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Showing posts with label Science and Engineering. Show all posts
Showing posts with label Science and Engineering. Show all posts

When, how to consider low-code development for industrial applications

 Intuitive, low-code development systems can enable the creation and customization of basic tools and dashboards to a broader set of employee skill sets, reducing the cost and time to deploy.

Intuitive, low-code development systems can enable the creation and customization of basic tools and dashboards to a broader set of employee skill sets, reducing the cost and time to deploy.

Learning Objectives

  • Learn how low-code development allows employees that are not developers to participate in creating or customizing software.
  • Accelerate development timelines for developers through low-code architectures.
  • Understand how faster development and deployment saves costs and time.

 Low-code development insights

  • Low-code development empowers industrial organizations to rapidly build and deploy applications, reducing downtime, enhancing flexibility and enabling seamless scaling through reusable, preconfigured components.
  • By leveraging “dockerized” applications running on-premise, businesses can achieve near real-time data processing, minimize reliance on specialized developers and adapt quickly to evolving operational demands.


In a competitive landscape, industrial organizations face constant pressure to enhance efficiency, reduce downtime and adapt to evolving business demands. The need for process agility to meet shifting customer requirements is also increasing.

Traditional software development approaches often struggle to keep pace with these requirements due to high costs, long development cycles and the need for specialized skills. Low-code applications, however, offer a compelling alternative.

By leveraging a low-code development environment with “dockerized” applications deployed and executed on-premise, industrial organizations can unlock significant cost and time savings. Dockerization — also known as containerization in coding parlance — is the process of packaging software, including its dependencies, into a standard, self-sufficient container. A Docker container is a lightweight, portable and executable package that includes everything needed to run an application, such as code, runtime, system tools, libraries and settings.

Low-code development allows users to create applications with minimal coding, allowing industrial facilities to speed and simplify the development process.

How low-code development reduces downtime, enables flexibility

Traditional software development in industrial environments often requires extensive time and resources, making it difficult to adapt to changing business needs. Low-code development platforms introduce a new level of flexibility by allowing organizations to deploy multiple instances of applications across several devices.

Additionally, these applications can forward data to the cloud when necessary, while maintaining critical functions on-premise. With features such as drag-and-drop functionality, an intuitive visual user interface and model-driven development, low-code platforms empower professional developers as well as nontechnical users to build and customize applications efficiently.

Figure 1: Customization using menu-based or drag-and-drop components means more team members can enact customizations at need. Courtesy: Siemens

This democratization of software development enables departments outside of information technology to participate in application development, ensuring faster adaptation to operational changes without relying solely on specialized developers.

One significant issue with deploying custom software to improve operations or dynamically change processes is the associated downtime. Every minute of unplanned downtime can result in substantial financial losses. Low-code applications address this issue by enabling custom applications to be created and deployed quickly and scaled dynamically.

Normal operational downtime is also reduced if low-code development applications are created for data collection and predictive maintenance at the shop floor level with real-time dashboarding and local data integration, allowing operators and decision-makers to monitor equipment status and production metrics instantaneously. This proactive approach to maintenance and monitoring significantly reduces unplanned downtime, improving operational efficiency.

Agile scaling with low-code development

Industrial settings often require custom software solutions to meet changing customer demands or evolving production goals. Expensive consultants and long lead times have plagued custom software development for industrial applications for years. Low-code applications offer a solution by enabling quick deployment and modification of applications.

Figure 2: Low-code development enables agility in automation development. Courtesy: Siemens

With preconfigured modules, templates, connectors and reusable elements, low-code applications allow organizations to develop solutions with greater efficiency. This means businesses can fast-track development cycles and deploy applications while ensuring production processes can be switched seamlessly when required.

The ability to extend application features and deploy multiple dockerized copies quickly enables businesses to scale their operations without incurring excessive costs. This scalability is a crucial benefit of low-code applications in industrial environments. Low-code applications ensure consistent quality across multiple deployments by relying on easily customizable, reusable components that have been pre-tested for performance and security.

Furthermore, these applications support continuous delivery, allowing organizations to implement improvements and updates with minimal disruption. This scalability not only reduces software development costs but also enhances long-term operational efficiency.

