Oriented perforation.

Types Of Sand Control Screens

Now we will talk about different types of sand control screens, along with their mechanisms and usage.

1. Slotted Liner

It is one of the oldest sand control methods. Slotted liner sand control is tubing with a series of slots. All these slots are cut through a wall of tubular, and that too in an axial orientation. The width of slots is designed in such a way that it develops inter-particle bridging across the slots.

Suppose you are looking for the least expensive way to make a standalone screen. The next part of this is very simple. Here the average flow area is around 3%. But it also can go upto 6% of the total pipe area. However, a flow area of more than 6% will be detrimental to the tensile strength of the pipe.

2. Wire-Wrapped Screen

Consider a pipe, which is perforated along with a welded jacket, which is wire-wrapped. The wire, which is wrapped around the vertical ribs, has a space of keystone. It is designed to mitigate the chances of sand plugging on the screen. As there is a self-cleaning action, there is no chance of sand plugging.

In comparison to a slotted linear, a wire-wrapped screen comes with a bigger flow area and thus offers accurate slot opening along with good strength. Here are the different types of wire wrap.

  • Pipe-based slip-on.
  • Rod-based screens.
  • Pipe-based direct build screens.

3. Premium Screens

The premium screen is basically a metal design, which comes with a metal mesh filtration and also a protective metal outer shroud. The ability to flow back the drilling fluid through the particular screen and also the plugging resistance are the main differences between premium screens and other sand screens.

Risks of the Oil and Gas Industry

As per the customer’s demand, the service provider produces different types of premium screens with different metal mesh designs. When it comes to pore throat, it can vary from around 60 microns to 300 microns. Her basic idea here is that the mesh will prevent large particles.

4. Pre-Packed Screen

Pre-packed screens are quite similar to wire-wrapped screens, but pre-packed screens have different filtration media. Here, a media gravel layer that can be with or without the resin coating is situated around the initial screen component. An external screen is also there to support it.

On the basis of the good requirements, the size and thickness of the medium layers vary. The requirements are as follows.

  • Hole size.
  • Flow rate.
  • Formation size etc.

5. Expandable Sand Screen

The latest screen technology is the expandable screen; it comes with a perforated pipe, an outer shroud, and, lastly, a filter medium. This screen is usually runs into a wellbore, and when it comes to the usage of the expansion insert, it is for expanding the screen to the production hole diameter.

Here are some of the advantages of an expandable sand screen.

  • Offers a high inflow area.
  • Provides maximum hole diameter.
  • Offers wellbore support.
  • Effective sand control.

Here are the parts of the expandable screen.

  • Integral expandable connector.
  • Outer protection shroud.
  • Filtration media.
  • Base pipe.

To conclude

We hope you have developed a proper understanding of the sand control screens and their different designs. We also understand how complicated it actually is to get grapes totally. So in case you have any doubts or queries, feel free to contact us.

The Complete Guide to Disposing of Contaminated Soil

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Do you need to remove contaminated soil from your property? If so, this article will explain how to dispose of it safely.

Hire a professional company

Ideally, you’ll want to hire a professional waste treatment company to remove contaminated soil, which will ensure the soil gets properly treated at a facility. If you hire a random company or person, the materials might only be discarded where they will pose a danger to the environment, animals, and people.

disposal of contaminated soil

Proper contaminated soil disposal requires reputable industrial treatment facilities that use EPA-approved treatment processes, including chemical fixation, bioremediation, chemical oxidation, and absorption.

Soil can be treated in four different ways:

  • Excavation. Contaminated soil is removed from the ground. New topsoil is tested and distributed where the old soil has been removed.
  • Treatment. Here, the soil is treated in the ground where it is. There are various methods of extracting contaminants without removing the soil.
  • Containment. When soil can’t be removed or treated in place, it may be contained within some kind of barrier (such as a silt fence) that prevents it from spreading.
  • Blending. Depending on the level of contamination, sometimes good soil is blended with contaminated soil to reduce the concentration of harmful chemicals to a safer degree.

Some treatment plants also focus primarily on sustainability to limit the environmental impact of their services.

What contaminants make soil dangerous?

