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The Effect of Excess Heat Utilization on the Production Cost of Cement 余热利用对水泥生产成本的影响
Pub Date : 2021-12-04 DOI: 10.31603/mesi.5987
O. Adetunji, Montfort C. Ogbuokiri, O. Dairo, O. Olatunde, I. Okediran
Industrial excess heat is a largely untapped resource that has the potential for external use that would be beneficial to the cement industry. Therefore, this work studied the excess heat utilization for the optimization of production cost in a cement plant within a period of three years. The study of plant layout in the selected plant in Nigeria (Ewekoro II Cement Plant of 200 tonnes/hour) was carried out to identify areas where excess heat is generated. The temperature and static pressure of precalciner, kiln, and cyclone were taken using a temperature probe, pitot tube, digital manometer, and light-emitting diode temperature reader. These parameters were used to obtain the mass flow rate and heat transfer needed for the heat energy analysis of the system. The kiln was maintained at constant tonnage per hour through a clinker truck weighed using the weighbridge. The result showed that the heat generated from the kiln was 577,640,260 MJ/hr. through excess air draft of 780,000 m3/hr (89.4%) at 250 °C and induced draft fan of 900,000 m3/hr at 350 °C. The result showed that excess heat can be utilized in pre-heater and air quenched cooler boilers, steam turbines and auxiliaries, and generators. The total estimated heat that could be saved amounted to 344,648,250 MJ with a total annual capacity of 2.25 million tonnes of cement. A saving of over two billion dollars could be achieved in production cost per year.
工业余热是一种很大程度上尚未开发的资源,具有对外利用的潜力,这将有利于水泥工业。因此,本文对某水泥厂三年的余热利用进行了研究,以达到生产成本的优化。对尼日利亚选定的工厂(200吨/小时的Ewekoro II水泥厂)的工厂布局进行了研究,以确定产生多余热量的区域。采用温度探头、皮托管、数字压力计和发光二极管温度读取器测量预分解炉、窑炉和旋流器的温度和静压。利用这些参数得到了系统热能分析所需的质量流率和换热量。通过一辆熟料车用地磅秤称重,使窑保持在每小时恒定的吨位。结果表明:窑内发热量为577,640,260 MJ/hr。250°C时的多余风量为780,000 m3/hr(89.4%), 350°C时的引风机为900,000 m3/hr。结果表明,余热可用于预热器和空气淬火冷却器锅炉、汽轮机和辅机以及发电机。估计可节省的总热量为344,648,250兆焦耳,总年产能为225万吨水泥。每年可节省20多亿美元的生产成本。
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引用次数: 2
A Report on Metal Forming Technology Transfer from Expert to Industry for Improving Production Efficiency 金属成形技术从专家向企业转移提高生产效率的报告
Pub Date : 2021-11-23 DOI: 10.31603/mesi.5613
Khoirudin Khoirudin, S. Sukarman, Murtalim Murtalim, Fathan Mubina Dewadi, Nana Rahdiana, A. Rais, Amri Abdulah, C. Anwar, Aries Abbas
This article reports on technological mastery assistance in three small metal forming industries in Indonesia. Problems in the blangking and piercing separately process caused increased production time which resulted in inefficiency cost. Therefore, the expert team aided in metal forming technology through participatory action research (PAR) methods and experimental methods through reverse engineering for several products. The PAR method involves optimal contribution and participation from the industry. Assistance in mastering technology in small metal-forming industries reduces the manufacturing process from seven to three stages, increasing efficiency. The press machine's tonnage capacity must balance with the force blanking/piercing requirement. The minimum press machine requirement is 6.7 tons, and based on the availability of existing press machines, the expert team recommends a 20-ton capacity press machine. Total efficiency can be further increased by implementing full progressive die technology by combining piercing, blanking, and bending processes.
