Process Systems Engineering-Incubating Sustainability for Industrial Revolution 4.0

Dear Colleagues,

Process systems engineering (PSE) plays a crucial role in enhancing the efficiency and sustainability of industrial systems by employing advanced methodologies to optimize processes. PSE allows for the meticulous design, modeling, and control of complex industrial systems, ensuring that every component operates at peak efficiency. With the advent of artificial intelligence (AI), these capabilities have been significantly augmented. AI-driven modeling and analysis tools enable more accurate predictions, better decision-making, and seamless integration of various subsystems, leading to improved overall performance. By leveraging AI, PSE can now tackle increasingly complex challenges, making it possible to manage and optimize large-scale industrial operations with unprecedented precision and efficiency.

In parallel, the global push towards carbon reduction has intensified the focus on environmental considerations within industrial operations. As industries are being held to stricter environmental standards, there is a growing need to evaluate and optimize processes not just for economic gain but also for their environmental impact. This holistic approach requires the analysis of industrial systems through multiple approaches, including energy consumption, waste generation, and emissions. PSE provides the tools to perform such multi-faceted analyses, enabling industries to balance economic performance with environmental responsibility. By integrating these methodologies, PSE not only helps industries to meet their carbon reduction targets but also ensures that these efforts are economically viable and technologically feasible. This systemic approach is essential for driving the transition towards more sustainable industrial practices while maintaining competitiveness in a rapidly evolving market.

The latest research in this intriguing field was presented and discussed at the 2024 PSE Asia International Symposium (https://www.pseasia2024.org/)held in Penang, Malaysia, on 5-8 August 2024. The PSE Asia series is a biennial international symposium in Asia, bringing together researchers and practitioners to discuss recent developments in Process Systems Engineering. PSE Asia 2024 is the 11th symposium, following previous events in Kyoto (2000), Taipei (2002), Seoul (2005), Xi’an (2007), Singapore (2010), Kuala Lumpur (2013), Tokyo (2016), Bangkok (2019), Taipei (2020), and Chennai (2022). This Special Issue is a reflection of the high-quality papers presented at the 2024 PSE ASIA International Symposium. This Special Issue aims to showcase the most recent advances in process dynamics and control, product and process design, supply chain management, PSE for circular economy/sustainable processes, PSE for process safety and operations,  process integration and optimization, artificial intelligence and big data, and education in process systems engineering and industry applications.

Dr. Lee Tin Sin
Prof. Dr. Thomas S.Y. Choong
Guest Editors

Manuscript Submission Information

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• process dynamics
• product and process design
• process integration and optimization
• artificial intelligence
• big data
• education
• supply chain management
• circular economy
• sustainability
• process safety

Title: Additive Manufacturing via Direct Ink Writing of Customized Silicone Foam for Diverse Applications
Authors: Tie Weiting Kenrick; Jia Huey Sim; Jing Yuen Tey; Wei Hong Yeo; Zhi Hua Lee; Law Yong Ng; Soo Tueen Bee; Tin Sin Lee; Luqman Chuah Abdullah
Affiliation: Chemical Engineering Department, Universiti Tunku Abdul Rahman (UTAR); Centre for Advanced and Sustainable Materials Research (CASMR), Universiti Tunku Abdul Rahman, 43000 Kajang, Selangor, Malaysia
Abstract: Direct ink writing (DIW) enables the additive manufacturing of silicone elastomers, offering an alternative to traditional moulding and casting methods for applications such as healthcare products to machine-human interaction sensors. Polydimethylsiloxane (PDMS) foam, a porous silicone elastomer, is valued for its elasticity, chemical and thermal resistance, hydrophobicity, and biocompatibility. The emulsion templating method is a simple and cost-effective approach to create silicone foams by incorporating and later removing of sacrificial dispersed phase from the PDMS precursor. This study developed glycerol/PDMS emulsion-based inks for DIW using high-shear centrifugal mixing, with ethanol as a solvent to remove the glycerol template, creating silicone foam. An optimal glycerol dosage of 50 parts per hundred rubber (phr) produced foam with 27.63% porosity and pore diameter up to 4.66 µm. Each 10 phr increase in glycerol content raised porosity by 10% and average pore diameter by 2 µm. Both tensile and compressive behaviour inversely correlated with porosity, with a 10% porosity rise in the silicone foam reducing tensile strength by 0.07 MPa and stiffness by 0.02 MPa. Models with strong data alignment were developed to benefit researchers in 3D printing to customize silicone foams (pores properties, mechanical properties, compressive properties) based on specific application requirements.

