Estudo e análise de sistemas de refrigeração industrial integrados a plantas de processo químico

This work approaches the analysis of industrial refrigeration systems applied to a chemical processing industry that, in this case, consists of refrigeration machines, cooling tower system, cold water system and brine system. In this study it is highlighted the function and characteristics of different systems, including the main components, the most important features, their functionality and best practices. The motivation for this work is the fact that refrigeration systems are essential in many industrial processes, presenting a high energy consumption that is related to a significant parcel of production costs. It has aimed to understand the case studied in order to evaluate the energy efficiency of systems and to compare with Carnot efficiency and best available technologies. The assessment aims to identify irregularities, find opportunities and propose solutions that increases the performance of equipment and the overall system efficiency. Therefore, the studies intend to reduce the operation costs and generate gains for the company

Real time optimization in chemical process: evaluation of strategies, improvements and industrial application.

The increasing economic competition drives the industry to implement tools that improve their processes efficiencies. The process automation is one of these tools, and the Real Time Optimization (RTO) is an automation methodology that considers economic aspects to update the process control in accordance with market prices and disturbances. Basically, RTO uses a steady-state phenomenological model to predict the process behavior, and then, optimizes an economic objective function subject to this model. Although largely implemented in industry, there is not a general agreement about the benefits of implementing RTO due to some limitations discussed in the present work: structural plant/model mismatch, identifiability issues and low frequency of set points update. Some alternative RTO approaches have been proposed in literature to handle the problem of structural plant/model mismatch. However, there is not a sensible comparison evaluating the scope and limitations of these RTO approaches under different aspects. For this reason, the classical two-step method is compared to more recently derivative-based methods (Modifier Adaptation, Integrated System Optimization and Parameter estimation, and Sufficient Conditions of Feasibility and Optimality) using a Monte Carlo methodology. The results of this comparison show that the classical RTO method is consistent, providing a model flexible enough to represent the process topology, a parameter estimation method appropriate to handle measurement noise characteristics and a method to improve the sample information quality. At each iteration, the RTO methodology updates some key parameter of the model, where it is possible to observe identifiability issues caused by lack of measurements and measurement noise, resulting in bad prediction ability. Therefore, four different parameter estimation approaches (Rotational Discrimination, Automatic Selection and Parameter estimation, Reparametrization via Differential Geometry and classical nonlinear Least Square) are evaluated with respect to their prediction accuracy, robustness and speed. The results show that the Rotational Discrimination method is the most suitable to be implemented in a RTO framework, since it requires less a priori information, it is simple to be implemented and avoid the overfitting caused by the Least Square method. The third RTO drawback discussed in the present thesis is the low frequency of set points update, this problem increases the period in which the process operates at suboptimum conditions. An alternative to handle this problem is proposed in this thesis, by integrating the classic RTO and Self-Optimizing control (SOC) using a new Model Predictive Control strategy. The new approach demonstrates that it is possible to reduce the problem of low frequency of set points updates, improving the economic performance. Finally, the practical aspects of the RTO implementation are carried out in an industrial case study, a Vapor Recompression Distillation (VRD) process located in Paulínea refinery from Petrobras. The conclusions of this study suggest that the model parameters are successfully estimated by the Rotational Discrimination method; the RTO is able to improve the process profit in about 3%, equivalent to 2 million dollars per year; and the integration of SOC and RTO may be an interesting control alternative for the VRD process.

Análise de confiabilidade de um moto-ventilador centrífugo: aplicação no sistema de pressurização de subestação industrial para garantia da segurança operacional na indústria petroquímica

The need of the oil industry to ensure the safety of the facilities, employees and the environment, not to mention the search for maximum efficiency of its facilities, makes it seeks to achieve a high level of excellence in all stages of its production processes in order to obtain the required quality of the final product. Know the reliability of equipment and what it stands for a system is of fundamental importance for ensuring the operational safety. The reliability analysis technique has been increasingly applied in the oil industry as fault prediction tool and undesirable events that can affect business continuity. It is an applied scientific methodology that involves knowledge in engineering and statistics to meet and or analyze the performance of components, equipment and systems in order to ensure that they perform their function without fail, for a period of time and under a specific condition. The results of reliability analyzes help in making decisions about the best maintenance strategy of petrochemical plants. Reliability analysis was applied on equipment (bike-centrifugal fan) between the period 2010-2014 at the Polo Petrobras Guamaré Industrial, situated in rural Guamaré municipality in the state of Rio Grande do Norte, where he collected data field, analyzed historical equipment and observing the behavior of faults and their impacts. The data were processed in commercial software reliability ReliaSoft BlockSim 9. The results were compared with a study conducted by the experts in the field in order to get the best maintenance strategy for the studied system. With the results obtained from the reliability analysis tools was possible to determine the availability of the centrifugal motor-fan and what will be its impact on the security of process units if it will fail. A new maintenance strategy was established to improve the reliability, availability, maintainability and decreased likelihood of Moto-Centrifugal Fan failures, it is a series of actions to promote the increased system reliability and consequent increase in cycle life of the asset. Thus, this strategy sets out preventive measures to reduce the probability of failure and mitigating aimed at minimizing the consequences.

