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Theoretical Foundations of Chemical Engineering, Vol. 38, No. 3, 2004, pp. 322–327. Translated from Teoreticheskie Osnovy Khimicheskoi Tekhnologii, Vol. 38, No. 3, 2004, pp. 343–348. Original Russian Text Copyright © 2004 by Bessarabov, Malyshev, Dem’yanyuk.

CALS-Based Information Model of the Technology of Biologically Active Additives of a New Generation A. M. Bessarabov, R. M. Malyshev, and A. Yu. Dem’yanyuk IREA State Research Institute of Chemical Reagents and Special-Purity Substances, Bogorodskii val 3, Moscow, 107076 Russia Received April 22, 2003

Abstract—An information model of the technology of biologically active additives (BAA) of a new generation is presented which is based on the Continuous Acquisition and Life Cycle Support (CALS) concept. The information model includes typical computer structures: marketing, design, production, service and repair, and realization and sale.

At the present time, as a promising information technology, methods of the Continuous Acquisition and Life Cycle Support (CALS) concept are widely BAA Production Technology.std - PSM

implemented [1–3]. The CALS concept is based on a complex of unified information models and the standardization of methods for information access and Microsoft Excel

Categories BAA PRODUCTION TECHNOLOGY 1. Marketing 1. Consumer Characteristics 2. Risk Factors Changes in Tax Laws, Termination of Exemptions Inflation Competition 1. Market Capacity 2. Import Substitution 3. Price Policy Diagram of Prices of Competing BAA 4. Mathematical Model Social and Military Conflicts 2. Design 3. Production 4. Service and Repair 5. Realization and Sale

Property Name: Description:

BAA Consumption Market Capacity US$ Bln

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Microsoft Excel - BAA Manufacturer Distribution bw.xls

Microsoft Excel - BAA Price s.xls

Degree of BAA Import Substitution Comparison between Prices of Competing BAA Rubles

Import Domestic Production

Fitokhol

Zolotoi Ussuri

Del’fin

Fig. 1. CALS Project element at the marketing step. 0040-5795/04/3803-0322 © 2004 MAIK “Nauka /Interperiodica”

CALS-BASED INFORMATION MODEL OF THE TECHNOLOGY

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Navigator Categories BAA PRODUCTION TECHNOLOGY 1. Marketing 2. Design Initial Data for Design 01. General Information on Technology BAA Production Technology Stages 1. Grinding.: 2. Extraction.: 3. Concentration.: 4. Mixing.: 5. Drying--Agglomeration.: 6. Packing.: 02. Characterization of Performed Research... 03. Feasibility Study... 04. Patent Form. 05. Technical Characterization of Initial Raw Material 06. Physicochemical Constants and Properties... 07. Chemical and Physicochemical Principles... 08. Operating Process Parameters... 09. Production Material Balance.

Property Notation: Name: Description:

Meaning 5. Drying--Agglomeration.

Characteristics Notation

Name

Approvals Version

Documents

Changes

Type

BAA Production Stages. doc (view) - Microsoft Word

BASIC BAA PRODUCTION STAGES GRINDING

EXTRACTION

10. Technical Characterization of Side Products... 11. Mathematical Description of Processes... 12. Data for Design and Choice... 13. Recommendation for Design... 14. Analytical Control of Production. 15. Methods and Process Parameters... 16. Safety Measures... 17. List of Reports and References... 3. Production 4. Service and Repair 5. Realization and Sale

CONCENTRATION

MIXING

DRYING-AGGLOMERATION

PACKING

Grinding of medicinal herbal raw material into particles 0.4 – 0.63 mm in diameter.

Extraction of ground medicinal herbal raw material. Extractant is distilled water. The concentration of the extract obtained is 5 wt %.

Concentration of the extract obtained in a pulsed vacuum vaporator. The final extract concentration is 20 wt %.