A variety of contaminants can make soil dangerous. Some of the most common one found in soils all over the world include:

  • Oil and grease
  • Asbestos
  • Adhesives, glues, resins, and latex
  • Laboratory chemicals
  • Filter cake
  • PFAS contaminants
  • Persistent organic pollutants (POPs)
  • Surfactants and detergents
  • Spent catalysts
  • Coolants and cutting fluids
  • Hydrocarbon contamination
  • Paints, inks, and dyes
  • Rags and absorbents
  • Heavy metals
  • Acid sulphate
  • Solvents and flammable waste
  • Contaminated sludge and slurries
  • Acids
  • Industrial wash waters
  • Dredge spoil

All of these contaminants can turn regular soil into hazardous waste.

Treat contaminated soil as hazardous waste

Soil contamination is considered hazardous waste and needs to be professionally removed and treated right away. Contaminated soil can become a major problem if you don’t take care of it quickly.

When left in place, contaminated soil can leach toxic chemicals into the ground and surface waters. The contamination may make its way into nearby rivers, streams, lakes, and drinking water supplies.

According to the EPA, contaminated soil can also affect indoor air quality and may be spread further as dust. In the water, contaminants accumulate in sediments that end up harming local ecosystems, wildlife, and humans.

If you don’t handle the problem, you could face lawsuits later on if future damage and harms can be traced back to the soil when you were responsible for it.

You will likely need a permit to remove contaminated soil

In many regions, you will have to obtain proper permits from your state’s environmental agency to remove hazardous soil.

The United States Environmental Protection Agency (EPA) has set specific guidelines for removal of contaminants from soil at Resource Conservation and Recovery Act (RCRA) and other hazardous waste facilities.

These guidelines can be helpful in understanding why you need a professional to do the job. If you’re facing the onerous task of taking care of contaminated soil, it’s not likely to be a DIY job.

Contaminated soil can come from anywhere

You may not even know you have contaminated soil on your property. You might order tons of good, clean soil for purchase and have hazardous waste delivered instead. That’s what happened to a couple in Kentucky.

David and Cindy Bell ordered thousands of tons of fill dirt and rock to level their property in preparation for building a garden and campground. They found a company willing to deliver the dirt for free.

Unfortunately, the company delivered contaminated black soil and sand removed from an industrial work site. When tests were run, the soil samples contained excessive levels of certain contaminants, including heavy metals and carcinogens.

how to remove remove contaminated soil

Even though it wasn’t their fault, the state issued the Bells a Notice of Violation that required the couple to install a special fence to prevent the contaminated soil from leaching into the Ohio River.

Test your soil regularly, especially if you grow food

You should test your soil regularly to make sure it’s not hazardous to the Earth, humans, or animals. If you discover you have contaminated soil on your property and there are farms nearby, for example, there’s a chance that farmland can become contaminated and you might be held liable for damages.

If you learn you have contaminated soil, don’t wait to get it cleaned up. Act quickly, because the effects can be far-reaching. Regular testing is the only way to know what’s going on with your soil.

How To Tackle Vibrations Using A Coriolis Mass Flow Meter

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Coriolis mass flow meters are acknowledged or well-known as an extremely precise and accurate flow measuring device. Plus, it offers plenty of benefits than other instruments. But take note that every measuring principle has its obstacles, and it is also true for the Coriolis principle.

For the most part, it can be difficult and hard to use Coriolis devices in most low flow applications in industries manufacturing large and heavy products. In these applications, you might have to face all types of vibrations.

Thus, the question is, how can you deal with these vibrations using the coriolis mass flow meter. For a little help, we will walk you through how to deal with all types of vibrations. So, take a read!

Coriolis Principle

This flow measuring device provides multiple benefits and advantages compared to other measuring instruments. First and foremost, coriolis flow meters calculate or gauge direct mass flow.

For many industries, it is a critical feature because it removes or eradicates inaccuracies induced by the fluid’s physical properties or characteristics. Aside from this, coriolis flow meters are extremely precise and accurate, have no mechanical parts in motion, have immense repeatability, a towering dynamic range, and many more.

The coriolis principle is simple yet very effective. Its operating principle is all around us in this world, such as the rotation of the earth and its impact on the weather. Coriolis flow meters have a tube powered by a fixed vibration. So, when a liquid or gas traverses through this tunnel or duct, the mass flow momentum will, more often than not, create a change or alteration in the vibration of the tube.