Estratégias de Competitividade Industrial em Empresas Cooperativas: O caso COMTERN

CAMPOS,Maria da Luz Góis; ANEZ,Miguel Eduar- do Moreno; CARÍCIO,Marcelo Rique. Estratégias de Competitividade Industrial em Empresas Cooperativas:O caso COMTERN. In:ENCONTRO NACIONAL DE ENGENHARIA DE PRODUÇÃO, 23, 2003, Minas Gerais. Anais...Ouro Petro: ADEPRO, 2003. p. 1-8.

Relações interorganizacionais e eficiência coletiva: um estudo de caso no arranjo produtivo local de confecções do Agreste de Pernambuco

This work is a study in the Local Productive Arrangement of confections from Agreste of Pernambuco, as a relevant sector in economic and social aspect. This research has as central aim to understand how the inter-organizational relations influence the collective efficiency of arrangement. The theoretical framework employed highlights the approaches that deal with the benefits of business agglomeration for the develop­ment of firms and regions. It has discussed the approach of small and medium enter­ prises and industrial districts (SCHMITZ, 1997), which introduce the concept of col­ lective efficiency, explaining that only those externalities explained by Marshall (1996) are not sufficient to explain the competitive advantage of enterprises, expand­ing the idea that organizations achieve competitive advantage not acting alone. To examine the influences of relations in the collective efficiency, it has been taken as analytical perspective theory of social networks (GRANOVETTER, 1973, 1985; BURT, 1992; UZZI, 1997) because it has believe that this approach provides subsi­ dies for a structural analysis of social relationships in face the behavior of human ac­tion. By examining the organizations in a social network, you should understand the reason of this establishment of the relationship, their benefits, and as the information flow takes place and density of links between the actors (Powell; SMITH-DOERR, 1994). As for the methods, this study is characterized as a case study, in according to the purposed objectives, in addition to qualitative method. Also, due to recovering of the historical milestones of the arrangement, it is used a sectional approach with longitudinal perspective (VIEIRA, 2004). The primary and secondary data were used in order to understand the evolutionary process of the sector and their inter-actors re­ lationships in the arrangement for the promotion of development, for both, was used the contend and documentary analysis technique, respectively (DELLAGNELO ; SIL­VA, 2005). The approach of social networks has permitted understand that social re­lationships may extend the collective efficiency of the arrangement, and therefore need to develop policies that encourage the legalization of informal companies in ar­rangement, by showing up themselves representative. Thus, the relations estab­ lished in LPA of confections from Agreste of Pernambuco need for more effective mechanisms to broaden the collective efficiency. Therefore, this way as take place has directly benefited only a group of companies that are linked in some way the sup­portive institutions. So we can conclude that the inter-actor relations have limited the collective efficiency of LPA, being stimulated by the institutions in support only to groups of entrepreneurs, even those that produce external relations for all clustered companies

Sensores de oxigénio para uso industrial

O presente trabalho incidiu sobre uma família de eletrólitos sólidos cerâmicos à base de óxido de zircónio, incluindo ainda óxido de magnésio como dopante, normalmente designados de Mg-PSZ (zircónia parcialmente estabilizada com magnésia). Dependendo da composição e condições de processamento (perfil de sinterização) estes materiais podem exibir interessantes combinações de propriedades mecânicas, térmicas e elétricas que permitem a sua utilização no fabrico de sensores de oxigénio para metais fundidos. O uso de sensores é hoje essencial numa lógica de controlo de processo e eficiência energética. No sentido de tentar compreender como influenciar estas propriedades, exploraram-se diversos níveis de dopante (de 2,5 até 10 mol%, com acréscimos de 2,5 mol% de MgO), diversas velocidades de arrefecimento (2, 3 e 5 °C.min-1) a partir de uma condição igual de patamar de sinterização (1700 °C, 3 horas), e ainda alguns ciclos de sinterização mais complexos, com patamares intermédios inseridos no processo de arrefecimento, com o objetivo de tentar alterar os processos de nucleação e crescimento de fases. Na realidade, as transformações de fases a que este tipo de materiais se encontra sujeito (cúbica  tetragonal  monoclínica, para temperaturas decrescentes), possuem diferentes velocidades características (uma é difusiva a outra displaciva), permitindo este tipo de condicionamento. Os materiais obtidos foram alvo de caracterização estrutural e microestrutural, complementada por um conjunto de outras técnicas de caracterização física como a espectroscopia de impedância, dilatometria e dureza. Os resultados obtidos confirmam a complexidade das relações entre processamento e comportamento mas permitiram identificar condições de potencial interesse prático para as aplicações em vista.

