Technological processes optimisation according to MSTP procedure

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1 o Achievements in Materials and Manuacturing Engineering VOLUME 31 ISSUE 2 December 2008 Technological es optimisation according to MSTP procedure R. Nowosielski, A. Kania, M. Spilka Division o Nanocrystalline and Functional Materials and Sustainable Pro-ecological Technologies, Institute o Engineering Materials and Biomaterials, Silesian University o Technology, ul. Konarskiego 18a, Gliwice, Poland Corresponding author: address: aneta.kania@pols.pl Received ; published in revised orm ABSTRACT Analysis and modelling Purpose: The paper presents optimization o technological es according to MSTP (Modiied Sustainable Technology Procedure) procedure by general analysis and estimation (with regard to BREF-BAT Reerence Documents) o three realistic zinc plating technological es. Design/methodology/approach: In this article one o the polyoptimization methods - genetic algorithms (GA) or technological es optimization has been proposed. As well as the universal sotware Poli-Opt version 1.0 or technological es optimization has been presented. Findings: Polyoptimization using simple genetic algorithms makes possible negative environmental inluences minimization. It also leading to ideal obtaining that in reality does not exist. Research limitations/implications: The solution in polyoptimization is not absolutely. This solution is about the largest probability o obtaining. This results rom the act o dierent criteria and dierent objective unction values using. Practical implications: The simple and universal Poli-Opt version 1.0 sotware using elementary, but quite suicient in practice, genetic algorithm could be in every company applied. Originality/value: The Modiied Sustainable Technology Procedure with computer supported could be or every materials technological es optimization used. Keywords: Artiicial intelligence methods; MSTP procedure; Genetic algorithms; inc plating technological 1. Introduction In the aim o materials technological es selection it is necessary a modern and simple tool creation [1, 2]. The MSTP (Modiied Sustainable Technology Procedure) procedure is one o such tools o the materials technological searching. The MSTP procedure [3, 4] makes possible the eicient and easy analysis and estimation o every technological operations. It is based on two supplementary sustainable development elements: the sustainable technology model and the environmental lie cycle o the product [5]. The modiication o both tools makes possible the designing o the technological regarding to the environmental lie cycle o technological or modernization o existing technological es based on BAT [6, 7]. The detailed technological analysis has a meaning, i identiied technological es about the dierent negative environmental inluences. It requires the database creation which is necessary or optimizing the group o dierent parameters o technological es with artiicial intelligence methods used. The MSTP procedure deines main conditions that must be realized or the technological es optimization eect. The main aim o the universal MSTP procedure is the objective unction deined. It is very important because rom it orm depends the correctness o the carried out optimization. For the materials technological optimization with regard to the accepted environmental criteria (minimum added Copyright by International OCSCO World Press. All rights reserved Research paper 547

2 Journal o Achievements in Materials and Manuacturing Engineering Volume 31 Issue 2 December 2008 materials used, minimum energy consumption, minimum waste, minimum costs) the Poli-Opt version 1.0 sotware can be used. This programme is based on the one o the polyoptimization methods - genetic algorithms (GA) [8-11]. 2. MSTP MSTP testing testing or the or zinc the plating zinc plating technological technological es es optimization optimization According to the elaborated procedure, it is necessary the ull ecological (taking into consideration added materials, energy consumption and waste quantities), technical and costs analysis o the selected technological es perormed The The identiication phase phase For illustration o MSTP procedure [3] using computer programme based on genetic algorithms, three realistic zinc plating technological es were chosen (Fig. 1, Table 1). Fig. 1. Schema o tanks set in the production hall [12]; 1) zinc plating technological 1, 2) zinc plating technological 2, 3) zinc plating technological 3 Stage I - deining o the unctional unit The analysed product o these es is the zinc coated platorm grid. In the elaboration, rom the ormal consideration, the II and III phase o the procedure were used [12, 13]. In the case o the zinc plating technological (and the others es coats too), the suitable unctional unit is the surace subjected to zinc coated. Considering this, that BAT (Best Available Techniques) appointed o limits: raw materials used, energy consumption, waste quantities