Mixing of the concentrated extract with gelatin--starch and sweeteners (sugar, aspartame, etc.). The moisture content of the ready mixture is 25%.complex a

Drying--agglomeration of the mixture obtained to a give moisture content of 1.5--2% with the simultaneous grinding to a given partile size of 4 mm.c

Packing of the ready product into foiled packs. The pack weight is 25 g.

Fig. 2. CALS Project element at the design step (basic stages of the technology of biologically active additives).

correct information interpretation according to the international standard ISO 10303 (STEP). A series of CALS projects were developed for a number of technologies for producing special-purity substances [4– 6]; however, in all the cases, CALS methods were used only to create project documentation. In this work, using CALS methods, an information model was elaborated which includes all the steps (marketing, design, production, service and repair, and realization and sale) of the technology of producing biologically active additives of a new generation from an extract of medicinal herbs and gelatin–starch complex [7–9]. In recent years, biologically active food additives—therapeutic and prophylactic preparations produced from herbal raw material—have successfully competed with synthetic drugs.

Let us sequentially consider elements of the information model that correspond to various steps of the technology of biologically active additives. On the basis of marketing research results, at the marketing step, two information-analytical blocks are formed: consumer characteristics and risk factors. Each of the blocks includes lower-level parameters, whose analysis gives a complete pattern of the entire analytical block. For convenience of using the system, the parameters are inputted in text and table formats, as well as in graphic form. As basic consumer characteristics, the income, age, and sex distributions of consumers are analyzed. In this block, the reasons for buying biologically active additives and the main factors affecting the purchase decision are also studied. In the block of risk factors (Fig. 1), an analysis is

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Navigator BAA PRODUCTION TECHNOLOGY 1. Marketing 2. Design Initial Data for Design 01. General Information on Technology 02. Characterization of Performed Research... 03. Feasibility Study... 04. Patent Form. 05. Technical Characterization of Initial Raw Material 06. Physicochemical Constants and Properties... 07. Chemical and Physicochemical Principles... 08. Operating Process Parameters... 09. Production Material Balance. 10. Technical Characterization of Side Products... 11. Mathematical Description of Processes... 12. Data for Design and Choice... Technical Documentation 1. BAA Production Flowchart 2. Dryer-Agglomerator 01. Shaped Bottom.: 02. Shaft.: 02. Shaft.:: 03. Teeth.: 04, 05. Housing Walls.: 06. Fluoroplastic Lining.: 07. Cover.: 08. Distributor of Heat-Transfer Medi.: 09. Inlet for Fresh Heat-Transfer Medi.: 10. Outlet for Spent Heat-Transfer Medi.: 11. Feed Hopper.: 12. Hatch for Unloading Final Product.: 3. Flowchart for Feeding Heat-Transfer Me... 13. Recommendation for Design... 14. Analytical Control of Production. 15. Methods and Process Parameters... 16. Safety Measures... 17. List of Reports and References... 3. Production


Meaning 2. Dryer-Agglomerator


Meaning 2. Dryer-Agglomerator

Agglomerator.jpg - Image and Fax Viewer

Dryer-agglomerator 1. Shaped bottom; 2. Shaft; 3. Teeth; 4, 5. Housing walls; 6. Fluoroplastic lining; 7. Cover; 8. Distributor of heat-transfer medium; 9. Inlet for fresh heat-transfer medium; 10. Outlet for spent heat-transfer medium; 11. Feed hopper; 12. Hatch for unloading final product.

Fig. 3. CALS Project element at the design step (dryer–agglomerator design).