Gestão de energia em ambiente industrial

A Sociedade da Água de Luso, S.A., localizada no concelho de Mealhada, é uma empresa do setor do engarrafamento de águas minerais naturais, de nascente e de consumo humano. Esta realiza as suas atividades, tendo em consideração a eficiência energética, ao longo do seu processo produtivo. Desta forma, o trabalho desenvolvido teve como objetivo o acompanhamento da implementação do sistema de monitorização e recolha de dados, que posteriormente foi útil na redução dos consumos energéticos (consumo de ar comprimido). Para além disto, também foi proposta uma medida de eficiência energética que visa a redução de energia elétrica na área da iluminação. O sistema de monitorização e recolha de dados e a criação de uma equipa de redução do consumo de ar comprimido permitiram a identificação das áreas de atuação, a monitorização das metas estipuladas no âmbito da equipa e a detecção de anomalias. A medida de eficiência energética aplicada incide na substituição de lâmpadas fluorescentes tubulares T8 por lâmpadas fluorescentes tubulares T5. Assim, a implementação deste sistema e a aplicação das medidas de eficiência energética na rede de ar comprimido no âmbito da equipa permitiram uma redução de 0,03 kWh/hL o que significa uma poupança de 5.600 € em quinze semanas. Ao nível da iluminação as medidas sugeridas permitem uma redução de 8.945 kWh/ano o que corresponde a uma poupança de 1.055 €/ano.

Estratégias de Competitividade Industrial em Empresas Cooperativas: O caso COMTERN

CAMPOS,Maria da Luz Góis; ANEZ,Miguel Eduar- do Moreno; CARÍCIO,Marcelo Rique. Estratégias de Competitividade Industrial em Empresas Cooperativas:O caso COMTERN. In:ENCONTRO NACIONAL DE ENGENHARIA DE PRODUÇÃO, 23, 2003, Minas Gerais. Anais...Ouro Petro: ADEPRO, 2003. p. 1-8.

Desenvolvimento de um flotador industrial

A presente dissertação apresenta uma investigação teórica e prática na área de Engenharia e Design de Produto com o objetivo principal de desenvolver um Flotador Industrial para a Adventech, procurando indicadores inovadores, competitivos e focando a necessidade de encontrar uma solução que reflita numa relação entre necessidade, utilizador, performance e design. Desta forma, no presente trabalho cruzam-se temas como a Engenharia e o Design de Produto, Tratamentos de Efluentes Líquidos e Flotação de modo a introduzir e compreender o desenvolvimento deste equipamento. Foi efetuada uma pesquisa sobre o tema para compreender, as suas características e limitações, bem como as formas e mecanismos utilizados para dar resposta aos requisitos e produzir um produto eficiente e eficaz. Paralelamente realizou-se uma abordagem teórica sobre Design de Produto e Processo de Flotação, de modo a conhecer o seu desenvolvimento e as suas restrições, preocupações e objetivos. Complementou-se o trabalho desenvolvido com pesquisa e analisaram-se os produtos existentes na concorrência com o objetivo de conhecer características técnicas, funcionais e físicas. Desta forma, o estudo desenvolvido nesta dissertação serviu e auxiliou o projeto no resultado final, incluindo a materialização do conceito para proporcionar uma boa relação entre utilizador, performance e design. Obtendo assim, um resultado final com características adequadas nas diversas aplicações deste produto nas Estações de Águas Residuais, reduzindo custos de operação e manutenção, eficiência do processo de flotação e vida útil do produto. Paralelamente o design proporciona uma apresentação estética do produto que transmite fiabilidade e profissionalismo.

Associação de sistema biológico do tipo lodo ativado com reatores air lift e fotocatálise heterogênea com TiO2 para a remediação de efluente oriundo da produção industrial de TNT

Trinitrotoluene in the purification step (TNT) produced in industries, are carried out two washes at the end of the process. The first wash is done with vaporized water, which originates from the first effluent called yellow water, then the second washing with the use of sodium sulfite is performed (Na2SO3), generating a second effluent red water. This study aimed to study the individual effects, as well as the association of heterogeneous photocatalysis using TiO2 and biological treatment in air lift reactor using activated sludge (bacterial biomass) for the remediation of wastewater contaminated with nitroaromatic compounds in order to reduce toxicity and adjust the legal parameters according to regulatory agencies for disposal in waterways. The photocatalytic treatment was conducted by factorial design obtaining the best reaction conditions (pH 6.5 and concentration of TiO2 0.1 gL-1), with best results obtained at 360 minutes of reaction, reducing the absorbance 97.00%, 94.20% of the chemical oxygen demand (COD), 67.70% of total phenols, as well as a total reduction of observed peaks and assigned to nitroaromatic compounds by high-performance liquid chromatography. In the biological treatment, there was a 53.40% reduction in absorbance at 275 nm 10.00% 36.00% COD and total phenols in a short time (3 days), while for extended periods (48 days) there was an antagonistic influence on the results so that was the elevation of these parameters (COD and total phenols) instead of reducing. Chromatographic analysis confirmed the effectiveness of the biological degradation by reducing the peaks corresponding to compounds DNT and TNT. The Association of photocatalytic and biological treatments decreased results in the order of 91.10% absorbance, 70.26% of total phenols and 88.87% of COD. While the combination of biological and photocatalytic treatments generated relatively lower efficiencies, with 77.30% of absorbance reduction, 62.10% reduction of total phenols and a decrease of 87.00% of COD. In general, when comparing the chemical and biological processes in isolation, the photocatalytic treatment showed the best results. However, comparing the results of isolation and established associations, the association biological x photocatalysis showed more promising results in the treatment of red water effluent.

Relações interorganizacionais e eficiência coletiva: um estudo de caso no arranjo produtivo local de confecções do Agreste de Pernambuco

This work is a study in the Local Productive Arrangement of confections from Agreste of Pernambuco, as a relevant sector in economic and social aspect. This research has as central aim to understand how the inter-organizational relations influence the collective efficiency of arrangement. The theoretical framework employed highlights the approaches that deal with the benefits of business agglomeration for the develop­ment of firms and regions. It has discussed the approach of small and medium enter­ prises and industrial districts (SCHMITZ, 1997), which introduce the concept of col­ lective efficiency, explaining that only those externalities explained by Marshall (1996) are not sufficient to explain the competitive advantage of enterprises, expand­ing the idea that organizations achieve competitive advantage not acting alone. To examine the influences of relations in the collective efficiency, it has been taken as analytical perspective theory of social networks (GRANOVETTER, 1973, 1985; BURT, 1992; UZZI, 1997) because it has believe that this approach provides subsi­ dies for a structural analysis of social relationships in face the behavior of human ac­tion. By examining the organizations in a social network, you should understand the reason of this establishment of the relationship, their benefits, and as the information flow takes place and density of links between the actors (Powell; SMITH-DOERR, 1994). As for the methods, this study is characterized as a case study, in according to the purposed objectives, in addition to qualitative method. Also, due to recovering of the historical milestones of the arrangement, it is used a sectional approach with longitudinal perspective (VIEIRA, 2004). The primary and secondary data were used in order to understand the evolutionary process of the sector and their inter-actors re­ lationships in the arrangement for the promotion of development, for both, was used the contend and documentary analysis technique, respectively (DELLAGNELO ; SIL­VA, 2005). The approach of social networks has permitted understand that social re­lationships may extend the collective efficiency of the arrangement, and therefore need to develop policies that encourage the legalization of informal companies in ar­rangement, by showing up themselves representative. Thus, the relations estab­ lished in LPA of confections from Agreste of Pernambuco need for more effective mechanisms to broaden the collective efficiency. Therefore, this way as take place has directly benefited only a group of companies that are linked in some way the sup­portive institutions. So we can conclude that the inter-actor relations have limited the collective efficiency of LPA, being stimulated by the institutions in support only to groups of entrepreneurs, even those that produce external relations for all clustered companies

Desenvolvimento de membranas porosas de alumina para fins de tratamento de efluente industrial têxtil

Textile production has been considered as an activity of high environmental impact due to the generation of large volumes of waste water with high load of organic compounds and strongly colored effluents, toxic and difficult biodegradability. This thesis deals with obtaining porous alumina ceramic membranes for filtration of textile effluent in the removal of contaminants, mainly color and turbidity. Two types of alumina with different particle sizes as a basis for the preparation of formulation for mass production of ceramic samples and membranes. The technological properties of the samples were evaluated after using sintering conditions: 1,350ºC-2H, 1,450ºC-30M, 1,450ºC-2H, 1,475ºC-30M and 1,475ºC-2H. The sintered samples were characterized by XRD, XRF, AG, TG, DSC, DL, AA, MEA, RL, MRF-3P, SEM and Intrusion Porosimetry by Mercury. After the characterization, a standard membrane was selected with their respective sintering condition for the filterability tests. The effluent was provided by a local Textile Industry and characterized at the entry and exit of the treatment plant. A statistical analysis was used to study the effluent using the following parameters: pH, temperature, EC, SS, SD, oil and grease, turbidity, COD, DO, total phosphorus, chlorides, phenols, metals and fecal coliform. The filtered effluent was evaluated by using the same parameters. These results demonstrate that the feasibility of the use of porous alumina ceramic membranes for removing contaminants from textile effluent with improved average pore size of 0.4 micrometre (distribution range varying from 0,025 to 2.0 micrometre), with total porosity of 29.66%, and average percentages of color removal efficiency of 89.02%, 92.49% of SS, turbidity of 94.55%, metals 2.70% (manganese) to 71.52% (iron) according to each metal and COD removal of 72.80%

Estudo de oportunidades de melhoria de eficiência energética na Rectimold

A melhoria de eficiência energética num contexto mundial é, na atualidade, uma área de grande relevância, devido ao constante aumento dos consumos energéticos, por motivo das necessidades de desenvolvimento dos países. A procura de estratégias de melhoria neste âmbito em ambiente industrial tem o potencial de trazer benefícios comerciais e ambientais significativos. Existem uma infinidade de medidas de eficiência energética e racionalização de consumos, que quando devidamente aplicadas aumentam o desempenho das empresas, com a consequente criação de riqueza e um menor impacte ambiental. O presente projeto teve como principal objetivo o estudo de oportunidades de melhoria de eficiência energética na empresa Rectimold. Esta é uma empresa inserida no ramo da indústria de moldes para injeção de plástico. Uma das etapas do trabalho consistiu na análise global dos consumos energéticos através das faturas, referentes aos anos de 2014 e 2015, onde se verificou que a empresa não está abrangida no âmbito do Sistema de Gestão dos Consumos Intensivos de Energia (SGCIE). Seguidamente, foram instalados analisadores de energia para a recolha de informação detalhada sobre os consumos de energia elétrica. A realização da análise energética incidiu sobre as áreas onde o potencial de economia e redução de consumos será maior, nomeadamente na iluminação, na climatização, na instalação de energias renováveis, no tipo de contratualização de energia elétrica e na introdução de um Sistema de Gestão de Energia (SGE). Nesse âmbito, foram apresentadas diversas propostas para elevar o desempenho energético da empresa, cuja implementação representa uma poupança de consumo energético em cerca de 20%.

Contributos para a implementação do sistema de gestão de energia numa unidade industrial de transformação e embalamento de arroz

Este documento apresenta os resultados obtidos através do contributo da implementação de um sistema de gestão da energia segundo os critérios e requisitos normativos da ISO 50001:2011, numa unidade industrial de transformação e embalamento de arroz. A aplicação deste referencial normativo deve ter como objetivos apoiar no planeamento das ações decorrentes da gestão de energia, pela monitorização e controlo dos consumos energéticos, bem como, identificar medidas de eficiência energética. Na necessidade da empresa fazer face à previsão do aumento da capacidade produtiva e da redução dos custos associados aos consumos de energia, foi designada uma equipa de gestão de energia que teve como objetivos, a certificação do sistema gestão da energia na empresa e consequentemente, reduzir os custos através de medidas para melhoria da eficiência energética. Os resultados desta implementação foram francamente positivos. Conseguiu-se uma melhoria do desempenho energético em 2015 de 28% face aos valores da primeira medida de gestão da energia, realizada em 2012, ao abrigo da legislação nacional em vigor. O sistema de gestão conseguiu nos primeiros dois anos de execução não só a certificação de conformidade por uma entidade externa, como também, proporcionou à empresa uma redução de 15 % dos valores de consumo específico face aos valores do ano de referência. De um modo geral, a empresa com a implementação deste sistema reduziu os custos energéticos. Esta redução permite aumentar a competitividade no mercado. Assim assegura-se um crescimento da empresa sustentado na gestão de recursos e numa maior diversidade de clientes.