Skill gaps addressed by low-code development

One of the biggest challenges facing industrial human resources departments today is the shortage of skilled developers. Low-code development platforms make application development accessible to a broader range of employees with intuitive visual interfaces and model-driven development. Individuals with limited coding experience can contribute to application creation and customization and experienced developers can rapidly prototype and deploy solutions.

Figure 3: Visualized elements replace walls of code, enabling quick understanding of process changes. Courtesy: Siemens

By empowering existing talent to build and deliver applications faster, low-code platforms reduce the reliance on outsourced developers or consultants. This allows employees to customize solutions that meet their departments’ specific needs and look to internal or external development resources for only the most complex needs. This not only accelerates development timelines but also fosters better collaboration and decision-making among cross-functional teams.

The adoption of low-code applications in industrial settings is a game-changer for organizations seeking to reduce costs, minimize downtime, enhance flexibility and scale their operations efficiently. By leveraging dockerized applications that operate on-premise, businesses can eliminate cloud latency and achieve near real-time data processing, leading to improved operational performance.

Low-code platforms enable rapid application development, allowing industrial organizations to switch processes faster, adapt to changing demands and empower their workforce with accessible development tools.

With preconfigured, reusable components, these applications offer long-term cost savings while maintaining high performance and security standards. As the industrial sector continues to evolve, the ability to deploy and modify applications is increasingly essential. Low-code development provides a strategic competitive advantage, ensuring that businesses remain agile and competitive in an ever-changing landscape.

Source

Low Temperature Activated Carbon Plant: Detail Engineering Design (DED)


📘 DED – Part 1: General Plant Layout and Plot Plan
1.1 Plant Location and Site Consideration
  • Site Area: Approx. 6,000 – 10,000 m² (for 5,000 TPA); expandable to 18,000 m² for 30,000 TPA.
  • Preferred Location: Near coconut/palm plantation; proximity <10 km from raw material source.
  • Topography: Flat to slightly sloped; elevation control required.
  • Utilities Required: Water supply (bore well or industrial), Electricity (300–500 kW min), Drainage, Access road.

1.2 Plant Layout (Zone Division)

  • Zone A – Raw Material Receiving and Crushing
  • Zone B – Drying and Carbonization Area
  • Zone C – Steam Activation and Cooling Area
  • Zone D – Screening, Pulverizing, and Packing
  • Zone E – Utilities: Boiler House, Genset Room, Compressor Area
  • Zone F – Control Room, Laboratory, Admin Office, Workshop
  • Zone G – Storage & Warehouse (Raw and Finished)
1.3 Plot Plan (Standard Distance Guidance)

Facility

Min Distance from Property Line

Kiln/Activation Unit

15 m

Crusher and Dryer

10 m

Control Room

8 m

Warehouse

5 m

Fuel Storage (if any)

20 m

1.4 Material Flow Arrangement

  • Linear Flow: From biomass reception → drying → carbonization → activation → product handling → packing.
  • Avoids cross-contamination and minimizes backtracking.
  • Includes dust control zoning and natural ventilation optimization.

1.5 Safety Setbacks and Access

  • Fire Access Lane: 4.5 m minimum width all around.
  • Fire Hydrant Points: Every 50 m.
  • Access for loading/unloading: 12 m wide road near warehouse.

📘 DED – Part 2: Mechanical Equipment Sizing & Layout

2.1 Main Equipment List and Description (Capacity: 5,000 TPA)

No

Equipment

Capacity/Spec

Qty

Material of Construction

1

Biomass Crusher

5–8 TPH

1

Mild Steel / SS-304 (wear area)

2

Storage Hopper

5 m³

1

Carbon Steel

3

Rotary Dryer

1.5 ton/hr drying capacity

1

SS-304 Inner Shell

4

Biomass Burner (Hot Gas Source)

0.5 MMKcal/hr

1

Firebrick Lined Steel

5

Carbonization Kiln (Rotary)

0.5 TPH

1

SS 310/316 (Inner) + CS Jacket

6

Steam Activation Chamber

Batch or Continuous (1–2 T/day)

1

SS-316

7

Cooling Screw Conveyor

0.5 TPH

1

SS-304

8

Vibratory Screener

2 deck – 10, 30 mesh

1

SS-304

9

Pulverizer/Mill

250–500 kg/hr

1

Hardened Steel/SS

10

Packing Machine (Semi-auto)

5–10 bags/min (25 kg)

1

Mild Steel/SS Hopper

11

Conveyor Systems

Belt/Screw

-

Galvanized Steel/SS-304

12

Boiler for Steam Activation

500 kg/hr @ 6 bar

1

Water Tube / Fire Tube

13

Dust Collector / Bag Filter

10,000 m³/hr air handling

1

CS with filter bags

14

Cyclone Separator

For dryer flue gas

1

Carbon Steel


2.2 Equipment Layout Considerations

  • Linear Flow from crusher → dryer → kiln → activation → screener → packing.
  • Dryer & Burner close-coupled with dust collection system.
  • Steam line from boiler routed to activation chamber with safety relief valve and condensate trap.
  • Pulverizer and screener area enclosed to control dust.
  • Overhead clearance: 4–6 m for rotary and cyclone systems.
  • Material Handling: gravity-assisted chutes where possible.

2.3 Mechanical Design Assumptions
  • 300 days/year operation.
  • 2 shifts/day (8 hours/shift).
  • Design factor: 1.2 on continuous load.
  • Future expansion to 30,000 TPA by replication in modules (x6 line).

📘 DED – Part 3: Electrical System Design & SLD Overview

3.1 Electrical Load Summary (Initial Capacity: 5,000 TPA)

System / Equipment

Estimated Load (kW)

Crusher

15 kW

Rotary Dryer Motor

10 kW

Induced Draft Fan (Dryer)

7.5 kW

Kiln Drive + ID Fan

10 kW

Steam Boiler (Auxiliary)

15 kW

Activation Chamber Fans

7.5 kW

Pulverizer / Grinder

22 kW

Screw Conveyor Motors

5 kW

Screener / Vibrator

3 kW

Packing Line

5 kW

Lighting + Office Loads

10 kW

Instrumentation & Control

2.5 kW

Total Connected Load

≈ 112.5 kW

Demand Factor (0.75)

≈ 85 kW


3.2 Power Source and Distribution

  • Primary Supply: PLN 3-phase, 400V, 50Hz.
  • Backup Generator: 125 kVA Silent Type Diesel Genset.
  • Main Panel (MDB): In Control Room with MCCs.
  • Distribution:
    • MCC-1: Crusher, Dryer, Kiln
    • MCC-2: Boiler, Activation, Pulverizer
    • Lighting DB: Office, Workshop, Perimeter
    • Control Panel: Local + Remote I/O, PLC, HMI

3.3 Cable & Trunking Layout

  • Underground armored cable for main power.
  • Cable trays for above-ground motor supply.
  • Separate conduit for signal cables (instrumentation).
  • Earthing system: 1 ohm or less resistance, with chemical earthing pit.

3.4 Lightning and Surge Protection

  • Lightning Arrestor Mast: ≥2 points based on coverage.
  • SPD: Surge Protection Device on MDB and PLC power supply.

3.5 Single Line Diagram (SLD) – Simplified Overview

 [PLN 400V] -----+

                |

             [ATS Panel] ----- [125 kVA Genset]

                |

             [MDB Panel]

                |

    +-----------+------------+

    |           |            |

 [MCC-1]     [MCC-2]     [Lighting DB]

    |           |            |

Motors 1-5  Motors 6-10    Office, Yard, Lab


📘 DED – Part 4: Instrumentation & Control System Design

4.1 Control Philosophy Overview

The plant will operate in semi-automatic mode with central control through PLC-HMI system. Operators can monitor, start/stop equipment, and receive alarms via HMI touchscreen located in the Main Control Room.

Key Control Modes:

  • Manual Local (maintenance mode)
  • Remote Start/Stop (normal ops)
  • Auto Batch Timing (activation, drying, screening)

4.2 Major Instrumentation and Sensors

Location

Instrument Type

Signal Type

Remarks

Biomass Hopper

Level Sensor (Ultrasonic)

4-20 mA

Material presence monitoring

Dryer Outlet

Temperature Sensor (RTD / TC)

4-20 mA

Heat control

Burner Flue Gas

Temp. + Oxygen Analyzer (optional)