Then, the duct will contort culminating a phase shift. This shift can be calculated or computed deriving a linear output corresponding to the flow. As the Coriolis principle calculates mass flow regardless of what’s inside the tube, it can be, for the most part, promptly implemented to any fluid traversing through it, gas or liquid.

While the thermal mass flow instruments are reliant on the fluid’s physical properties, thus, similar to the phase shift in frequency between outlet and inlet, it’s possible to calculate the actual natural frequency change.

This frequency change is incongruity to the fluid’s density, and it can derive a further signal output. It’s possible to calculate the volume flow rate having computed both the density and the mass flow rate.

Working of Coriolis Mass Flow Meters

Coriolis mass flow meters calculate or gauges the mass via inertia. A dense gas or liquid moves or traverse through a tunnel or duct which is pulsated by a small actuator. This vibration generates a measurable contorting force on the duct corresponding to the mass. More advanced models of this flow measuring technology apply dual-curved tunnels for lower pressure drop and higher sensitivity.

Although considered or known as the most precise flow meters, coriolis mass flow meters are prone to errors or inaccuracies when bubbles are existing in the liquid. These bubbles can produce or generate splashing inside the tube, make noise, and modify or alter the energy required for tube vibration. Huge spaces boost the energy required for tube vibration in excess and can end up in complete failure.

Impact of Vibrations on Accuracy of Coriolis Flow Meters

In manufacturing, factory, commercial, business, trade applications, all types of vibrations with various sizes are quite common. Mass-flow controllers measure and control the flow of gas or liquid while Coriolis mass flow meters calculate mass flow through a vibrating sensor duct. The variation gets purposely out of phase when the gas or liquid traverses through.

This technique or approach is relatively susceptible to unnecessary vibrations with a recurrence close to the sensor tube’s resonance frequency or a towering concordant of this frequency. However, it depends on the design of the sensor tube.

The odds of the frequency of these unnecessary vibrations is greater than in an industrial environment. Manufacturers of coriolis mass flow meters do their best to minimize the effect of vibrations on the measurement using some technical solutions including pigtails, active and passive vibration compensation, mass inertia, different sensor shapes, dual-sensor tubes, and higher driving frequencies.

In other words, vibrations can affect the accuracy of the measurements of coriolis mass flow meters. However, only if the frequency of the vibrations is close to the concordant frequency.

Types of Vibrations

In industrial applications, vibrations can be produced by usage-based vibration sources, building-based vibration sources, and environmentally related vibration sources. These vibrations move or traverse through a medium such as the fluid itself, through pipes, in the air, or the floor. If any of these vibrations disrupt the frequency of the device, then the output could be incorrect.

Takeaway

It is helpful to determine the sources to lessen or reduce the effects of unwanted vibrations. Oftentimes, it’s possible to move the measuring device or instrument just a little bit, take advantage of huge mass blocks, use suspension alternatives, or use flexible tubes.

How AI Is Supercharging Product Development

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Manufacturers regularly face various obstacles — from unexpected machinery breakdowns to poor product delivery. However, this can be easily fixed with modern technology in place. Companies may increase operational efficiency, launch new products, and customize product designs by leveraging AI solutions. How does that work? Let’s figure that out!

AI Applications in the Manufacturing Sector

AI Applications in the Manufacturing Industry

AI use in industrial facilities is gaining popularity among businesses. According to Capgemini’s research, more than half of European companies (51%) are deploying AI solutions, with Japan (30%) and the United States (28%) coming in second and third.

Hundreds of factors influence the manufacturing process. While these are difficult for humans to detect, machine learning algorithms can accurately forecast the influence of specific factors in such complicated circumstances. Machines still function below human skills in other areas involving language or emotions, limiting their acceptance. But where exactly is AI used?

1. Building Digital Twins

A digital twin is a virtual replica of a real manufacturing system. In the manufacturing industry, there are digital twins of certain equipment assets, full machinery systems, or specific system components. The most popular applications for digital twins include real-time diagnosis, tic and evaluation of manufacturing processes, prediction and visualization of product performance, and so on.

Data science engineers use supervised and unsupervised machine learning methods to educate digital twin models to improve the physical system by analyzing historical and unlabeled data from continuous real-time monitoring. These algorithms aid in the optimization of production scheduling, quality enhancements, and maintenance.