in the count over again or 1 Mg treatment details, the agreed surace o zinc coated details (the platorm grid) equal 64.5m 2 applying to 1 Mg accepted. For the estimation deined the unctional unit: Raw and added materials used, energy consumption to the technological used and total raw materials costs, energy costs, quantities o waste in the counted over again on the zinc coated surace equal 64.5 m 2. Stage II and III - inventory and database creation; data reerence to BREF limits This stage involves the quantitative and qualitative description o the inputs and outputs needed to determine where the starts and ends and the unction o the unit. For this aim, it is helpul to do: resources and added materials balance, energy balance, waste balance and costs balance. It is necessary that these balances or every analyzed zinc plating technological operation separately perormed. The analysed zinc plating technological es (subjected to estimation and polyoptimization) are characterized with the ollowing production parameters [12]: platorm grid dimension: 1000x500; mesh dimension: 34.3x25.4; lat (h = 20, g = 2); ribbed reinorcing bar (ø 5.8) the average production (the mass o zinc coated details): zinc plating technological Mg/year zinc plating technological Mg/year zinc plating technological Mg/year surace o zinc plating technological es: 64.5 m 2 /Mg the zinc coated details surace: zinc plating technological m 2 /year zinc plating technological m 2 /year zinc plating technological m 2 /year working time - 3 changes 24 h tanks dimension: zinc plating technological x1000x1500 zinc plating technological x1000x2000 zinc plating technological x1600x1200 working days quantity 240 days/year One o the main elements o materials technological es optimization considering environmental criteria is the database creation. This database should be transparent and clear, because rom it depends the inal result o the optimization. It is signiicant, that the database creation stage allows to comparison o all results relating various technological es or every estimation criterion (added materials used, energy consumption, quantity o waste and costs o technological es realization). According to the MSTP procedure, or analysis needs, the inventory table or every criterion separately created (the computer database). In this Table includes data o: raw and added materials used (Table 2), waste quantities (Table 3), energy consumption (Table 4) and costs (Table 5) or every separated operations o analysed zinc plating technological es. The last, ourth line o the database includes average limits o: raw and added materials used, energy consumption, waste quantities or every zinc plating technological es operation which are deined or the zinc plating in BAT Reerence Documents (unity zinc plating) [14, 15]. These data we can ind on the internet page: For Raw and added materials used criterion distinguished ollowing raw and added materials: water consumption (in the operation, rinsing I operation, rinsing II operation, pickling operation and luxing operation), inhibitor used, hydrochloric acid used, lux and zinc and zinc ash used (Table 2). 548 Research paper R. Nowosielski, A. Kania, M. Spilka

3 Analysis and modelling Table 1. Technological data (or every operation) o analysed zinc plating technological es comparison [12] operations inc plating technological inc plating technological inc plating technological alkaline alkaline acid NaOH, Na 2 CO 3 (on the base NaOH) HCl temperature 50 o C temperature 50 o C temperature 50 o C rinsing _ pickling rinsing luxing zinc plating HCl pickling inhibitor dry luxing ncl 2, NH 4 Cl 1 electrolytic zinc A1 (n-al) alloy HCl pickling inhibitor wet luxing ncl 2, NH 4 Cl glycerine 5 zinc A1 (n-al) alloy Table 2. Raw and added materials o analysed zinc plating technological es used (with BREF limits) [g/mg] [3, 8] No o the rinsing I pickling rinsing II luxing medium HCl (2 tanks) pickling inhibitor temperature 30 o C dry luxing ncl 2, NH 4 Cl temperature 60 o C 5 zinc A1 (n-al) alloy HCl acid inhibitor lux zinc zinc ash Table 3. Waste quantity o analysed zinc plating technological es (with BREF limits) [g/mg] [12, 14] No o the sewage and - oiled pickling sewage luxing - sewage washings I washings II sludge sludge Table 4. Energy consumption o analysed zinc plating technological es (with BREF limits) [kwh/mg] [12, 14] No o the pickling luxing zinc plating Table 5. Costs o analysed zinc plating technological es [PLN/Mg] [12, 14] No o the rinsing I pickling rinsing II luxing zinc plating Technological es optimisation according to MSTP procedure 549