4-20 mA

Combustion efficiency

Rotary Kiln

Speed Encoder + Thermocouple

Pulse / 4-20 mA

Rotational monitoring

Activation Steam Inlet

Pressure Transmitter + Flow Meter

4-20 mA

Steam pressure control

Cooling Conveyor Outlet

Temp Sensor

4-20 mA

Material readiness

Bag Filter Dust Chamber

Differential Pressure Transmitter

4-20 mA

Bag health monitoring

Packing Line Hopper

Weight Cell / Load Cell

4-20 mA

Bag filling automation


4.3 PLC & HMI Specification

  • PLC: Siemens S7-1200 / Allen Bradley MicroLogix (as per vendor availability)
  • HMI: 7” or 10” Touchscreen with multi-page navigation
  • I/O Capacity:
    • Digital Input: 24
    • Digital Output: 16
    • Analog Input: 16
    • Analog Output: 4

4.4 Communication and Protocol

  • Internal Communication: Modbus RTU or Ethernet/IP
  • Expandable I/O Modules for future 30,000 TPA upgrade.
  • Optional SCADA Interface via PC with data logging features (CSV export).

4.5 Alarm & Safety Interlocks

Alarm / Interlock

Action

Over temperature in Dryer/Kiln

Auto shutdown burner, activate cooling fan

Steam pressure low in Activation

Delay in cycle start, send alarm

Power Failure

Auto restart delay and safe shutdown

Bag Filter Pressure High

Warn operator to clean filter

Emergency Stop

Total plant trip, manual reset required


📘 DED – Part 5: Safety & Environmental Engineering

5.1 Process Safety Overview

The Low Temperature Activated Carbon Plant operates with thermal units, rotating machinery, combustible materials, and pressurized steam, requiring a detailed safety and environmental engineering approach.

Key Safety Objectives:

  • Prevent fire/explosion due to fine carbon dust and high temperatures.
  • Ensure safe handling of biomass and hot equipment.
  • Protect personnel and environment from emissions and physical hazards.

5.2 HAZOP & Risk Assessment Summary

Process Node

Potential Hazard

Cause

Mitigation

Dryer + Kiln

Overheating, Fire

Burner malfunction

Temp sensor + shutdown interlock

Activation Chamber

Overpressure

Valve stuck, steam surge

Relief valve + pressure switch

Pulverizer

Dust explosion

Static build-up, spark

Grounding, dust extraction

Bagging Unit

Repetitive strain

Manual handling

Ergonomic design, semi-auto packer

Boiler Room

Steam burst, fire

Poor maintenance

Certified operator + safety valve


5.3 Fire Protection System

  • Fire Extinguishers: Dry chemical + CO₂ units near thermal zones.
  • Hydrant System: Around fuel storage and biomass dryer.
  • Smoke Detectors: In control room and packaging area.
  • Spark Arrestor: Installed on flue gas exhaust line.

5.4 Dust & Emission Control

  • Cyclone Separator: Captures >70% of particulates from dryer.
  • Bag Filter / Dust Collector: Captures fine carbon & biomass dust.
  • Chimney Stack Height: Minimum 12 m for proper dispersion.
  • Air Emission Limit Compliance: PM < 150 mg/Nm³ (based on WHO/local standard).

5.5 Noise Control Measures

  • Enclosures for crusher, dryer fan, and grinder.
  • Silencers on boiler exhaust and pneumatic line.
  • PPE: Mandatory ear protection in high noise zones.

5.6 Waste & Effluent Management

  • Solid Waste: Collected char fines → reused as fuel.
  • Ash: From burner → collected in sealed container.
  • Wastewater: Minimal; condensate reused; floor wash directed to soak pit.
  • Oil & Grease: Stored in spill-proof containers, sent to recycling vendor.

5.7 Occupational Health & Safety (OHS)

  • Daily Toolbox Meeting
  • Permit to Work (PTW) for maintenance jobs
  • PPE Requirements:
    • Safety shoes
    • Heat-resistant gloves
    • Dust mask / Respirator
    • Face shield (pulverizer area)

📘 DED – Part 6: Utility & Facility Engineering

6.1 Utility Requirement Summary (for 5,000 TPA Capacity)

Utility Type

Estimated Consumption

Source

Water

~10 m³/day

Deep well / local supply

Electric Power

~85 kW average

PLN + 125 kVA genset

Steam

~400–500 kg/hr

Biomass-fired steam boiler

Fuel (Biomass)

~4,500 tons/year

Supplied from plantation

Compressed Air

4–6 bar, 10 Nm³/hr

For actuator & cleaning


6.2 Water System

  • Sources: Borewell with submersible pump.
  • Storage Tank: 20 m³ elevated tank.
  • Distribution: For steam generation, floor cleaning, and cooling.

Note: No wastewater treatment required due to dry process.


6.3 Steam Generation System

  • Boiler Type: Biomass-fired package boiler, 600 kg/hr @ 7 bar
  • Fuel: Biomass waste (coconut shell, wood chips)
  • Water Treatment: Softener + blowdown tank
  • Safety: Pressure gauge, relief valve, level indicator

6.4 Air Compressor System

  • Compressor Type: Screw type, 10 HP
  • Air Receiver Tank: 500 liters
  • Dryer & Filters: Installed for clean air
  • Applications: Instrumentation valves, bag filter pulse jet

6.5 Storage and Logistics

Facility

Capacity / Area

Notes

Raw Biomass Yard

~500 tons (10 days stock)

Open yard with roof

Finished Goods WH

~50 tons (10 days stock)

Ventilated building

Packing Area

2–3 MT/day capacity

Manual + semi-auto filler

Boiler Room

20 m²

With heat-resistant coating

Control Room

12–15 m²

Air-conditioned, HMI + PC

Office/Rest Room

30 m²

Toilets, pantry, small meeting room


6.6 Site Layout Suggestions

  • Wind Direction: Boiler stack downwind of office.
  • Traffic Flow: One-way truck path (delivery–loading).
  • Fire Access: 3m-wide clearance all around.
  • Green Buffer: 10% area for landscaping & dust control.

📘 DED – Part 7: Expansion Engineering for 30,000 TPA Capacity

7.1 Design Considerations for Scalability

The plant is originally designed for 5,000 TPA, but several engineering allowances are embedded to enable smooth expansion to 30,000 TPA (6× increase). Key considerations include:

Modular Layout:

  • Each processing line (crusher → dryer → kiln → activation → cooling) sized for ~5,000 TPA.
  • Plant layout accommodates up to 6 parallel modules.

Utility Scalability:

  • Boiler Room: Reserved area for up to 3 additional boilers.
  • Compressor System: Expandable manifold with additional air dryers.
  • Main Electrical Panel: Built with 40% spare I/O and 50% spare MCC slots.

7.2 Expansion Equipment Sizing (Per 5,000 TPA Unit)

Equipment

Base (1 Line)

Expanded (6 Lines)

Crusher

1 Unit

6 Units

Dryer

1 Unit

6 Units

Kiln

1 Unit

6 Units

Activation Chamber

1 Unit

6 Units

Cooling Conveyor

1 Unit

6 Units

Screening + Packing

1 Line

6 Lines

Boiler (500 kg/hr)

1 Unit

6 Units or 1×3 TPH

Automation can be centralized with 1 main PLC system and 6 distributed Remote I/O stations.


7.3 Site Expansion Layout (Conceptual)

  • Centralized Utility Core: Boiler, air compressor, electrical control remain shared.
  • Parallel Process Lines: Each with its own biomass input and product output.
  • Integrated Conveyor System: Optional for common raw material feeding.
  • Separate Product Silos or Bagging: Depending on market packaging format.

7.4 Manpower & Logistics Adjustment

Parameter

5,000 TPA

30,000 TPA

Total Workers (Shifts)

~15

~45

Truck Movements/Day

2–3

12–15

Water Consumption

10 m³

~60 m³

Power Consumption

~85 kW

~500 kW

Automation Level increase will reduce proportional manpower requirement.


7.5 Financial Feasibility Checkpoint (Indicative)

Description

5,000 TPA

30,000 TPA

Capex Estimate (USD)

$450,000 – $600,000

~$2.5 – $3.0 Million

Product Sale Price (per ton)

$700 – $1,200

Same (volume discount)

Break-even Period (Estimate)

2–3 Years

3–4 Years


For further inquiries or full project proposal assistance, feel free to contact or follow updates via this blog.

📌 If you are interested in seeing articles in other science & engineering or investment proposal, you can find them 👉 here and here

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