Dissertations / Theses on the topic 'Industrial Process Heat (IPH)'

This dissertation is a complete unifying approach to the fundamentals, industrial applications and software implementation of an important branch of process-engineering principles and practice, called process integration. The latter refers to the system-oriented, thermodynamically-based and integrated approaches to the analysis, synthesis and retrofit of process plants, focusing on integrating the use of materials and energy, and minimizing the generation of emissions and wastes. This work extends process integration to include applications for industrial water reuse and wastewater minimization and presents previous developments in a unified manner. The basic ideas of process integration are: (1) to consider first the big picture by looking at the entire manufacturing process as an integrated system; (2) to apply process-engineering principles to key process steps to establish a priori targets for the use of materials and energy, and for the generation of emissions and wastes; and (3) to finalize the details of the process design and retrofit later to support the integrated view, particularly in meeting the established targets. Pinch technology is a set of primarily graphical tools for analyzing a process plant's potential for energy conservation, emission reduction and waste minimization. Here, we identify targets for the minimum consumption of heating and cooling utilities, mass-separating agents, freshwater consumption, wastewater generation and effluent treatment and propose economical grassroots designs and retrofit projects to meet these goals. An emerging alternative approach to pinch technology, especially when analyzing complex water-using operations and effluent-treatment systems, is mathematical optimization. We solve nonlinear programming problems for simple water-using operations through readily available commercial software. However, more complex, nonconvex problems require sophisticated reformulation techniques to guarantee optimality and are the subject of continuing academic and commercial development. This work develops the principles and practice of an environmentally significant breakthrough of process integration, called water-pinch technology. The new technology enables the practicing engineers to maximize water reuse, reduce wastewater generation, and minimize effluent treatment through pinch technology and mathematical optimization. It applies the technology in an industrial water-reuse demonstration project in a petrochemical complex in Taiwan, increasing the average water reuse (and thus reducing the wastewater treatment) in the five manufacturing facilities from 18.6% to 37%. This dissertation presents complete conceptual and software developments to unify the known branches of process integration, such as heat and mass integration, and wastewater minimization, and explores new frontiers of applications to greatly simplify the tools of process integration for practicing engineers.
Ph. D.

 Drying process needs lots of energy and usually prone to high equipment and operational cost. Research tasks have focused on improving the drying performance and reducing the energy consumption rate. Among a number of industries, textile manufacturing needs the process intensively. It is surprising that little research has concerned principle enhancement and drying process design. In the support by Fong’s National Engineering Company Limited, a series of research that targeting to the inadequacy of technology development for machinery and process design have been conducted. The redevelopment of machinery design has based upon a heat setting machine –ECO dryer. The machine was used as a working platform to supply all necessary testing information before and after the enhancement. The ductwork and air distribution system design have been revised to improve the unevenness drying problems appeared in the heat setting of fabrics. Two main research scopes have been performed that included the development of a new duct sizing approach –Uniform Jet Velocity (UJV) and redesigning the air chambers. The proposed UJV approach is a new air duct design model developed from fluid dynamics principles. The air jet speed along each nozzle is maintained at a constant rate to provide a uniform jet impingement effect. A duct size algorithm was proposed to adjust the cross sectional area ratio between the main and branch streams for the target of producing a constant impingement velocity across the entire air duct. In the enhancement of the air distribution system design, Computational Fluid Dynamics (CFD) analytical approaches were used to model air flow patterns before and after the redesign of air chambers. The CFD analysis results told that a linear air distribution system with four sub-chamber design could produce the best air distribution pattern on the ECO dryer. The request of an accurate drying cycle time predication is also large in textile industry. It is because the problems of under-and over-drying usually happen in the jet impingement process. The second essential objective in the research is to develop systematical approaches for a good qualifying of a drying cycle. Four analytical models have been studied that included First order kinetics, Diffusion, model based on solutions of diffusion equation and Wet surface. An equation for each of the models was developed to describe the characteristics of a porous type fabric drying process. In the study, the required modeling parameters were empirically determined, and the accuracy among the models has been compared. Findings from the research have proved that the model based on solutions of diffusion equation can be the best strategy in presenting a drying cycle under different machine settings. The investigation has not ceased after the completion of the hot air jet impingement research. The study objectives have moved onto an alternative drying technology using steam as the drying medium. Due to many problems reported in the drying of yarn packages using electro-magnetic waves, moist heat drying technology is urgently needed. At the final part of the research, two CFD simulation models namely constant viscous resistance and increasing viscous resistance were studied. A preliminary result generated from ANSYS CFD analysis results was obtained that has opened up a new study area for further elaboration of a new drying technology, and hopefully can be practically applied to textile industry in the near future.