4 Journal o Achievements in Materials and Manuacturing Engineering Volume 31 Issue 2 December 2008 For Waste quantity criterion, or pollution areas identiication accepted: sewage quantity and oiling up sludge in operation, washings I (II) quantity, sewage and sludge quantity in operation and also sewage quantity in luxing operation (Table 3). In case o Energy consumption criterion and Costs criterion, total energy consumption and total costs o every zinc plating technological es were appointed (Tables 4 and 5). The tables above (or Poli-Opt version 1.0 sotware needs) in Excel programme known as BazaDanych.xls (every estimation criterion in individual sheet) were created. Ater computer database creation the ile known as BazaDanych.xls to Poli-Opt version 1.0 sotware was transerred. Stage IV and V - materials technological es optimization and veriication o the technological The optimization o analysed technological es is the next stage o MSTP procedure. In this aim weights o individual estimation criteria were deined. Weight values or accepted estimation criteria can suitably be modiied. For zinc plating technological es optimization the same weight values were established. In case o GA [8-11] the ollowing parameters o the genetic operators were deined [12]: mutation probability 0.35, crossing 0.01, generations number 100, person number 100. Poli-Opt sotware counted modiied objective unction () (1-4) [12]. Ater calculations end the programme shows window about avourable or unavourable end o optimization. The solution (zinc plating technological 1) with input data and limits o BREF represented in Table 6. The zinc plating technological 1 does not realize all requirements o BREF or zinc plating (unity zinc plating). Because o that several areas separated (on restrictive conditions basis, which deined as added materials used values, energy consumption values, waste quantities and also costs values o each zinc plating technological operation with reerence to suitable BREF limits; restrictive condition or modernization should be greater than 1) which should be modernization subjected. In case o raw and added materials used should be reduced [12]: water consumption in operation restrictive conditions: /B = 1.83 water consumption in rinsing I operation restrictive conditions: /B = water consumption in rinsing II operation restrictive conditions: /B = lux used restrictive conditions: /B = 9.7 In case o waste should be minimized [12]: sewage quantity in operation restrictive conditions: O/B O = (or sewage ) restrictive conditions: O/B O = 6.25 (or oiling sludge) sewage quantity in luxing operation restrictive conditions: O/B O = Considering costs o each zinc plating technological operation, it is necessary total costs reduction [12]: rinsing I operation restrictive conditions: K/B K = rinsing II operation restrictive conditions: K/B K = luxing operation restrictive conditions: K/B K = Energy consumption in the zinc plating technological suited the limits o BREF (Table 6). Table 6. Comparison o raw and added materials used, energy consumption, waste quantity and costs o technological and BREF limits [12, 14] Raw and added materials used [g/mg] rinsing I pickling rinsing II luxing medium HCl inhibitor lux n BREF Energy consumption [kwh/mg] pickling luxing zinc plating BREF Waste quantity [g/mg] - sewage - oiled sludge washings I pickling - sewage washings II recovery n luxing - sewage BREF Costs [PLN/Mg] rinsing I pickling rinsing II luxing zinc plating BREF Research paper R. Nowosielski, A. Kania, M. Spilka

5 Analysis and modelling 2.2. The The collection o solutions o solutions phase phase Considering that all areas o zinc plating technological 1 do not accomplish limits o BREF several improvements were proposed. ( x) w w [ ( x)] w w [ ( x)] w w [ ( x)] w w [ ( x)] [,, 1 1min 2 2 min, ] 3 3min 4 4 min w1 w2 w In case, when: 1min 3min w w i 0 then i=1,2,3,4 i i min 0 (4) where: (x) - modiied objective unction, x - ollowing technological, 1 (x), 2 (x), 3 (x), 4 (x) - objective unctions concerning o adequate criteria, w 1, w 2, w 3, w 4 - weights value reerence to technological es criteria, w 1, w 2, w 3, w 4 - weights value reerence to scaling objective unction with regard to accepted criteria. From a group o possible solutions chosen these, which a smallest restrictive condition values characterized. The proposed modernizations characterized simplicity and low realization costs. They provide also to total negative environmental inluences improvement and cause increasing o company eiciency. Collecting all inormation about possible modernization variants it is necessary the solution selection (Table 7). 2 min 4 min (1) (2) (3) During solutions analysis airmed that both biological operation and micro and ultrailtration operation realized limits o BREF. For these modernizations, to select the solution, simpliied objective unction value was counted [3,12] (Equation 5). E O K x) w1 ( x) w2 ( x) w3 ( x) w ( x) B B B B ( 4 E O (5) min where: x - decision variables (ollowing environmental data concerning: resources used, energy consumption, waste quantities and costs o each technological subjected to optimization), - total resources and added materials used in technological, E - total energy consumption in technological, O - total waste quantity in technological, K - costs o technological realization, B - resources used in regarding to conventionally