本文报道了印尼三个小型金属成形行业的技术掌握援助情况。落料和冲孔分开加工的问题导致生产时间增加,成本低。因此,专家团队通过参与式行动研究(PAR)方法和实验方法,对多个产品进行逆向工程,辅助金属成形技术。PAR方法涉及行业的最优贡献和参与。协助掌握小型金属成形工业的技术,将制造过程从七个阶段减少到三个阶段,提高了效率。压力机的吨位容量必须与冲裁/冲孔力的要求相平衡。压力机的最低要求是6.7吨,根据现有压力机的可用性,专家团队推荐一台20吨容量的压力机。通过将冲孔、落料和弯曲工序结合起来,实施全级进模技术,可以进一步提高总效率。
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引用次数: 5
The Role of Composites for Sustainable Society and Industry 复合材料在可持续社会和工业中的作用
Pub Date : 2021-11-06 DOI: 10.31603/mesi.6188
R. Widyorini, N. H. Sari, M. Setiyo, Gunawan Refiadi
In the last few decades, the global community's demands are getting stronger for more environmentally friendly materials. Natural fiber reinforced composites have been applied as reinforcement in concrete, sound absorbers, buildings, aeronautical, aerospace, sanitation, electronics, bridge decks, interior, automotive, sports equipment and furniture industries, modular structures, and others. Natural fibers are receiving high attention due to their sustainability, environmental friendliness, low density, low cost, low abrasiveness, renewability, and biodegradability, as well as contributing to the consumption of CO2 gas. As reported by many researchers, Indonesia has several natural resources for natural fibers such as bark fiber, leaf fiber, seed/fruit fiber, grass fiber, stalk fiber, and wood fiber.
在过去的几十年里,全球社会对更环保的材料的需求越来越强。天然纤维增强复合材料已被应用于混凝土、吸声器、建筑、航空、航天、卫生、电子、桥面、室内、汽车、运动器材和家具行业、模块化结构等领域。天然纤维因其可持续性、环境友好性、低密度、低成本、低磨耗性、可再生性和可生物降解性以及有助于消耗二氧化碳气体而受到高度关注。据许多研究人员报道,印度尼西亚有几种天然纤维资源,如树皮纤维、叶子纤维、种子/水果纤维、草纤维、茎纤维和木材纤维。
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引用次数: 7
Emphasis of Weld Time, Shielding Gas and Oxygen Content in Activated Fluxes on the Weldment Microstructure 焊接时间、保护气体和活性助焊剂中氧含量对焊件组织的影响
Pub Date : 2021-10-29 DOI: 10.31603/mesi.5903
Surinder Tathgir, Dinesh W. Rathod, A. Batish
The activated-TIG (A-TIG) process is a recognised process for achieving higher depth-of- penetration (DoP) and it could be used for various stainless-steel grades welding. The oxygen content of oxide based activated fluxes provide the extra heat during decomposition of flux and result into deep penetration. This study reveals the effect of short weld time of 2 sec in stationary arc, shielding environment (Ar and Ar + 2.5 % H2) and an effect of oxygen element in activated flux (CrO3 and SiO2) on the microstructure and weld metal micro-hardness. Use of hydrogen mix shielding gas during A-TIG process has significant impact on the dilution rate, grain size and dendrite arm spacing. The fraction of oxygen in the flux and the presence of silicon in SiO2 flux play a significant role in achieving higher DoP. To evaluate the impact of different shielding environment on grain growth, the samples were investigated with weld pool morphology, depth of penetration, weld chemistry, optical microscopy and SEM analysis. The extra heat produced due to oxygen fraction in activated flux and H2 induced shielding have been quantified in the study. The ferrite and austenite grain growth as well as the dendrite arm spacing found to be increased due to presence of H2 in shielding gas.
活化tig (a - tig)工艺是一种公认的获得更高熔透深度(DoP)的工艺,可用于各种不锈钢等级的焊接。氧化基活性助焊剂的氧含量在助焊剂分解过程中提供了额外的热量,导致深度渗透。本研究揭示了固定电弧短焊时间(2秒)、保护环境(Ar和Ar + 2.5% H2)以及活性助焊剂中氧元素(CrO3和SiO2)对焊缝显微组织和焊缝金属显微硬度的影响。在A-TIG过程中,混合氢保护气的使用对稀释率、晶粒尺寸和枝晶臂间距有显著影响。助熔剂中氧的含量和SiO2助熔剂中硅的存在对获得较高的DoP起着重要的作用。为了评估不同保护环境对晶粒生长的影响,对试样进行了焊池形貌、熔深、焊缝化学、光学显微镜和扫描电镜分析。对活化通量中氧组分和H2诱导屏蔽所产生的额外热量进行了量化研究。保护气体中H2的存在使铁素体和奥氏体晶粒长大,枝晶臂间距增大。
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引用次数: 4
Data on Emission Factors of Gaseous Emissions from Combustion of Woody Biomasses as Potential Fuels for Firing Thermal Power Plants in Nigeria 尼日利亚木质生物质作为火力发电厂潜在燃料燃烧产生的气体排放因子数据
Pub Date : 2021-09-08 DOI: 10.31603/mesi.5548
F. Elehinafe, O. Okedere, Queen Edidiong Ebong-Bassey, J. Sonibare
This work generated data on the emission factors of air emissions from combustion of woody biomasses collected from southwest, Nigeria. This was with a view to finding their potentials as sustainable and environmentally friendly fuels for firing thermal power plants compared to coals. The data on heating values and elemental contents (carbon, sulphur and nitrogen) responsible for gaseous emissions in the 100 woody biomasses were collected from the previous results of this work to determine the gaseous emission factors on the expected condition of complete combustion. The current results showed that the CO2 emission factors ranged from 0.0147 kg/(MJ/kg) for Ficus mucuso to 0.1499 kg/(MJ/kg) for Spondias mombin, SO2 emission factors ranged from 0.0000000 kg/(MJ/kg) for Pterygota macrocarpa, Irvingia grandifolia, and fifteen others, to 0.0011341kg/(MJ/kg) for Khaya ivorensis, while NO2 emission factors ranged from 0.0000000 kg/(MJ/kg) for Citrus medica to 0.0035824 kg/(MJ/kg) for Ficus carica. Considering the minimal emissions from biomasses compared to coal species, serious political will is needed on the part of the Nigerian government to propagate these biomasses for fuels in firing the thermal plants in the country.