undertaken regarding the possibility of a change in tax laws and concerning inflation and competition, market capacity, degree of import substitution, and prices for similar products. At the marketing step, a conclusion is drawn about the expedience and prospects of developing technology and equipment for producing biologically active additives of new generation. At the design step (Fig. 2), the initial data for design are analyzed, which contain information on six basic stages: grinding of medicinal raw material, extraction, concentration, mixing, drying–agglomeration, and packing. Particular attention was given to the limiting stage—drying–agglomeration. The main methods for drying biologically active additives were analyzed; these are spray drying, fluidized-bed drying, infrared drying, and drying in a vacuum dryer equipped with a rake agitator. It was shown that the equipment considered is inefficient if the product contains astringent substances (fructose, lactose, gelatin– starch complex, and others), which, during drying–

agglomeration, form clots, stick to moving parts and the housing of the apparatus, and can render the apparatus inoperative. Therefore, a continuous convective agitator dryer was proposed, which gives a product of required quality and given particle size distribution (Fig. 3). At the design step, four variants of agitator design are considered (Fig. 4). The ultimately chosen variant was the design that ensured required product quality at minimal energy consumption, with the agitator of this design being constructed at minimal material and labor expenditures. Three methods for introducing a heat-transfer medium were analyzed, and the optimal variant ensuring the maximal uniformity and efficiency of heat transfer was chosen. Intermediate and final variants described in text and graphic files were included into the CALS project. At the production step, technical documentation of extractors, dryers–agglomerators, and other equip-


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Navigator Categories BAA PRODUCTION TECHNOLOGY 1. Marketing 2. Design Initial Data for Design 01. General Information on Technology 02. Characterization of Performed Research... 03. Feasibility Study... 04. Patent Form. 05. Technical Characterization of Initial Raw Mat... 06. Physicochemical Constants and Properties... 07. Chemical and Physicochemical Principles... 08. Operating Process Parameters... 09. Production Material Balance. 10. Technical Characterization of Side Products... 11. Mathematical Description of Processes... 12. Data for Design and Choice... Technical Documentation 1. BAA Production Flowchart 2. Dryer--Agglomerator 3. Flowchart for Feeding Heat-Transfer M.. 4. Variants of Agitator Design Variant 1: Shaft Shape Variant 1: Shaft Shape: Variant 2: Variant 3: Variant 4: 13. Recommendation for Design... 14. Analytical Control of Production. 15. Methods and Process Parameters... 16. Safety Measures... 17. List of Reports and References... 3. Production 4. Service and Repair 5. Realization and Sale


Meaning 4. Variants of Agitator Designigures\...

Variant

τ, min

Description

Wpeak, kW

Xk

Pitch of teeth is = S, one flight is 4 teeth, shift of teet with respect to axis is 72°, shape of teeth is blade Pitch of teeth is = S, one flight is 3 teeth, shift of teeth with respect to axis i Pitch of teeth is = S/2, one flight is 3 teeth, shift of teeth with respect to axis is 90°, shape of teeth is triangle

Pitch of teeth is = S/2, one flight is 3 teeth, shift of teeth with respect to axis is 90°, shape of teeth is lens

Fig. 4. CALS Project element at the design step (agitator design).

ment is analyzed by industrial equipment manufacturing plants. At the service step, technical information on the main stages (switching on, operation, switching off, washing) of service of extractors, dryers–agglomerators (Fig. 5), and other equipment is introduced. Information at the repair step (Fig. 6) is structured at three levels: trouble–cause–troubleshooting. The developed module enables one to promptly, in dialog mode, select the optimal variant of troubleshooting. The step of realization and sale includes product promotion to market (advertising in printed and electronic mass media; participation in exhibitions, contests, tenders, etc.) and also analysis of information on the use of the developed equipment not only in the technology of biologically active additives but also in

the chemical and pharmaceutical industries. Under the conditions of the rapid development of the Internet with allowance for its potentialities, one of the elements of this step is the development of the information web site of OOO Ob’’edinenie IREA-PENZMASh, the parent organization in the production of the biologically active additives considered in this work and promising equipment for drying highly viscous extracts of medicinal raw material. On the basis of accumulated information, the optimal structure of the web site was developed, necessary information contents were analyzed, and a system for rapidly surfing the site was implemented. The site combines two main Internet systems: FTP and WWW. The WWW system is used to illustratively and conveniently store information, to structure information, and to easily


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Navigator Categories BAA PRODUCTION TECHNOLOGY 1. Marketing 2. Design 3. Production 4. Service and Repair 1. Service 1. Switching on Apparatus Switching on Apparatus: Manual Switching on Apparatus: Ma.: 2. Apparatus Operation 3. Switching off Apparatus 4. Washing of Apparatus 2. Possible Troubles, Their Causes... 5. Realization and Sale

Property Notation: Name: Description:

Meaning Switching on Apparatus Manual 1.1 Test the tightness of the joints...