2. Generative Design

Generative design is a method where software generates some outputs to fulfill certain requirements. Designers or engineers use generative design software to investigate AI product design options by entering design goals and factors like materials, production processes, and cost limitations. The approach employs machine learning techniques to understand what works and what doesn’t with each iteration.

The program finds numerous methods to create a simple object, such as a chair. You must enter the specifications such as four legs, elevated seat, weight requirements, minimal materials, etc. Based on the input data, the solution generates a number of design possibilities and features.

Online Manufacturing is the future of manufacturing

3. Predictive Maintenance

Manufacturers use AI technology to analyze sensor data to identify future downtime and accidents. AI systems assist manufacturers in forecasting when or whether functioning equipment will fail, allowing maintenance and repair to be arranged prior to the breakdown. Manufacturers can enhance productivity while lowering the cost of equipment failure thanks to AI applications for predictive maintenance.

4. Assembly Line Optimization

Furthermore, by incorporating Artificial Intelligence into your IoT environment, you may generate many automation opportunities. Supervisors, for example, may be notified when equipment operators exhibit indications of weariness. When a piece of equipment fails, the system might initiate contingency planning or other reorganization actions.

5. Quality Assurance

Traditionally, quality assurance was a manual procedure that required a highly qualified engineer to ensure that electronics and microprocessors were made correctly. All of its circuits were properly set up. Modern processing techniques may now automatically assess whether an object was manufactured appropriately. This sorting may be done automatically and in real-time by putting cameras at important places around the production floor.

Optimize Your Product Development!

AI and machine learning (ML) are making significant contributions to expediting new product development — from startups to companies rushing to introduce new products. Today, Indeed, LinkedIn, and Monster have 15,400 job openings for DevOps and product development engineers using AI and machine intelligence. According to Capgemini, the connected goods industry will be between $519 billion and $685 billion this year as revenue models based on AI and machine learning become more popular. And the above are just some of the AI applications. More to come!

Shedding Light on Non-Destructive Testing with Ultraviolet Lamps

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Non-destructive testing (NDT) can be simplistically described as a method used to conduct an inspection without moving or breaking the item or surrounding area under examination. Although not limited to medicine, aerospace, and industry, these three large sectors are particularly dependent on non-destructive inspection methodologies. One of the most helpful tools for NDT is the Ultraviolet (UV) lamp.

Let’s take a brief look at the presence of UV lamps in NDT settings.

Non-destructive testing is a broad field

The definition of NDT can be quite broad unless one limits its description to a test, evaluation, or inspection, in a particular field of engineering or medicine. As well, the type of inspection that is required also comes from a long list of possibilities.

Non Destructive Testing

Fluorescent Magnetic Particle Inspection (FMPI or MT) and Fluorescent Penetrant Inspection (FPI or PT) are strongly associated with the use of fluorescent lighting and NDT.

Let the light come in

UV light is longer than X-rays, and shorter than visible white light, placing it into the 10 to 400 nm wavelength range. Known as black light, non-visible UV light can be harmful. The shorter UV-C rays, up to 290 nm, however, rarely reach the earth, and this is fortunate. Also be wary of UV-B rays, which are responsible for sunburns. The longer rays of UV-A, between 320 and 400 nm, are the least dangerous to humans.

In the past, magnetic particle penetrants used a mercury base, which became fluorescent with a UV-A light of 365.4 nm. This led to the requirement of today’s UV light sources for NDT. The standard requirement for a peak wavelength is between 360 – 370 mm.

The UV lamp advantage

One aspect of UV lighting that gives it the edge is that it provides visibility into the area under inspection where otherwise, there is none. The magnetic particles or penetrants that are applied to the surfaces of the areas to be inspected become fluorescent, providing visibility into the tiniest of flaws, such as cracks, breaks, and positioning changes.

What to look for in a UV lamp

There are UV lamps and then there are UV lamps. To achieve the most efficient, successful, and safe examinations, it is important to choose the correct UV lamp for the task at hand.

LED illumination

UV LED lamps are highly recommended for non-destructive testing. In fact, for the most part, LED lamps have replaced incandescent and fluorescent lamps, which may not be easily available in the near future.