这项工作产生了从尼日利亚西南部收集的木质生物质燃烧产生的空气排放因子的数据。这样做的目的是与煤相比,发现它们作为火力发电厂的可持续和环境友好型燃料的潜力。收集了100个木质生物质中产生气体排放的热值和元素含量(碳、硫和氮)的数据,以确定完全燃烧预期条件下的气体排放因子。结果表明:黏液榕的CO2排放因子范围为0.0147 ~ 0.1499 kg/(MJ/kg),大角翼鱼、大叶子叶等15种植物的SO2排放因子范围为0.0000000 ~ 0.0011341kg/(MJ/kg),黄花柑的NO2排放因子范围为0.0000000 ~ 0.0035824 kg/(MJ/kg)。考虑到与煤炭相比,生物质的排放量最小,尼日利亚政府需要严肃的政治意愿来推广这些生物质作为该国火力发电厂的燃料。
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引用次数: 5
Recent Progress on the Production of Aluminum Oxide (Al2O3) Nanoparticles: A Review 纳米氧化铝(Al2O3)制备研究进展
Pub Date : 2021-09-08 DOI: 10.31603/mesi.5493
Adzra Zahra Ziva, Yuni Kartika Suryana, Yusrianti Sabrina Kurniadianti, A. Nandiyanto, T. Kurniawan
This study aims at discussing several methods to produce aluminum oxide (Al2O3) synthesis methods along with the advantages and disadvantages of each method used. In general, several methods are available: (1) precipitation, (2) combustion, (3) sol-gel, (4) wet chemical, (5) synthesis in supercritical water conditions, (6) microwave, (7) mechanochemical, and (8) hydrolysis, and the most efficient method for synthesizing Al2O3 is precipitation because it is facile and the simplest method (compared to other methods), can be proceeded using inexpensive raw materials, produces less pollution, and has several advantages: high purity product, high thermal stability, nearly homogeneous nanoparticle in size, and control desired particle size. The results of the study help to provide comparisons in producing various Al2O3 synthesis methods.
本研究旨在讨论几种生产氧化铝(Al2O3)的合成方法,以及每种方法的优缺点。一般来说,有几种方法可用:(1)沉淀法,(2)燃烧法,(3)溶胶-凝胶法,(4)湿化学法,(5)超临界水条件下合成法,(6)微波法,(7)机械化学法,(8)水解法,而合成Al2O3最有效的方法是沉淀法,因为它是最容易和最简单的方法(与其他方法相比),可以使用廉价的原料进行,产生的污染少,并且有几个优点:产品纯度高,热稳定性好,纳米颗粒大小几乎均匀,可控制所需的颗粒大小。研究结果有助于对生产各种Al2O3合成方法进行比较。
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引用次数: 14
Tensile Strength and Density Evaluation of Composites from Waste Cotton Fabrics and High-Density Polyethylene (HDPE): Contributions to the Composite Industry and a Cleaner Environment 废棉织物和高密度聚乙烯(HDPE)复合材料的拉伸强度和密度评价:对复合材料工业和更清洁的环境的贡献
Pub Date : 2021-07-29 DOI: 10.31603/mesi.5252
S. M. B. Respati, H. Purwanto, Ilham Fakhrudin, P. Prayitno
The growth of the textile industry and the massive use of plastic-based materials create economic growth, but it produces waste from post-use, such as clothing waste from cotton fabrics and HDPE that can be recycled and combined as composite materials. Therefore, an experiment was carried out to investigate and analyze the effect of the fiber volume fraction of waste cotton fabric (1.5%, 3.5%, 4.5%, 6%, and 7.5%) with straight fiber arrangement on the tensile strength and density. From the test results, a tensile strength of 178.4 MPa and 182.6 MPa was obtained for yield and max stress, respectively at a fiber volume fraction of 7.5%. Meanwhile, the highest density of 0.95 g/cm3 was obtained at 1.5% fiber volume fraction. The fracture macroscopic view of the specimen shows a resilience fracture (uneven and appears stringy). Although the strength of this composite cannot yet compete with the new composite material, it has a decent environmental contribution. Considering the availability of waste cotton fabrics and HDPE, it promises to be produced as a low-strength composite for construction, ornamentation, or coatings.