Composition

Characteristics

Property Version: Name: Description:

Approvals

Documents

Changes

Meaning Manual Switching on Apparatus

SERVICE1.DOC (view) - Microsoft Word

75%

SWITCHING ON APPARATUS

APPARATUS SERVICE

SWITCHING OFF APPARATUS

Service.doc (view) - Microsoft Word

Close

100%

1 Switching on Apparatus

Test the tightness of the joints of pipes for feeding the heat-transfe medium and the joint of the apparatus with the receiving hopper Switch on air feed

1.1 Test the tightness of the joints... 1.1 Switch on air feed. 1.2 Switch on air heating.

Switch on air heating

1.3 Switch on the agglomerator shaft drives. 1.4 Load the product to the feeder. 1.5 Switch on the feeder.

Switch on the agglomerator shaft drives Load the product to the feeder

During the apparatus operation, control the following parameters

Switching of the apparatus in the following order

Temperature of the heat-transfer medium, no more than 60°C

Switch off the feeder

Current in the circuit of the agglomerator shaft drives, no more than 50 A Pressure in the agglomerator, no more than 20 mm H2O Agglomerator shaft speeds, chosen specially

Switch off air heating

Switch off air feed Switch off the agglomerator shaft drives

Switch on the feeder

Fig. 5. CALS Project element at the step of service of the dryer–agglomerator.

move between sections. The FTP service is used for data (file) storage and exchange. Basic elements of the CALS project for the technology of biologically active additives are placed on the Internet on the CALS-khimiya (CALS Chemistry) web site in the Pilot Projects section. Also here are links to CALS files containing data in STEP exchange format. The files themselves are located on an FTP server and are accessed via FTP protocol with an ordinary WWW browser. This scheme (in which information is place in FTP rather than WWW) is chosen for new files to be conveniently uploaded to the CALSkhimiya web site by various developers, rather than solely by the server administrator. The CALS-khimiya web site is one of the promising elements for training scientists and specialists of industrial plants in implementing CALS methods to the chemical industry.

The results of this work were implemented at plants of the OOO Ob’’edinenie IREA-PENZMASh. The developed CALS documentation significantly reduces the service, maintenance, and repair costs. According to predictions of foreign specialists, after 2005, it will be impossible to sell high-tech products in the international market without electronic documentation created in compliance with international CALS standards (ISO 10303 (STEP)) [2]. Therefore, one can believe that the electronic description of the technology of biologically active additives in accordance with the international CALS standard ISO 10303 (STEP) enables one to increase sales of new equipment. ACKNOWLEDGMENTS This work was supported by INTAS (project no. 971-30770); the Ministry of Industry, Science,


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Property Meaning Name: 2. Seizure of the agglomerator shafts because of... Categories Description: Remove foreign objects from the apparatus BAA PRODUCTION TECHNOLOGY 1. Marketing 2. Design Property Meaning 3. Production Name: 2. Seizure of the agglomerator shafts because of... 4. Service and Repair 1. Service Repair.doc - Microsoft Word 2. Possible Toubles, Their Causes, and Troubleshootingr 1. After Switching on the Agglomerator, the Shafts Do Not Rotate 1. There is No Current in the Circuit of Electric Motors 2. Seizure of the Agglomerator Shafts because of Jamming... 2. Decrease in the Temperature of the Heat-Transfer Mediu... 3. Increase in the Temperature of the Heat-Transfer Mediu.. TROUBLESHOOTING TROUBLE CAUSE 4. Spontaneous Decrease in the Shaft Speeds 5. Particle Size Distribution of the Finished Product is Inconsistent... Check the serviceability There is no current in th After switching on 5. Realization and Sale of the control panel and electric motors of the the agglomerator, the replace faulty parts shaft drives hafts do not rotate MANUAL.DOC (view) - Microsoft Word Check the contacts in the circuit of the shaft drives and clear them, if necessary