UV Lamp

However, some legacy UV lamps can be modified to accept LED bulbs. UV LED lamps are lighter, making them very manageable. The bulbs are long-lasting, not prone to fading, and can be housed in cooler casings.

Handheld or stationary

The advantage of handheld UV LED lamps is, of course, their portability and their low energy consumption. However, unlike their predecessors, the mercury vapor bulbs, they do not offer the intensity and the wide beams that are required in some inspections.

Meeting the challenge, some UV lamp producers are using LED lighting to create stationary overhead lamps with intense, wide beam coverage, and adaptable frames, allowing easy vigilance over production in assembly lines. This is a low-cost alternative to frequently-replaced fluorescent bulbs.

The importance of a filter

With a peak wavelength between 360 – 370 nm, violet tail emissions of visible light above 400 nm can mask flaws and cracks with light glare. A filter improves visibility by providing more contrast.

Additional considerations

Science and engineering are always in flux. Similarly, developments in the field of non-destructive testing brings with it much to consider.

  • With the introduction of LED bulbs in UV light sources, dangers resulting from potential accidents in non-invasive fault-seeking, are no longer concerns. Burns resulting from filaments in mercury vapor are becoming a thing of the past. With less electrical demands from LED bulbs, power supplies can be lightweight, making the lamp easier to handle in tough conditions.
  • Just the fact that mercury will no longer be needed is enough of a cause for celebration.
  • Visibility with LED lamps is instantaneous.
  • For some conditions, a narrower beam is required. NDT requirements must lead the way when determining the lamp’s specifications for a particular type of inspection.
  • One challenge that designers are working on is the emission of heat flux at the emitters of UV LED lamps. This is a result of smaller technology with increased energy levels.

Non-destructive testing has broadened its scope over the years, giving rise to compliance standards for specific NDT applications. The most well-known compliance standard to look for in UV-A lamps for NDT with FMPI and FPI, is the ASTM E3022 standard. Whatever the standards of compliance are for a particular industry, non-destructive testing and its reliance on dependable lighting for inspections, is now an important branch of engineering in its own right.

Preparing an Effective Industrial Waste Management Plan

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Did you realize over 7 billion tons of industrial waste is produced in the United States each year? If you are the owner of an industrial business, having an adequate waste management plan is essential. Without a waste management plan, you run the risk of doing a lot of damage to the environment.

If you are new to the world of industrial waste management, you need to take your time when develop a plan of action. Consulting with waste management professionals is a great way to ensure the plan you develop is successful. Below are few crucial tips to  prepare an effective industrial waste management plan.

industrial-waste

Collaborating With the Right Waste Management Company

Unless your company has the ability to transport and dispose of industrial waste, you will need to work with a third-party. Most business owners fail to realize just how many different waste management companies there are on the market. Ideally, you want to find a company that offers services like industrial cleaning, hazardous material transportation and spill response.

If you need services like this for a competitive price, you need to go through PROS Services. By pairing with the right waste management company, you can avoid making mistakes when it comes to disposing of hazardous and non-hazardous materials.

Make Recycling a Focal Point of Your Strategy

Being a business owner in the modern age requires you to be more eco-conscious. One of the best ways for an industrial business to do their part for the environment is by recycling as much as possible. When running an industrial business, you will undoubtedly have a number of recyclable materials. Turning these materials over to companies that can actually do something with them is imperative.

waste-management-plan

Making a new recycling program work will require to get your entire team on board. Informing your team about the importance of recycling is the first step in making your program successful. You also need to implement easy and effective solutions when it comes to how your team will store the recyclable materials. By laying out the details of your plan, you can address any concerns your team may have.

Leave Flexibility in Your Plan

As waste management technology and requirements change, you will have to adapt your strategy. This is why leaving a high-degree of flexibility in your plan is so important. Accomplishing this will be easy if you do things like sign short-term contracts with the companies hired to dispose of your industrial waste. Staying on the cutting edge of industrial waste management technology can help you see when changes are coming and what you can do to embrace these changes.

Don’t Wait to Implement Your Plan

As you can see, having a way to properly dispose of industrial waste is important. This is why you need to avoid procrastinating when developing a plan of action. Allowing professionals to weigh in on the details of your waste management plan can help you avoid making mistakes.