纺织工业的发展和塑料基材料的大量使用创造了经济增长,但它产生了使用后的废物,例如棉织物和HDPE产生的服装废物,这些废物可以回收利用并组合成复合材料。因此,通过实验研究分析了直纤维排列方式下废棉织物的纤维体积分数(1.5%、3.5%、4.5%、6%、7.5%)对织物抗拉强度和密度的影响。试验结果表明,当纤维体积分数为7.5%时,屈服强度为178.4 MPa,最大应力为182.6 MPa。当纤维体积分数为1.5%时,密度最高,为0.95 g/cm3。试件断裂宏观观察显示为弹性断裂(不均匀且呈丝状)。虽然这种复合材料的强度还不能与新的复合材料竞争,但它对环境有不错的贡献。考虑到废棉织物和HDPE的可用性,它有望作为建筑、装饰或涂料的低强度复合材料生产。
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引用次数: 5
Biodiesel Production from Waste Cooking Oil: Characterization, Modeling and Optimization 从废食用油生产生物柴油:表征、建模和优化
Pub Date : 2021-07-25 DOI: 10.31603/mesi.5320
Aditya Kolakoti, M. Setiyo, Budi Waluyo
In this study, waste and discarded cooking oils (WCO) of palm, sunflower, rice bran and groundnut oils are collected from local restaurants. The high viscous WCO was converted into waste cooking oil biodiesel (WCOBD) by a single-stage transesterification process. During the transesterification process, the important parameters which show a significant change in biodiesel yield are studied using the optimization tool of response surface methodology (RSM). Results reported that 91.30% biodiesel yield was achieved within L18 experiments and NaOH catalyst was identified as the most influential parameter on WCOBD yield. Artificial Intelligence (AI) based modeling was also carried out to predict biodiesel yield. From AI modeling, a predicted yield of 92.88% was achieved, which is 1.70% higher than the RSM method. These results reveal the prediction capabilities and accuracy of the chosen modeling and optimization methods. In addition, the significant fuel properties are measured and observed within the scope of ASTM standards (ASTMD6751) and fatty acid profiles from chromatography reveal the presence of high unsaturated fatty acids in WCOBD. Therefore, utilizing the waste cooking oils for biodiesel production can mitigate the global challenges of environmental and energy paucity.
在本研究中,从当地餐馆收集棕榈油、葵花籽油、米糠油和花生油的废弃和废弃食用油。采用单段酯交换法,将高粘性WCO转化为废食用油生物柴油。利用响应面法优化工具,对酯交换过程中影响生物柴油产率的重要参数进行了研究。结果表明,L18实验的生物柴油产率达到91.30%,NaOH催化剂是影响WCOBD产率最大的参数。基于人工智能(AI)的建模也被用于预测生物柴油的产量。人工智能模型的预测收率为92.88%,比RSM方法提高了1.70%。这些结果显示了所选择的建模和优化方法的预测能力和准确性。此外,在ASTM标准(ASTMD6751)范围内测量和观察了重要的燃料特性,色谱法的脂肪酸谱显示WCOBD中存在高不饱和脂肪酸。因此,利用废弃食用油生产生物柴油可以缓解全球环境和能源短缺的挑战。
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引用次数: 19
Mechanical Engineering for Society and Industry: A Preface 社会与工业机械工程:前言
Pub Date : 2021-07-21 DOI: 10.31603/mesi.5313
H. Hermansyah, L. Lukman, H. Prayitno, Lilik Andriyani, Y. A. Fatimah
In a research cycle, researchers need to publish their work and readers expect reliable arguments and information. Seeing society and industry needs relate to mechanical engineering for now and in the future, Mechanical Engineering for Society and Industry (MESI) is an important journal to discuss problems and solutions in mechanical engineering practice. The articles in this journal are a representation of scientific editors and advisory boards' dedication, reviewers' contributions in improving articles quality, and authors contributions in providing standardized articles. Hopefully, this journal can be a source of new insights and inspiration for further research, as well as a new reference for society and industry to solve their problems.
