As part of the Singapore MIT Alliance (SMA) we have established the Center for Polymer Microfabrication (CPM) with an initial focus on processes and systems related to volume production of microfluidic devices. This research has focused on topics as diverse as material processing property characterisation and simulation, tooling and equipment design and control, and process control and metrology. This paper details a unique project undertaken by this group to explore how all this related by disparate research can be combined to actually produce functional products in volume at acceptable production rates and quality levels. The goals of this work are not only to test the individual research findings of the group, but to explore and experience the needs that are added by such a production goal. For example we found that rate is an overwhelming constraint, and that tooling and fixturing are major requirements for successful production. Also, our metrology methods had to be adapted to meet our rate goals, which were set at a Takt time of less than four minutes.
Wastewater-Solids Dewatering Odor Control - Case Study
BackgroundThe Milan Wastewater Treatment Plant, located just south of Moline, Illinois, is a 1.7 MGD (6,434 m3/day) activated sludge facility with an average wastewater flow of 700,000 gpd to 800,000 gpd. This facility dewaters primary sludge using a belt filter press (Figure 1). The press operates an average of three times per month, 8 hours per day at a pump rate of 100 gpm. The sludge is dewatered from 3-4% solids to about 23% solids. ProblemOn days when the bio-solids from the primary settling tank are...
The Beltran biomass cogeneration system
An effective, economical solution for harvesting safe, renewable domestic energy, mitigating wastes and achieving environmental goals.BackgroundThe Beltran Biomass Cogeneration System (BBCS) is an integrated, three-stage process that uses proprietary gasification technology to convert biomass and other organic wastes into versatile, cleanburning synthesis gas. The purified gas can then be burned to generate energy as combined heat and power (CHP), or to produce valuable hydrogen, liquid biofuels, synthetic...
Case Study - Carbon Fiber: Oven Emission Control Strategies
OVERVIEW Carbon fiber (fibre) and graphite reinforced polymers are materials that have, and will continue to revolutionize the products we use everyday by making them stronger, lighter and more durable. However, the manufacturing process can have serious environmental ramifications and immediate danger to human health if careful consideration is not given to emission control at the production phase of these materials.ACTIONA carbon fiber company in the Peoples Republic of China was faced with this challenge...
Case Study - Fiberglass Polymer Emissions: RTO Control Technology
OVERVIEWA producer and supplier of corrosion resistant piping systems was looking to improve the reliability and lower operating expenses of an existing air pollution control system at their facility. During their manufacturing process, centrifugally cast mortar pipe systems are reinforced with a fiberglass polymer. This makes the pipe ideally suited for most corrosive piping applications but also produces a significant amount of styrene emissions that need to be destroyed. Plant personel knew that their existing...
The design of static mixer heat transfer equipment for adhesives, sealants, resins and polymers.
The fluids handled within the adhesives and sealant industries are amongst the most difficult to handle of any in the main process industries globally. The characteristics which make them particularly difficult to handle include: High viscosities (typically 1-2000 Pa.s, or 1000 to 2 million cP). Often non-Newtonian (viscosity is not constant and varies with shear rate). Some must be processed at temperatures close to their solidification/hardening points where they are close to changing phase from liquid to...