Optimizing Plant Processes: Best Practices for Efficiency and Cost Reduction

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Industrial plants form the backbone of global economic infrastructures, producing essential goods that sustain everyday life while creating vast employment opportunities. In a world characterized by fierce international competition, dynamic consumer demands, unstable costs and unpredictable disruptions, the imperative for cost reduction within these plants has never been more critical.

As we delve deeper into strategic cost-reduction measures, it’s impossible to overlook the revolutionary impact of digitalization. For an extended insight, you’re invited to read more about how embracing digitalization not only makes manufacturing processes safer and more robust but also significantly smarter, fortifying the industry’s future.

cost reduction measures in industrial plants

By implementing these strategic cost-reduction measures, plants refine their operational processes, leading to improved profitability and enhanced overall efficiency.

Adopting Lean Manufacturing: The Gateway to Operational Excellence

Lean manufacturing, a concept born from Toyota’s production system, champions eliminating waste without compromising product quality. It’s a pivotal strategy for plants aiming to curtail manufacturing costs. By identifying and mitigating waste in all forms—be it through overproduction, time delays, unnecessary transportation, over-processing, excess inventory, redundant motions, or defects—plants stand to benefit from enhanced operational efficiency and reduced costs.

Key techniques include:

  1. Value Stream Mapping (VSM): This visual tool is instrumental in tracking the product’s journey from raw material to the final consumer, highlighting areas where waste occurs and providing a roadmap for operational improvement within the plant.
  2. Kanban System: Focusing on just-in-time production, this method ensures that production processes are tightly synchronized with demand, significantly reducing inventory costs and streamlining workflow on the plant floor.

Embracing Technological Integration: The Digital Revolution in Plant Processes

The evolution of plant operations is tightly bound to technological advancements. Digital transformation, facilitated by developments in Artificial Intelligence (AI), the Internet of Things (IoT) and robotics, is critical in enhancing process efficiency, reducing operational downtime and minimizing errors.

Strategies for technological integration include:

  • Predictive Maintenance: This involves using sensors and advanced algorithms to predict equipment failures before they occur, thus preventing costly downtime and extending machinery life.
  • Automation: Implementing robotics and automation tools decreases the need for human intervention—thereby reducing labor costs—and increases accuracy and efficiency in repetitive, mundane tasks.

Optimizing the Supply Chain: Strategic Procurement Management

Procurement expenses, especially concerning raw materials, components and supplies, make up a significant portion of a plant’s operational costs. Therefore, streamlining the supply chain process is an effective avenue for cost reduction.

Best practices in supply chain optimization include:

  1. Supplier Negotiation and Consolidation: By renegotiating terms with existing suppliers or finding more cost-effective alternatives, plants can significantly reduce material costs. Consolidating purchases with a single supplier may also lead to bulk discounts.
  2. Just-in-Time Inventory: This strategy minimizes inventory holding costs by ensuring materials are ordered and received only as needed, reducing storage expenses and the risks associated with dead inventory.

Investing in Workforce Expertise and Robust Quality Control

A competent, skilled workforce is a plant’s greatest asset. Employees who are well-versed in operating advanced machinery contribute to the plant’s efficiency, minimize production bottlenecks and reduce errors, ultimately saving costs.

Online Manufacturing is the future of manufacturing

Furthermore, continuous investment in quality control ensures that product defects are kept to a minimum, thus avoiding the financial drain associated with product recalls or waste.

Enhancing Plant Operations Through Energy Efficiency

Energy efficiency represents a dual opportunity for plants, offering cost savings while bolstering their commitment to sustainability. By integrating energy-efficient technologies and practices, such as high-efficiency motors, advanced HVAC systems and energy management solutions, plants can significantly reduce power consumption, leading to lower utility bills.

Furthermore, transitioning to renewable energy sources, like solar or wind power, positions plants as environmentally responsible community members. These green initiatives resonate positively with eco-conscious consumers and stakeholders, potentially attracting new market segments.

Ultimately, energy efficiency is not merely a cost-cutting measure but a transformative component of a plant’s long-term operational and branding strategy.

solar marketing strategy

The Significance of Holistic Cost Reduction Strategies

A comprehensive cost-reduction plan examines all operational facets, considering both direct and indirect costs. Such an exhaustive approach enables plants to identify potential savings across their operations while maintaining, if not improving, production quality and efficiency. In this vein, cost-saving measures aren’t just about cutting expenses but strategically enhancing the plant’s entire operational ecosystem.