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1. AFTER SWITCHING ON THE AGGLOMERATOR, THE SHAFTS DO NOT ROTATE 1.1 There is no current in the electric motors of the shaft drives. 1.1.1 Check the contacts in the circuit of the shaft drives and clear them, if necessary. 1.1.2 Check the serviceability of the control panel and replace faulty parts. Decrease in the temperature of th heat-transfer medium at the agglomerator inlet

1.2 Seizure of the Shafts because of Jamming Foreign Objects 1.2.1 Remove foreign objects from the apparatus. 1.3 Seizure of the Shafts because of Their Axial Misalignment 1.3.1 Check the shaft supports and the agglomerator sleeves and gears, replace damaged parts, if necessary.

Seizure of the shaft because of jamming foreign objects

Remove foreign objects fro the apparatus

Seizure of the shafts because of their axial misalignment

Check the shaft supports and the agglomerator sleeves and gears, replace damaged parts, if necessary

Increased flow rate of the heat-transfer medium

Check and, if necessary, change the flow rate of the heat-transfer medium

Insufficient voltage in the air heater

Check and, if necessary, change the voltage in the air heater

2. DECREASE IN THE TEMPERATURE OF THE HEAT-TRANSFER MEDIUM AT THE AGGLOMERATOR INLET 2.1 Increased flow rate of the heat-transfer medium.

Fig. 6. CALS Project element at the step of repair of the dryer–agglomerator.

and Technologies of the Russian Federation (project no. 140-20-19); and the Federal Scientific and Technical Program of Research and Design in High-Priority Lines of the Development of Science and Technology in 2002–2006.

5. Bessarabov, A.M. and Afanas’ev, A.N., CALS Technologies in the Design of Promising Chemical Production Plants, Khim. Tekhnol., 2002, no. 3, p. 26.

REFERENCES

6. Bessarabov, A.M., Efimova, V.P., and Dem’yanyuk, A.Yu., CALS Concept in the Development of Automated Control Systems, Pribory Avtomatizats., 2002, no. 10, p. 48.

1. Dmitrov, V.I., To the Question of the State Strategy of Russia in CALS Technologies, Inform. Tekhnol., 1996, no. 5, p. 25. 2. Davydov, A.N., Barabanov, V.V., and Sudov, E.V., CALS Technologies: Main Lines of Development, Standarty Kachestvo, 2002, no. 7, p. 12. 3. Kabanov, A.G., Barabanov, V.V., and Sudov, E.B., CALS Technologies for Military Products, Standarty Kachestvo, 2000, no. 3, p. 65. 4. Bessarabov, A.M., Afanas’ev, A.N., Efimova, V.P., and Ryabenko, E.A., CALS Technologies and Their Imple-

mentation in the Chemical Industry of Russia, Khim. Rynok, 2001, no. 3, p. 43.

7. Bomshtein, V.E., Dem’yanyuk, A.Yu., Malinovskii, V.N., and Malyshev, R.M., Continuous Technology for Producing Dry Agglomerated Nutritional Drinks, Pivo Napitki, 2001, no. 1, p. 38. 8. Malyshev, R.M., Kutepov, A.M., Zolotnikov, A.N., Sedov, A.A., Bomshtein, V.E., and Ryabenko, E.A., Pulse Extraction Applied to Herbal Raw Materials, Teor. Osn. Khim. Tekhnol., 2001, vol. 35, no. 1, p. 57. 9. Bessarabov, A.M., Malyshev, R.M., Dem’yanyuk, A.Yu., et al., CALS Modeling of Drying (Sol–Gel Transition) of Highly Viscous Extracts of Medicinal Raw Material, Khim. Prom–st. Segodnya, 2003, no. 12, p. 23.


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