accepted values; in paper BREF limits proposed, B E - energy consumption in the technological regarding to conventionally accepted values; BREF limits proposed, B O - waste quantity in technological regarding to conventionally accepted values; BREF limits proposed, B K - conventionally costs o technological, e.g. considering BREF limits, w l - criteria weights. The objective unction () or biological operation: 0.25 ( ) 0.25 ( ) Ater objective unction values checked (or both variants), to real zinc plating technological 1 modernization were selected ollowing solutions [12]: using micro and ultrailtration (objective unction value ) with tank cover using, cascade rinsing (using ionic exchange) or rinsing I and II operation, rinsing optimization and deiron washings cleaning or luxing operation. K Table 7. Comparison o restrictive conditions o proposed zinc plating technological 1 modernizations [12] operation water sewage energy medium oils consumption consumption total costs biological micro and ultrailtration rinsing operation water used rinsing I, II costs cascade rinsing luxing operation water consumption lux used sewage total costs rinsing optimization and recovery Technological es optimisation according to MSTP procedure 551

6 Journal o Achievements in Materials and Manuacturing Engineering Volume 31 Issue 2 December 2008 Added materials [g] rinsing lux technological proposed solution BREF Fig. 2. Comparison o added materials used or proposed solution, technological and BREF [12] The ecological eects concerning added materials used or proposed solution, the technological and BREF presented in Fig Discussion The problem o decision making (management) in the companies usually relates to technological es. The selection o the best technological (taking into consideration chosen criteria) is connected with the optimization. In this article multiobjective optimization methods [16, 17] with genetic algorithms (GA) was proposed. The GA was proposed because o the plurality o the estimation criteria (minimum added materials used, minimum energy consumption, minimum waste, minimum costs). The universal MSTP procedure with Poli-Opt version 1.0 sotware or three realistic zinc plating technological es optimization were presented. The main aim o this procedure is the proper objective unction delimitation, because rom its orm depends correctness o the optimization realization. From this reason the universal Poli-Opt computer programme using elementary, but quite suicient in practice, genetic algorithm elaborated. Reerences [1] R. Nowosielski, R. Babilas, W. Pilarczyk, Sustainable technology as a basis o cleaner production, Journal o Achievements in Materials and Manuacturing Engineering 20 (2007) [2] R. Nowosielski, M. Spilka, A. Kania, Strategies o sustainable development in practice, Journal o Achievements in Materials and Manuacturing Engineering 20 (2007) [3] R. Nowosielski, A. Kania, M. Spilka, Application o the MSTP or the technological es optimization, Proceedings o the 11 th Scientiic Conerence Contemporary Achievements in Mechanics, Manuacturing and Materials Science CAM 3 S'2005, Gliwiceakopane, 2005, (CD-ROM). [4] R. Nowosielski, M. Spilka, A. Kania, The technological es optimization according to the sustainable technology procedure, Journal o Achievements in Materials and Manuacturing Engineering 14 (2006) [5] T. Ekvall, Cleaner Production tools: LCA and beyond, Journal o Cleaner Production 10 (2002) [6] R. Dijkmans, Methodology or selection o best available techniques (BAT) in the sector level, Journal o Cleaner Production 8 (2000) [7] J. Geldermann, O. Rentz, The reerence installation approach or the techno-economic assessment o emission abatement options and the determination o BAT according to the IPPC-directive, Journal o Cleaner Production 12 (2004) [8] R. Knosala, T. Wal, A production scheduling problem using genetic algorithm, Journal o Materials Processing Technology 109 (2001) [9]. Michalewicz, Genetic algorithms + data structures = evolutional programmes, WNT, Warsaw, 1999 (in Polish). [10] L.M. Schmitt, Theory o genetic algorithms, Theoretical Computer Science 259 (2001) [11] S. Tongchim, P. Chongstitvatana, Parallel genetic algorithm with parameter adaptation, Inormation Processing Letters 82 (2002) [12] A. Kania, The materials technological es optimization methodology in relate to environmental criteria, PhD Thesis, Gliwice, 2005 (in Polish). [13] M. Spilka, Application o the sustainable technology model to the analysis and modernization o the materials technology, PhD Thesis, Gliwice, 2004 (in Polish). [14] Website: [15] The Integrated Pollution Prevention and Control (IPPC) Directive 96/61/WE ( ) (in Polish). [16] A. Kania, M. Spilka, Optimization as an alternative in search o sustainable technological es, Journal o Achievements in Materials and Manuacturing Engineering 17 (2006) [17] Q.J. Wang, Using genetic algorithms to optimise model parameters, Environmental Modelling and Sotware 12 (1997) Research paper READING DIRECT: