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Development of Mistmeister, a Solution for Oil Mist in Factories

February 10, 2015 - SHINRYO CORPORATION (“SHINRYO”) has developed Mistmeister, a technology for tackling the problem of oil mist in factories. This technology provides a highly effective analytical approach for diagnosing and addressing the problem of oil mist.

Oil mist is a common problem in the productive processes of factories. In plants where oil is forced through narrow spaces or comes into contact with hot surfaces, oil droplets can become suspended in the factory air, posing a danger to workers’ health and adversely affecting product yield. Current measures against oil mist suffer from a number of problems. In the ventilation approach, outside air is forced into the plant. This approach requires processing of the outside air, increasing energy consumption and swelling running costs. Electric dust collectors can be installed at relatively low running cost, but establishing the right installation position and airflow can be tricky; if these are not incorrect, effectiveness in oil-mist removal can be seriously compromised. Achieving an effective solution against oil mist requires an accurate grasp of how the oil mist is generated. Until now, technologies for this purpose have been lacking, and accurately measuring oil-droplet concentration has proven difficult. SHINRYO developed the Mistmeister to address these issues, delivering a comprehensive solution to the problem of oil mist.

The Mistmeister is an oil-mist solution developed by SHINRYO. It combines a measurement technology, which accurately quantifies the concentration of oil droplets in the air, with an analytical technology called computational fluid dynamics (CFD), which draws on the measured values to build a highly accurate numerical simulation of mist behavior. Based on actual measurements of oil-mist concentration in the factory, the generated volume of oil mist is calculated and entered into the calculation parameters for CFD analysis. The resulting CFD analysis is highly accurate, delivering accurate reproduction of the distribution of oil-mist concentration in the factory air. The Mistmeister thus serves as a diagnostic tool, enabling factory management to pinpoint the source of the oil and causes of its dispersion, leading to the formation of an accurate and effective solution.

The Mistmeister operates by a three-step process as described below.

1. Measurement of oil mist using the latest instruments
  The Mistmeister uses the latest measuring instruments, capable of measuring oil-mist concentration for each droplet size. Using this technology, the Mistmeister measures and surveys the sources of mist in the factory and the volumes of mist generated.
2. Forecasting of oil-mist behavior using CFD analysis

The CFD uses the measurement data obtained in 1) above as a forecast of future oil-mist volume. Applying this forecast as a calculation parameter, the CFD calculates the expected distribution of oil-mist concentration in the air with high precision. In this way oil-mist generation and dispersion in the factory, formerly considered extremely difficult to grasp, is faithfully reproduced, pinpointing the causes of damage from oil mist.

3. Test-run simulations of proposed solutions
  With the causal factors established, solutions can be proposed. The Mistmeister uses simulations based on CFD analysis to forecast the effectiveness of each proposed solution (Figure 1), ensuring the proposal of accurate and effective solutions. For example, the simulations can identify the minimum amount of outside air necessary to improve the environment, as well as the optimum placement and minimum necessary number of electric dust collectors. Factory management can thus propose an ideal solution, yielding energy savings and reduced running costs.

Figure 1@Sample Comparison

Figure 2 <Reference> Process of Mistmeister, a Solution for Oil Mist

Development of a Room Visualization System for data centers

January 22, 2015 - SHINRYO CORPORATION (gSHINRYOh) has developed a Room Visualization System which uses CFD technology to automatically display the temperature and airflow in the server room of data centers.
In order to protect servers, appropriate temperature control is required in the server room of data centers. However, it is difficult to maintain appropriate temperature control when replacing servers, adding servers, or changing the layout.
Furthermore, in order to conduct appropriate temperature control of a server room, it is necessary to install a large number of temperature sensors throughout the entire room. This is not a practical solution because such sensors are a hindrance when conducting maintenance and changing the position or model of servers.
In response, SHINRYO used our unique in-house CFD (Computation Fluid Dynamics) analysis technology to develop a Room Visualization System which automatically provides visual display of the temperature and airflow in the server room. Please refer to gFigure 1: System Overview.h
This system conducts CFD analysis based on the operation status of servers and air conditioning equipment. The system features a gCFD Auto-Execution Functionh which automatically calculates the temperature and airflow in the server room at fixed intervals. This system makes it possible to continuously monitor changes in temperature and wind speed without installing numerous temperature sensors throughout the server room. Please refer to gFigure 2: CFD Auto-Execution Function.h
Moreover, the visualized data is automatically accumulated (Auto-Report Function), making it easy to identify problems in the server room. This data can be used to reform the room environment or to perform renewal work for existing servers. Please refer to gFigure 3: Auto-Report Function.h
SHINRYO will conduct proposal-based sales using this system. We will target customers experiencing difficulty in controlling server temperature in data center server rooms, or having difficulty control temperature and airflow when replacing servers, adding servers, or changing the layout.

System Overview
Figure 1: System Overview

CFD Auto-Execution Function

Figure 3: Auto-Report Function
Figure 2: CFD Auto-Execution Function
Figure 3: Auto-Report Function

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