published_or_final_version
Mechanical Engineering
Master
Master of Philosophy

At a sawmill, the most energy demanding process is the wood drying. The drying process also has a great impact on quality parameters determined for the boards in the final sorting and thereby affects the sales value to a great extent. The objective of the work described in this compilation thesis was to find ways to improve the industrial wood drying process through better input, feedback and process itself. As input and feedback to the drying process, ways to improve the accuracy in estimating the moisture content (MC) was investigated. For the drying process itself, an investigation of the airflow distribution in a batch kiln at several different fan speeds was performed. Potential energy savings by introducing a new kiln layout was also investigated.To estimate the green MC, i.e. the MC of boards prior to drying, the average green MC of batches rather than individual boards were considered since large batches are handled in the drying anyway. Two different methods were investigated, one method in which the MC of the heartwood was presumed to be constant and a certain relation between the heartwood and sapwood basic density was present. In the other method, the average basic density was estimated as a function of the logs diameters. It was found that both methods worked satisfactory.To improve the accuracy in measuring the MC of the dried boards two approaches were used. The first approach was to combine different measurement techniques, i.e. microwaves and X-rays, to predict the same properties with a multivariate approach. By adding X-ray measurements to microwave measurements, the amount of boards with a predicted MC deviating less than 1% MC from the oven dry reference increased with 7%. The second approach was to investigate the potential of increasing the measurable board area by compensating for the vicinity of the boards edge with aid of a function developed through final element simulations. It was shown that this was possible although the magnitude of the improvement will depend on the actual measurement setup.The airflow distribution in drying was investigated by industrial trials in which the air speed was measured simultaneously at 20 spots throughout the load with the air circulating fans run at a number of different speeds. It was found that the airflow distribution did not change remarkably as a function of the fan speed and once the airflow is measured at a certain fan speed, the effect of changing the fan speed can be estimated using the fan affinity laws. Finally, potential energy savings with a new kiln layout was investigated through drying simulations and associated determinations of the drying air condition in the kiln. It was found that heat savings of roughly 30% could be accomplished in comparison to a kiln with no heat recovery.
Godkänd; 2015; 20150527 (tomvik); Nedanstående person kommer att disputera för avläggande av teknologie doktorsexamen. Namn: Tommy Vikberg Ämne: Träfysik/Wood Physics Avhandling: Industrial wood drying Airflow distribution, Internal Heat Exchange and Moisture Content as Input and Feedback to the Process Opponent: Professor Mihaela Campean, Transilvania University of Brasov, Brasov, Romania Ordförande: Professor Diego Elustondo, Avd för träteknologi, Institutionen för teknikvetenskap och matematik, Luleå tekniska universitet, Skellefteå Tid: Fredag 9 oktober kl 10.00 Plats: Hörsal A i Skellefteå, Luleå tekniska universitet

Solar energy can be converted into heat in small-scale or large-scale systems that work at low, medium or high temperatures. Presently, a major growth is being observed in large-scale systems for district heating and industrial process heat. Linear concentrators have a well-recognized role in this context and new configurations and solutions are in demand. These must be within the scope of product certification schemes, which rely on international testing standards. This thesis discusses the limitations of the current standards for linear concentrators and presents the design and construction of the Solar Concentrators Testing Platform at the University of Évora. The use of ray-tracing simulation tools to complement and extend the experimental results is also explored. This thesis goes on to present the development of new collector solutions for medium temperature applications (100–250 °C). The principles of non-imaging optics were used in the design of low-concentration (1 to 5) linear CPC-type solar reflectors with evacuated receivers that can generate high-performance, flexibly mounted and affordable solutions. Two collector concepts were investigated. The first is a stationary CPC-type collector with acceptance of 90°. The manufacturing process was considered by analysing different virtual absorber geometries. A prototype was built and tested. The second concept is a quasi-stationary CPC-type collector that only requires a few changes in its position along the year and does not need a sun-tracking system. As the search for the optimal collector design for a specific installation is complex, a thermo-economic optimization method was developed. Two prototypes were built and tested in a collaboration with the company MCG mind for metal. This collector, which is now at its final development stage, will be installed at an industrial facility - KEMET Electronics - in Évora, Portugal; Sumário: Concentradores solares lineares: novas ferramentas e infraestruturas de ensaio, aplicação a novos colectores do tipo CPC para calor de processo industrial A energia solar pode ser convertida em calor em sistemas de pequena ou grande escala, que funcionam a baixas, médias ou altas temperaturas. Actualmente, regista-se um grande crescimento na instalação de sistemas de grande escala para redes de calor e calor de processo industrial. Os concentradores lineares têm um papel reconhecido neste contexto e novas configurações e soluções estão em desenvolvimento. Estas devem integrar-se do âmbito dos esquemas de certificação, que se baseiam em normas de ensaio internacionais. Esta tese discute as limitações das normas actuais no ensaio de concentradores lineares e apresenta o projecto e a construção da Plataforma de Ensaio de Concentradores Solares na Universidade de Évora. O uso de ferramentas de simulação, através de técnicas de traçado de raios, é explorado com o fim de complementar e ampliar os resultados experimentais. A tese prossegue apresentando o desenvolvimento de novas soluções de colectores para aplicações a média temperatura (100–250 °C). Os princípios da óptica não reprodutora de imagem foram usados no desenho de refletores solares lineares do tipo CPC, de baixa concentração (1 a 5), com receptores evacuados que podem originar soluções com bom desempenho, montagem flexível e custos acessíveis. Dois conceitos de coletores foram investigados. O primeiro é um coletor estacionário do tipo CPC com aceitação de 90 graus. O processo de fabricação foi considerado através da análise de diferentes geometrias dos absorsores virtuais. Um protótipo foi construído e ensaiado. O segundo conceito é um coletor quasi-estacionário do tipo CPC, que requer apenas algumas mudanças na sua posição ao longo do ano, dispensando sistemas de seguimento solar. Devido à complexidade na definição do design ideal do coletor para uma instalação específica, foi desenvolvido um método de otimização termoeconómica. Foram construidos e ensaiados dois protótipos em colaboração com a empresa MCG mind for metal. Este colector, que se encontra actualmente no seu estágio final de desenvolvimento, será instalado num edifício industrial - a KEMET Electronics - em Évora, Portugal.

Mist or aerosol explosions present a serious hazard to process industries. Heat transfer fluids are widely used in the chemical process industry, are flammable above their flash points, and can cause aerosol explosions. Though the possibility of aerosol explosions has been widely documented, knowledge about their explosive potential is limited. Studying the formation of such aerosols by emulating leaks in process equipment will help define a source term for aerosol dispersions and aid in characterizing their explosion hazards. Analysis of the problem of aerosol explosions reveals three major steps: source term calculations, dispersion modeling, and explosion analysis. The explosion analysis, consisting of ignition and combustion, is largely affected by the droplet size distribution of the dispersed aerosol. The droplet size distribution of the dispersed aerosol is a function of the droplet size distribution of the aerosol formed from the leak. Existing methods of dealing with the problem of aerosol explosions are limited to enhancing the dispersion to prevent flammable concentrations and use of explosion suppression mechanisms. Insufficient data and theory on the flammability limits of aerosols renders such method speculative at best. Preventing the formation of aerosol upon leaking will provide an inherently safer solution to the problem. The research involves the non-intrusive measurement of heat transfer fluid aerosol sprays using a Malvern Diffraction Particle Analyzer. The aerosol is generated by plain orifice atomization to simulate the formation and dispersion of heat transfer fluid aerosols through leaks in process equipment. Predictive correlations relating aerosol droplet sizes to bulk liquid pressures, temperatures, thermal and fluid properties, leak sizes, and ambient conditions are presented. These correlations will be used to predict the conditions under which leaks will result in the formation of aerosols and will ultimately help in estimating the explosion hazards of heat transfer fluid aerosols. Heat transfer fluid selection can be based on liquids that are less likely to form aerosols. Design criteria also can incorporate the data to arrive at operating conditions that are less likely to produce aerosols. The goal is to provide information that will reduce the hazards of aerosol explosions thereby improving safety in process industries.

The industrial sector accounts for a large share of greenhouse gas emissions. To reduce its negative impact on the environment is crucial in the quest for a sustainable future. In discussions of the industrial sector's impact on the environment guidelines have been highlighted as a tool to assist the industries in their efforts to change the relationship between the consumption of energy and production. This by improving energy efficiency and a shift to the best available technology. During the past 30 years the steel industry has reduced its energy consumption per ton of steel produced by 50 percent. However, due to this dramatic improvement in energy efficiency, it is estimated there is now only room for a marginal further improvement on the basis of existing technology. More innovative solutions are therefore required to further improve energy efficiency and achieve a more sustainable use of resources. In a description of the program Efficiency of Energy Use in Industry – Research and Development undertaken by the Swedish Energy Agency the interaction between industry and society is accentuated as an important factor in energy efficiency efforts. Today, there are already several examples of where the industry and the community work together to achieve a better utilization of resources. The steel industry SSAB EMEA has a manufacturing plant in Borlänge, Sweden, where they have been recycling waste heat from the industrial processes for a long period of time. In 1991 SSAB initiated collaboration with the local energy company regarding recovery of waste heat within the industrial enterprise. Since then, SSAB has contributed to the heating of the residences that are connected to the local district heating network. The present study aims to examine the values that the utilization of waste heat add to the industrial company and the community, and to explore how the use of industrial waste heat can be developed ahead. The examination consists of a case study and is mainly based on qualitative interviews with people from SSAB, the local energy company Borlänge Energi, Borlänge Municipality and the Swedish Energy Agency. Some quantitative data, such as measurements of heat deliveries, have also been used for the analysis. In addition a literature review with a focus on district heating in Sweden, industrial waste heat and instruments in energy and climate policy has been conducted. Through varied system levels the waste heat collaboration in Borlänge has been analyzed from a business, social and sustainable perspective. The result of the case study proves that the waste heat collaboration has added value in all perspectives. Business values that have been identified are reduced purchases of oil, compensation for delivered waste heat, exchange from vapour to in-house district heating within the steel factory site, reduced emissions of carbon dioxide, media attention and an improved brand and that the waste heat collaboration possibly made SSAB a more desirable employer. The use of industrial waste heat for district heating in Borlänge has also generated a range of social benefits, which consist of low operating costs for heat, low price of district heating, good energy mix and better air quality and less acidity. From a sustainability perspective, the waste heat utilization resulted in reduced emissions of carbon dioxide and other air pollutants and has been contributive to a sustainable use of raw materials and energy resources. The results also demonstrate that there are both opportunities and threats to a continued use of industrial waste heat. The opportunities identified are regional district heating networks, which can improve the conditions for effective use of waste heat, district cooling, which may increase the need for waste heat in the summer and in-house electricity production, which can accommodate some of the steel company's electricity need. A few threats to a continued use of waste heat have also been identified, which the first consists of co-generation and waste incineration, which can adversely affect energy companies incentives to enter into and renew agreements on waste heat deliveries since the companies do not want to be afflicted with reduced revenues from sales of electricity and electricity certificates or from the reception of waste. Furthermore has changes in energy policy been identified as a threat since for example a new tax on waste heat could worsen the conditions for both continuing and new waste heat collaborations.
Industrisektorn står för en stor andel av växthusgasutsläppen. Att minska dess negativa inverkan på klimatet är således grundläggande i strävan efter ett hållbart samhälle. I diskussioner kring industrisektorns påverkan på miljön har riktlinjer lyfts fram som ett instrument för att bistå industrin i arbetet med att förändra förhållandet mellan konsumtion av energi och produktion. Detta genom en förbättring av energieffektiviteten och en förskjutning till bästa möjliga teknik. Under de senaste 30 åren har stålindustrin reducerat sin energikonsumtion per ton producerat stål med 50 procent. Det sägs dock att dessa dramatiska framsteg i energieffektivitet har lett till att det nu endast finns rum för en marginell fortsatt förbättring förutsatt befintlig teknik. Om så är fallet måste våra vyer vidgas för att vi ska kunna hitta lösningar som innebär större effektivitetsvinster och ett bättre nyttjande av resurser. I en beskrivning av programmet Effektivisering av industrins energianvändning – forskning och utveckling som drivs av Energimyndigheten betonas samspelet mellan industri och samhälle som en viktig faktor i energieffektiviseringsarbetet. Idag finns det redan flera exempel på där industrin och samhället samarbetar för att uppnå ett bättre nyttjande av resurser. I Borlänge har stålföretaget SSAB EMEA en produktionsanläggning där de sedan länge återvinner restenergier från verksamhetens processer. År 1991 ingick SSAB avtal med det lokala energibolaget avseende tillvaratagande av restvärme vid industriföretaget. Sedan dess har SSAB bidragit till uppvärmningen av de bostäder som är anslutna till ortens fjärrvärmenät. Föreliggande studie har som syfte att undersöka vilka värden som tillvaratagandet av restvärmen tillför industriföretaget och samhället, samt ta reda på hur användandet av industriell restvärme kan komma att utvecklas framåt. Undersökningen består av en fallstudie och bygger i huvudsak på kvalitativa intervjuer med personer från SSAB, det lokala energibolaget Borlänge Energi, Borlänge kommun och Energimyndigheten men också på kvantitativ data, såsom mätningar av värmeleveranser. Sedan har även en litteraturstudie genomförts med fokus på fjärrvärme i Sverige, industriell restvärme och styrmedel i energi- och klimatpolitiken. Genom varierade systemnivåer har restvärmesamarbetet i Borlänge analyserats ur företagsekonomiskt, samhällsekonomiskt och hållbart perspektiv. Resultatet av fallstudien visar att restvärmesamarbetet tillfört värden inom samtliga perspektiv. De företagsekonomiska vinster som har identifierats är minskade inköp av olja, ersättning för levererad restvärme, byte från ånga till intern fjärrvärme inom stålföretagets verksområde, minskade utsläpp av koldioxid, medial uppmärksamhet och stärkt varumärke och att restvärmesamarbetet eventuellt gjort SSAB till en mer attraktiv arbetsgivare. Användandet av industriell restvärme som fjärrvärme i Borlänges lokala fjärrvärmenät har även genererat en rad samhällsekonomiska vinster, vilka utgörs av låg driftskostnad för värmeproduktion, lågt pris på fjärrvärme, bra miljömix samt bättre luftkvalitet och mindre försurning. Ur ett hållbarhetsperspektiv har restvärmenyttjandet resulterat i minskade utsläpp av koldioxid och andra luftföroreningar och varit bidragande till ett hållbart nyttjande av råvaror och energiresurser. Resultatet visar också att det finns både möjligheter och hot för ett fortsatt användande av industriell restvärme. De möjligheter som identifierats är regionala fjärrvärmenät, som genom omfattande värmeunderlag kan förbättra förutsättningarna för effektiv användning av restvärmen, fjärrkyla, som kan öka behovet av restvärmen under sommarhalvåret och egen elproduktion, som kan tillgodose en del av industriföretagets elbehov. Sedan har även hot för ett fortsatt användande av restvärme identifierats, vilken den första utgörs av kraftvärme och avfallsförbränning, som kan inverka negativt på energibolags incitament till att ingå och förnya avtal om restvärmeleveranser då bolagen inte vill riskera att drabbas av minskade intäkter från försäljning av el och elcertifikat eller från mottagande av avfall. Även förändringar i energipolitiken har identifierats som ett hot då exempelvis en ny beskattning på restvärme kan försämra förutsättningarna för både fortsatta och nya restvärmesamarbeten.

Thesis (Ph. D.)--Ohio State University, 2004.
Title from first page of PDF file. Document formatted into pages; contains xx, 199 p.; also includes graphics. Includes bibliographical references (p. 196-199).

Orientador: Antonio Carlos Luz Lisboa
Dissertação (mestrado) - Universidade Estadual de Campinas, Faculdade de Engenharia Quimica
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Resumo: O xisto é uma rocha betuminosa sedimentar rica em querogênio, a qual pode ser extraída sob a forma de óleo e gás, hidrocarbonetos com aplicação similares a dos produtos derivados do petróleo. A etapa industrial do processamento do xisto que demanda maiores investimentos é a extração da matéria orgânica da rocha por aquecimento (pirólise) em um equipamento denominado retorta, contendo o gás de pirólise. A descrição das trocas de calor entre as partículas de rocha e o gás leito de pirólise pode ser avaliada por modelos matemáticos e numéricos. Nesse contexto, a proposta do trabalho foi elaborar e solucionar um modelo matemático que descreve o gradiente térmico no interior das partículas de xisto e do gás nas fases de troca de calor dentro da retorta. Os dados para a elaboração do modelo foram obtidos na usina comercial de xisto da Petrobrás. Consideram-se as propriedades físicas da partícula, tais como calor específico, condutividade térmica e o coeficiente de transferência de calor. Verificam-se também os balanços de energia no reator. Com o resultado do modelo para o balanço térmico no reator considerando gradiente de temperatura no interior das partículas foi possível observar como ocorre a influência da temperatura do gás no perfil de temperatura da partícula
Abstract: Shale is a sedimentary rock rich in kerogen, organic complex mixture which can be extracted in the form of oil and gas. Industrial shale processing description is based models representing the heat transfer in drying, heating and pyrolysis. The extraction of organic matter from rock by heating (pyrolysis) is a great investment on industrial process. The condition of the rock particles along the retort, which occurs the extraction, can be assessed by mathematical and numerical models. In this context, the purpose of this study was to develop and solve a mathematical model that describes the thermal gradient inside the particles of shale and gas in the retort. Data for developing the model were obtained from Petrobras. It was considered the physical properties of the particle, such as specific heat, density, thermal conductivity and coefficient of heat transfer. There are also the energy balances in the reactor. Model results for the heat balance in the reactor considering temperature gradient within the particles shows the influence of the gas temperature in the temperature profile of the particle
Mestrado
Engenharia de Processos
Mestre em Engenharia Química

Neste trabalho, foi estudado o desempenho de um sistema constituído de torres de resfriamento e a sua integração em uma planta industrial de hidrogenação de butadieno. Caracterizou-se o desempenho das torres de resfriamento com base em um modelo fenomenológico, cujos parâmetros foram obtidos a partir da medição de variáveis operacionais reais. O processo de hidrogenação foi configurado em um simulador de processos, sendo o caso base estabelecido nas condições de projeto. Elaborou-se um módulo específico referente às torres de resfriamento, que foi integrado ao processo configurado no simulador. Em seguida, analisaram-se as interações das condições operacionais da torre de resfriamento no desempenho do processo industrial.
In the present work, the performance of a system composed of a cooling tower integrated in butadiene hydrogenation plant was studied. An experimental investigation was made to characterize the cooling towers based on a phenomenological model and in real process conditions. The hydrogenation process was configured on a process simulator and design specifications were considered as base case. A cooling tower module was developed and integrated to the process simulator. The interaction of the cooling tower system and the plant operation was investigated.

Este trabalho tem por objetivo analisar as perspectivas dos gases combustíveis como energia final para a obtenção de energia útil, em aquecimento direto (AD) e calor de processo (CP), identificando e quantificando potenciais como alternativa da eletrotermia. São comparados dois panoramas na avaliação das economias de energia primária pela substituição da eletrotermia: o primeiro considerando que a energia substituída oriunda de energéticos do parque gerador; e o segundo levando em conta que a redução se refletiu nas termelétricas. Para atingir este objetivo, o trabalho se inicia com uma revisão bibliográfica, onde são tratados os aspectos necessários para um melhor entendimento do texto, com os conceitos de eletrotermia, calor e termodinâmica, seguindo-se um capítulo destinado aos gases combustíveis, suas características e disponibilidade futura para a conversão. As informações básicas para a análise dos potenciais nos setores foram tomadas a partir do último Balanço de Energia Útil, além de trabalhos desenvolvidos no mercado industrial pelo autor. O trabalho discorre também sobre configurações tecnológicas usadas nas conversões, incluindo os custos envolvidos. Na conclusão, os cálculos mostraram que significativas economias de energia primária podem ser obtidas com a conversão da eletrotermia para gases combustíveis no setor industrial brasileiro, considerando a eletricidade produzida a partir de plantas termelétricas.
This paper aims to analyze the prospects of fuel gases as final energy in order to get useful energy in direct heating and process heat, identifying and qualifying potentials as the alternative of electrothermy. Two panoramas are compared in the evaluation of primary energy displacement: the first one considering the replaced energy coming from energy generating facilities and the second taking into account that the reduction was reflected in thermoelectric power plants. To achieve this goal, the work begins with a literature review which covers the aspects needed for a better understanding of the text, with the concepts of electrothermy, heat and thermodynamics, followed by a chapter intended for fuel gases, their characteristics and future readiness for conversion. The basic information for the analysis of potential sectors were taken for the last Useful Energy Balance, and work undertaken by the author in the industrial market. The paper also discourses about technological configurations used in conversions, including also the costs involved. In conclusion, the calculations showed that significant primary energy savings can be obtained through the conversion of electrothermy by fuel gases in the Brazilian industrial sector, taking into account the electricity produced from thermoelectric power plants.

The objective of this thesis was to investigate the potential for introducing a concentrating solar thermal (CST) central receiver plant system based on flexible heliostats - HelioPods - to provide high-temperature process heat in industrial applications. A CST plant system was designed in MATLAB, optically simulated for three design days in the ray-tracing software Tonatiuh and further analyzed in MATLAB by interpolating the results for each hour of the year. A case study was made on introducing a CST plant system based on HelioPods in a South African manganese sinter plant. The study included an investigation of the profitability of up- and downsizing the heliostat field annually with fluctuating heat demand. A circular heliostat field was modelled for the chosen location. The final field had a radius of 53 meters with the receiver located 60% from the field centre. The storage size was 16 demand hours and 17 plants were required. The results showed that 88% of the annual heat demand could be covered by solar heat in the design year. The marketing approach used for the following years was that the heat demand covered by solar heat should never be below the share at the first year, despite the predicted fluctuations in demand. Thus, a minimum solar share of 88% was used as a strategy for annual up- and downsizing of the fields throughout the investigated period of 25 years. That resulted in a field radius differing between 52 and 55 meters. The payback period of the final system was 4.35 years, the NPV was 54.33 MUSD over a period of 25 years and the LCOH was 35.39 USD/MWht. However, it was found that the profitability of the system was sensitive to the different scenarios for predicted future diesel prices, this since the pricing of the solar heat was set to 90% of the diesel price. The results in this thesis show that a CST plant system based on HelioPods is a suitable solution to supply high-temperature process heat to industrial applications. It also shows that the HelioPods can unlock potential for flexibility with changing production patterns in the industry of implementation. The results from the study can be used also for other industries with similar temperature range and heat demand. Thus, it could be argued that the implementation of a HelioPod based CST plant system also can be suitable for other industries located in high-DNI areas with dependency on conventional fuels and steady production throughout the whole day.
Syftet med denna uppsats var att undersöka potentialen för implementering av koncentrerad termisk solvärme (CST) från ett soltorn med ett heliostatfält baserat på flexibla heliostater - HelioPods – för att generera högtempererad processvärme för industriell tillämpning. Ett CST-system designades i MATLAB, simulerades för tre designdagar i det optiska ray-tracingprogrammet Tonatiuh och analyserades sedan åter i MATLAB genom att interpolera de genererade resultaten för årets alla timmar. En fallstudie av ett CST-system baserat på HelioPods i ett sydafrikanskt sinterverk för mangan genomfördes därefter. Studien innehöll en undersökning av lönsamheten av årlig ökning och minskning av heliostatfältet vid fluktuerande värmebehov. Ett cirkulärt heliostatfält modellerades för den valda platsen. Det slutgiltiga fältet hade en radie om 53 meter med mottagaren placerad 60% från fältets mittpunkt. Storleken på lagringsfaciliteten var 16 timmar av full tillförsel och antalet verk uppgick till 17. Resultaten visade att 88% av det årliga värmebehovet kunde förses med solvärme under designåret. Marknadsstrategin för de resterande åren var att den procentuella andelen solvärme aldrig skulle vara lägre än under designåret, oberoende av fluktuationer i värmebehovet på grund av ändrad produktion. Således sattes 88% solvärme som ett minimikrav och utgjorde strategin för den årliga ökningen och minskningen av fältet för den undersökta perioden av 25 år. Det resulterade i en fältradie mellan 52 och 55 meter. Återbetalningstiden för det slutgiltiga fältet var 4.35 år, nuvärdesberäkningen av det framtida kassaflödet var 54.22 miljoner USD över en 25-årsperiod och produktionskostnaden för värme (LCOH) var 35.39 USD/MWht. Dock var systemets lönsamhet känslig för de olika prognoser av framtida dieselpriser som undersöktes, detta eftersom priset för solvärme sattes till 90% av dieselpriset. Resultaten i denna uppsats visar att ett CST-system baserat på HelioPods är en lämplig lösning för att generera högtempererad processvärme för industriell tillämpning. De visar även att HelioPods kan öka potentialen för flexibilitet vid förändringar i produktionsmönstret i vederbörande industri. Resultaten kan även användas i andra industrier med likartade temperaturer och värmebehov. Hävdas kan således att implementation av ett CST-system kan vara lämpligt även för andra industrier belägna i områden med högt DNI som är beroende på konventionella energikällor och har jämn produktion dygnet runt.

Catalytic hydrotreating (HDT) is a mature process technology practiced in the petroleum refining industries to treat oil fractions for the removal of impurities (such as sulfur, nitrogen, metals, asphaltene). Hydrotreating of whole crude oil is a new technology and is regarded as one of the more difficult tasks that have not been reported widely in the literature. In order to obtain useful models for the HDT process that can be confidently applied to reactor design, operation and control, the accurate estimation of kinetic parameters of the relevant reaction scheme are required. This thesis aims to develop a crude oil hydrotreating process (based on hydrotreating of whole crude oil followed by distillation) with high efficiency, selectivity and minimum energy consumption via pilot plant experiments, mathematical modelling and optimization. To estimate the kinetic parameters and to validate the kinetic models under different operating conditions, a set of experiments were carried out in a continuous flow isothermal trickle bed reactor using crude oil as a feedstock and commercial cobaltmolybdenum on alumina (Co-Mo/¿-Al2O3) as a catalyst. The reactor temperature was varied from 335°C to 400°C, the hydrogen pressure from 4 to10 MPa and the liquid hourly space velocity (LHSV) from 0.5 to 1.5 hr-1, keeping constant hydrogen to oil ratio (H2/Oil) at 250 L/L. The main hydrotreating reactions were hydrodesulfurization (HDS), hydrodenitrogenation (HDN), hydrodeasphaltenization (HDAs) and hydrodemetallization (HDM) that includes hydrodevanadization (HDV) and hydrodenickelation (HDNi). An optimization technique is used to evaluate the best kinetic models of a trickle-bed reactor (TBR) process utilized for HDS, HDAs, HDN, HDV and HDNi of crude oil based on pilot plant experiments. The minimization of the sum of the squared errors (SSE) between the experimental and estimated concentrations of sulfur (S), nitrogen (N), asphaltene (Asph), vanadium (V) and nickel (Ni) compounds in the products, is used as an objective function in the optimization problem using two approaches (linear (LN) and non-linear (NLN) regression). The growing demand for high-quality middle distillates is increasing worldwide whereas the demand for low-value oil products, such as heavy oils and residues, is decreasing. Thus, maximizing the production of more liquid distillates of very high quality is of immediate interest to refiners. At the same time, environmental legislation has led to more strict specifications of petroleum derivatives. Crude oil hydrotreatment enhances the productivity of distillate fractions due to chemical reactions. The hydrotreated crude oil was distilled into the following fractions (using distillation pilot plant unit): light naphtha (L.N), heavy naphtha (H.N), heavy kerosene (H.K), light gas oil (L.G.O) and reduced crude residue (R.C.R) in order to compare the yield of these fractions produced by distillation after the HDT process with those produced by conventional methods (i.e. HDT of each fraction separately after the distillation). The yield of middle distillate showed greater yield compared to the middle distillate produced by conventional methods in addition to improve the properties of R.C.R. Kinetic models that enhance oil distillates productivity are also proposed based on the experimental data obtained in a pilot plant at different operation conditions using the discrete kinetic lumping approach. The kinetic models of crude oil hydrotreating are assumed to include five lumps: gases (G), naphtha (N), heavy kerosene (H.K), light gas oil (L.G.O) and reduced crude residue (R.C.R). For all experiments, the sum of the squared errors (SSE) between the experimental product compositions and predicted values of compositions is minimized using optimization technique. The kinetic models developed are then used to describe and analyse the behaviour of an industrial trickle bed reactor (TBR) used for crude oil hydrotreating with the optimal quench system based on experiments in order to evaluate the viability of large-scale processing of crude oil hydrotreating. The optimal distribution of the catalyst bed (in terms of optimal reactor length to diameter) with the best quench position and quench rate are investigated, based upon the total annual cost. The energy consumption is very important for reducing environmental impact and maximizing the profitability of operation. Since high temperatures are employed in hydrotreating (HDT) processes, hot effluents can be used to heat other cold process streams. It is noticed that the energy consumption and recovery issues may be ignored for pilot plant experiments while these energies could not be ignored for large scale operations. Here, the heat integration of the HDT process during hydrotreating of crude oil in trickle bed reactor is addressed in order to recover most of the external energy. Experimental information obtained from a pilot scale, kinetics and reactor modelling tools, and commercial process data, are employed for the heat integration process model. The optimization problem is formulated to optimize some of the design and operating parameters of integrated process, and minimizing the overall annual cost is used as an objective function. The economic analysis of the continuous whole industrial refining process that involves the developed hydrotreating (integrated hydrotreating process) unit with the other complementary units (until the units that used to produce middle distillate fractions) is also presented. In all cases considered in this study, the gPROMS (general PROcess Modelling System) package has been used for modelling, simulation and parameter estimation via optimization process.
Tikrit University, Iraq

L’industrie de métallurgie est demandeuse de propriétés thermophysiques essentielles pour la modélisation et l’optimisation des procédés d’élaborations.Les propriétés thermophysiques des métaux et des alliages métalliques à l’état liquide sont mal connues. Ces propriétés dépendent de la température et sont difficiles à mesurer surtout à haute température. A l’état liquide, le métal est réactif et facilement polluable. Dans les années 1980, Egry a développé un lévitateur électromagnétique TEMPUS pour mesurer en apesanteur sans contact matériel les propriétés thermophysiques des métaux et alliages en fusion. Dans l’espace, les effets du brassage électromagnétique et de la déformation des échantillons fondus sont beaucoup plus faibles que sur terre.L’emploi de cet outil spatial est coûteux. C’est pour, à terme, diminuer les coûts tout en maintenant voire améliorant la qualité des mesures, que nous avons souhaité remplacer la microgravité par un champ magnétique continu.Les travaux réalisés dans cette thèse consistent à mesurer les propriétés thermiques des métaux par procédé électromagnétique en utilisant une méthode de calorimétrie modulée.Elle comporte deux parties.-Une partie numérique dans laquelle nous avons simulé d’une part le lévitateur spatial TEMPUS et d’autre part le lévitateur terrestre AEXAM.La simulation du lévitateur spatial TEMPUS a pour but de déterminer l’effet de la superposition de courants inducteurs de fréquences différentes (courants de chauffage et de centrage) sur les comportements hydrodynamique et thermique de la goutte. Les résultats des calculs nous ont montré que le courant de centrage est susceptible d’agir sur les mesures.La simulation du lévitateur terrestre AEXAM consiste à déterminer la fréquence d’oscillation verticale de la goutte, la puissance Joule dissipée dans celle-ci, les champs de vitesse et de température. La goutte prend la forme d’une poire et elle oscille à une fréquence de 7 Hz. La puissance Joule dissipée dans la charge est maximale vers le bas de la charge dans les premiers millimètres à mi-hauteur entre l’équateur et le pôle. Elle diminue en pénétrant dans la charge et est nul sur l’axe de symétrie. La convection dans la goutte crée un brassage électromagnétique et homogénéise le champ de température.-Une partie expérimentale dans laquelle le lévitateur AEXAM a été placé dans un champ magnétique continu horizontal pour amortir l’oscillation verticale et le brassage électro-magnétique de la goutte mentionnée dans les calculs. Ceci nous a permis la mise en œuvre d’un protocole de mesure original sur un métal liquide. Ce protocole est un programme de traitement des donnés basé sur le comportement du champ de température lorsque les sources thermiques internes à l’échantillon sont instationnaires. Dans ce programme, nous avons utilisé une fonction d’identification qui permet d’obtenir un modèle mathématique à partir de mesures. Pour obtenir un modèle mathématique consistant, il est important d'exciter le système avec toutes les fréquences de sa plage de fonctionnement. C’est ce que nous faisons quand nous appliquons un bruit blanc sur la consigne d’entrée du générateur. Nous avons précédemment validé le protocole sur du solide en remontant aux valeurs de la capacité calorifique et de la conductivité thermique.Pour optimiser les pertes de masse, les instabilités sur les mesures du courant inducteur et la bonne reproductivité des mesures sur une goutte, nous avons choisi une masse initiale de 3,5 g pour faire les mesures avec modulation du courant inducteur dans un champ magnétique continu de 1 Tesla. Nous avons obtenu les valeurs de la capacité calorifique et de la conductivité thermique de la goutte. Celles-ci sont voisines des valeurs données par la littérature. Ce qui nous a permis de valider en partie le protocole de traitement des mesures.Dans le futur, ce protocole peut être appliqué sur des alliages métalliques
The metal industry is requesting essential thermophysical properties for modeling and optimizing elaboration processes.Thermophysical properties of metals and metal alloys in liquid state are well known. These properties depend on the temperature and are difficult to measure especially at high temperature. In the liquid state, the metal is reactive and easily contaminated .In the 1980s, Egry developed an electromagnetic levitator TEMPUS developed an electromagnetic levitator TEMPUS to measure thermophysical properties of molten metals and alloys using a contactless technique under microgravity conditions. In space, the effects of electromagnetic stirring and deformation in molten samples are much lower than on Earth.The use of this space tool is expensive. In order to reduce the cost while maintaining or even improving the quality of measurements, we wanted to replace microgravity by a continuous magnetic field.The work in this thesis includes measuring the thermal properties of metals by electromagnetic method using a modulated calorimetry technique.The work has been divided in two parts:-The first consisted in the numerical simulation of space levitator TEMPUS and a terrestrial levitator AEXAM.The numerical simulation of space levitator TEMPUS aims to determine the effect of the superposition currents of different induction frequencies (heating currents and centering) on the hydrodynamic and thermal behavior of the drop. Calculation results showed that in some cases the centering current is likely to act on the measures and therefore it should be taking into account.The numerical simulation of terrestrial levitator AEXAM was destined to determine the vertical oscillation frequency of the drop, the power dissipated, the velocity fields developed inside and temperature. The drop takes the form of a pear and oscillates at a frequency of 7 Hz. The Joule power dissipated in the load is maximum on the lower part of the drop and decreases towards the interior of the drop vanishing at the center. Convection in the drop creates an electromagnetic stirring and homogenizing the temperature field.-The second part present the experiments performed using the levitator AEXAM placed in a horizontal continuous magnetic field for dampening the vertical oscillation and the turbulence produced by the effect of the electromagnetic stirring as it was mentioned in the calculations.This allowed us the implementation of a new protocol for measuring thermal properties in liquid metals.The protocol is a post processing program based on the temperature field variation resulting from unsteady joule power dissipation in the charge. An implemented identification function provides a mathematical model based on performed measurements. The use of a wide range of system frequencies was required to obtain a robust mathematical model. This was achieved by using pseudo-white noise perturbation at the generator inlet. The program has been validated successfully on solid matter by reverse determination of thermal conductivity and heat capacity.The preliminary studies under continuous magnetic field without modulation have mounted for a maximum initial weight of 3.5, we have less mass loss and improved measurement stability of the inductor current, as well as the reproductivity of the measurements.The protocol was validated successfully on the liquid charge using modulated perturbation under a continuous magnetic field of 1 Tesla. The obtained values of the heat capacity and thermal conductivity were comparable to the values given by the literature which partially validates the protocol.As a perspective, this protocol can be applied to a wide range of metal alloys

碩士
國立臺灣大學
化學工程學研究所
101
This thesis aims at developing a mathematical model for the synthesis of a heat exchanger network which can integrate with the organic rankine cycle (ORC) for recovery of low-grade waste heat. An integrated stagewise superstructure, which is analogous to the superstructure introduced by Yee and Grossmann for the synthesis of heat exchanger networks, is proposed for including the ORC as part of the heat recovery system. The integrated stagewise superstructure can represent all possible interconnections and interactions between process streams and the ORC. Based on this superstructure, the synthesis of heat exchanger networks with the ORC streams is formulated as a mixed-integer nonlinear program (MINLP). A two-steps solution method is suggested to solve the MINLP problem: (1) A heat exchanger network excluding the ORC is solved for minimizing the utility consumption; (2) Based on the results of step one, a modified network including the ORC below the pinch point is synthesized for maximizing the generated work from the ORC turbine. Some numerical examples from the literature are supplied to demonstrate the applicability the the proposed approach.