Title: Artificial Intelligence in Manufacturing Industry for Safety: A New Paradigm for Hazard Prevention and Mitigation
Authors: Utkarsh Chadha
Affiliation: Faculty of Applied Sciences and Engineering, University of Toronto, St. George Campus, Toronto, ON M5S 1A1, Canada

Title: A Comparative Review on IG-541 System Use in Total Flooding Application for Energized Electrical Fire
Authors: Kheng Hooi Loo; Tin Sin Lee; Soo Tueen Bee
Affiliation: Technip Energies (M) Sdn. Bhd., Menara Technip Energies, 38, Jalan Inai, Imbi, 55100 Kuala Lumpur, Federal Territory of Kuala Lumpur, Malaysia. [email protected]
Abstract: Clean agent fire suppression systems have become essential in protecting high-value assets, especially in data centers and electrical substations, where traditional fire suppression methods are less effective or hazardous. This review evaluates the IG-541 fire suppression system as an alternative to halocarbon-based agents like HFC-227ea and FK-5-1-12, which are being phased out under environmental regulations, focusing on their application in energized electrical fires. IG-541 offers environmental advantages, including zero ozone depletion potential, no global warming potential, and negligible atmospheric lifetime, making it compliant with stringent environmental regulations. The review compares IG-541 with halocarbon agents across parameters such as extinguishing efficacy, safety considerations, environmental impacts, cost impacts and system design considerations. Key findings underscore IG-541’s effectiveness in reducing fire damage without producing harmful by-products or exacerbating climate change. Furthermore, the study highlights the regulatory frameworks influencing the phase-out of halocarbon agents and the transition toward environmentally sustainable alternatives. While IG-541 emerges as a promising replacement for halocarbon agents, further exploration into its application in varied fire scenarios and energy-intensive environments is recommended to optimize its deployment.

Title: The Recovery of Unburned Carbon from Coal Bottom Ash Using Froth Flotation: Taguchi Optimization Method
Authors: Cik Jamla Farhan; Thomas Shean Yaw Choong; Wan Azlina Wan Ab Karim Ghani; Farah Nora Aznieta Abd Aziz
Affiliation: Universiti Putra Malaysia, Institute of Forestry and Forest Product (INTROP)
Abstract: Abstract: The large amount of coal consumption in thermal power plants produces a significant quantity of bottom ash. Most of them are now treated by landfill. The presence of unburned carbon in bottom ash limits its applications. It is necessary to reduce the amount of unburned carbon in bottom ash for application in construction material. Flotation is a potential technique to remove or to recover unburned carbon owing to its high throughput and efficiency. The purpose of this study was to optimize key parameters in the flotation of bottom ash to recover unburned carbon. The tailing left should have a loss of ignition (LOI) less than 6% in accordance with ASTM C 618 for the purpose of concrete. The parameters studied are frother dosage, collector dosage, air flowrate, and pH. The optimization of the process was carried out using Taguchi method. The Taguchi method indicated that the frother dosage had the highest effect in the flotation recovery with 80.55% contribution and the air flowrate as the most affecting parameter with 73.34 % contribution in combustible recovery and 41.05% in carbon content of concentrate. The LOI for tailing ash is between 1 to 4 %, meeting the requirements of ASTM C618. These results suggested the practicality of the Taguchi approach for the optimization of flotation process.

Title: Implementation of a Sustainable Framework for Process Optimization through the Integration of Robotic Process Automation and Big Data in the Evolution of Industry 4.0
Authors: Leonel Patrício; Leonilde Varela; Zilda Silveira
Affiliation: Department of Production and Systems, Algoritmi/LASI, University of Minho, 4804-533 Guimarães, 6
Abstract: This study explores the integration of Robotic Process Automation (RPA) and Big Data within a sustainable framework for process optimization in the context of Industry 4.0. As industries strive to enhance operational efficiency while maintaining sustainability, the need for innovative solutions has become crucial. The research applies the PICO methodology (Population, Intervention, Comparison, Outcome) to assess the impact of combining these technologies on process optimization and sustainability. Through a real-world case study, the study demonstrates that the integration of RPA and Big Data significantly reduces execution times, minimizes operational errors, and promotes sustainable business practices. The results show that the combined framework not only enhances efficiency but also contributes to lower economic, environmental, and social impacts. The findings validate the research hypotheses, proving that the proposed framework fosters a balance between technological advancement and sustainability. This study provides valuable insights into the potential of Industry 4.0 technologies to drive both operational efficiency and corporate responsibility, offering a novel approach for industries seeking to embrace digital transformation while achieving long-term sustainability. The research contributes to the growing body of knowledge on the synergy between RPA, Big Data, and sustainability in industrial contexts.