在一个研究周期中,研究人员需要发表他们的工作,而读者期望可靠的论点和信息。《社会与工业机械工程》(MESI)是一本讨论机械工程实践中遇到的问题和解决方案的重要期刊。本刊刊登的文章是科学编辑和顾问委员会的奉献精神、审稿人对提高文章质量的贡献和作者对提供标准化文章的贡献的体现。希望这本杂志能够为进一步的研究提供新的见解和灵感,并为社会和行业解决他们的问题提供新的参考。
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引用次数: 0
Industry 4.0: Challenges of Mechanical Engineering for Society and Industry 工业4.0:机械工程对社会和工业的挑战
Pub Date : 2021-07-21 DOI: 10.31603/mesi.5309
M. Setiyo, T. A. Purnomo, Dori Yuvenda, M. K. Biddinika, N. Sidik, O. Samuel, Aditya Kolakoti, A. Calam
Today, in the industry 4.0 era, the boundaries of scientific disciplines are blurred, everything seems to be interrelated and shows the ability to be combined. Intelligent sensors combined with Artificial Intelligence (AI) have demonstrated their ability to influence processes, design, and maintenance in manufacturing systems. Mechanical engineering tasked with solving complex engineering problems must be able to adapt to this transformation, especially in the use of digital and IT to combine the principles of physics and engineering mathematics with materials science to design, analyze, manufacture, and maintain mechanical systems. On the other hand, mechanical engineering must also contribute to a better future life. Therefore, one of the keys to consistently playing a role is to think about sustainability, in order to provide benefits for society and industry, in any industrial era.
今天,在工业4.0时代,科学学科的界限被模糊,一切似乎都是相互关联的,并显示出结合的能力。与人工智能(AI)相结合的智能传感器已经证明了它们影响制造系统过程、设计和维护的能力。负责解决复杂工程问题的机械工程必须能够适应这种转变,特别是在使用数字和IT将物理和工程数学原理与材料科学相结合来设计,分析,制造和维护机械系统方面。另一方面,机械工程也必须有助于更好的未来生活。因此,持续发挥作用的关键之一是考虑可持续性,以便在任何工业时代为社会和工业提供利益。
{"title":"Industry 4.0: Challenges of Mechanical Engineering for Society and Industry","authors":"M. Setiyo, T. A. Purnomo, Dori Yuvenda, M. K. Biddinika, N. Sidik, O. Samuel, Aditya Kolakoti, A. Calam","doi":"10.31603/mesi.5309","DOIUrl":"https://doi.org/10.31603/mesi.5309","url":null,"abstract":"Today, in the industry 4.0 era, the boundaries of scientific disciplines are blurred, everything seems to be interrelated and shows the ability to be combined. Intelligent sensors combined with Artificial Intelligence (AI) have demonstrated their ability to influence processes, design, and maintenance in manufacturing systems. Mechanical engineering tasked with solving complex engineering problems must be able to adapt to this transformation, especially in the use of digital and IT to combine the principles of physics and engineering mathematics with materials science to design, analyze, manufacture, and maintain mechanical systems. On the other hand, mechanical engineering must also contribute to a better future life. Therefore, one of the keys to consistently playing a role is to think about sustainability, in order to provide benefits for society and industry, in any industrial era.","PeriodicalId":177693,"journal":{"name":"Mechanical Engineering for Society and Industry","volume":"394 1","pages":"0"},"PeriodicalIF":0.0,"publicationDate":"2021-07-21","publicationTypes":"Journal Article","fieldsOfStudy":null,"isOpenAccess":false,"openAccessPdf":"","citationCount":null,"resultStr":null,"platform":"Semanticscholar","paperid":"115984836","PeriodicalName":null,"FirstCategoryId":null,"ListUrlMain":null,"RegionNum":0,"RegionCategory":"","ArticlePicture":[],"TitleCN":null,"AbstractTextCN":null,"PMCID":"","EPubDate":null,"PubModel":null,"JCR":null,"JCRName":null,"Score":null,"Total":0}
引用次数: 11
期刊
Mechanical Engineering for Society and Industry
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