Eco-Efficiency: Reducing Costs While Protecting the Environment

One prime example of a holistic cost-reduction strategy is improving energy efficiency. Plants consume substantial amounts of energy and focusing on eco-efficiency can lead to significant savings. Measures can include:

  • Conducting detailed energy audits.
  • Investing in renewable energy sources.
  • Upgrading to energy-efficient machinery.
  • Retrofitting plants with LED lighting.

Such initiatives not only reduce energy bills but also potentially qualify the plant for tax credits, all while minimizing environmental impact.

Final Note

In an era where efficiency and sustainability are more than buzzwords, plants must adopt a multifaceted approach to cost reduction. Plants can thrive in a competitive market by strategically enhancing various aspects of operations—from lean manufacturing and technological integration to supply chain management and energy efficiency.

Types of Biogas Storage Systems

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Selection of an appropriate biogas storage system makes a significant contribution to the efficiency and safety of a biogas plant. There are two basic reasons for storing biogas: storage for later on-site usage and storage before and/or after transportation to off-site distribution points or systems. A biogas storage system also compensates fluctuations in the production and consumption of biogas as well as temperature-related changes in volume.

There are two broad categories of biogas storage systems: Internal Biogas Storage Tanks are integrated into the anaerobic digester while External Biogas Holders are separated from the digester forming autonomous components of a biogas plant.

The simplest and least expensive storage systems for on-site applications and intermediate storage of biogas are low-pressure systems. The energy, safety, and scrubbing requirements of medium- and high-pressure storage systems make them costly and high-maintenance options for non-commercial use. Such extra costs can be best justified for biomethane or bio-CNG, which has a higher heat content and is therefore a more valuable fuel than biogas.

Low-Pressure Biogas Storage

Floating biogas holders on the digester form a low-pressure storage option for biogas systems. These systems typically operate at pressures below 2 psi. Floating gas holders can be made of steel, fiberglass, or a flexible fabric. A separate tank may be used with a floating gas holder for the storage of the digestate and also storage of the raw biogas. A major advantage of a digester with an integral gas storage component is the reduced capital cost of the system.

The least expensive and most trouble-free gas holder is the flexible inflatable fabric top, as it does not react with the H2S in the biogas and is integral to the digester. These types of covers are often used with plug-flow and complete-mix digesters.

Flexible membrane materials commonly used for these gas holders include high-density polyethylene (HDPE), low-density polyethylene (LDPE), linear low density polyethylene (LLDPE), and chlorosulfonated polyethylene covered polyester. Thicknesses for cover materials typically vary from 0.5 to 2.5 millimeters.

Medium-Pressure Biogas Storage

Biogas can also be stored at medium pressure between 2 and 200 psi. To prevent corrosion of the tank components and to ensure safe operation, the biogas must first be cleaned by removing H2S. Next, the cleaned biogas must be slightly compressed prior to storage in tanks.

High-Pressure Biogas Storage

The typical composition of raw biogas does not meet the minimum CNG fuel specifications. In particular, the CO2 and sulfur content in raw biogas is too high for it to be used as vehicle fuel without additional processing. Biogas that has been upgraded to biomethane by removing the H2S, moisture, and CO2 can be used as a vehicular fuel.

Biomethane is less corrosive than biogas, apart from being more valuable as a fuel. Since production of such fuel typically exceeds immediate on-site demand, the biomethane must be stored for future use, usually either as compressed biomethane (CBM) or liquefied biomethane (LBM).

Two of the main advantages of LBM are that it can be transported relatively easily and it can be dispensed to either LNG vehicles or CNG vehicles. Liquid biomethane is transported in the same manner as LNG, that is, via insulated tanker trucks designed for transportation of cryogenic liquids.

Biomethane can be stored as CBM to save space. The gas is stored in steel cylinders such as those typically used for storage of other commercial gases. Storage facilities must be adequately fitted with safety devices such as rupture disks and pressure relief valves.

The cost of compressing gas to high pressures between 2,000 and 5,000 psi is much greater than the cost of compressing gas for medium-pressure storage. Because of these high costs, the biogas is typically upgraded to biomethane prior to compression.