Optimização energética da olaria de uma cerâmica

Na indústria cerâmica o consumo de energia é elevado, fazendo com que este custo represente uma parte significativa dos custos totais de produção das peças. De forma a diminuir esta dependência, a energia deve ser gerida de forma contínua e eficazmente. O presente trabalho consistiu na análise da situação energética e na elaboração de propostas de optimização da etapa de conformação que ocorre na Olaria número quatro da Fábrica Cerâmica de Valadares, S.A. Determinou-se o rendimento efectivo da Olaria, tendo-se obtido um valor de 24,7%. As perdas térmicas ocorrem na Olaria, a nível da envolvente, da ventilação, da exaustão de gases e da inércia térmica, representando, respectivamente, 18122 MJ, 50222 MJ, 39228 MJ e 4338 MJ por semana de trabalho. Numa última fase sugeriram-se algumas medidas de optimização energética. A primeira medida visa uma melhoria na manutenção dos geradores, um aumento na gama de temperaturas de funcionamento dos geradores e uma minimização dos tempos de abertura dos portões. Na segunda medida propõe-se a diminuição da percentagem de excesso de ar para 10%, equivalendo a uma poupança de 8839 €/ano. Na terceira medida avaliou-se a possibilidade da aplicação de um permutador de calor de modo a aproveitar os gases de combustão. Esta permitiria uma poupança de 119 €/ano, no entanto, devido ao elevado tempo de retorno do investimento (12,6 anos) considerou-se que esta medida não era viável. A quarta proposta relaciona-se com a optimização da ventilação da Olaria por aumento do ciclo de renovação de ar para 5 h, promovendo uma poupança de 8583 € anuais. Como última sugestão de optimização, aconselhou-se a diminuição do volume da olaria em 6935 m3. Com esta proposta é possível obter uma poupança de 4993 €/ano. Esta medida envolve um investimento de 12000 €, sendo o tempo de retorno do investimento de 2,4 anos. Das cinco propostas estudadas concluiu-se que quatro são viáveis permitindo uma melhoria do funcionamento da Olaria e uma poupança significativa na factura energética.

Uso Sustentável de Vapor

Em 2006, a IEA (Agência Internacional de Energia), publicou alguns estudos de consumos mundiais de energia. Naquela altura, apontava na fabricação de produtos, um consumo mundial de energia elétrica, de origem fóssil de cerca 86,16 EJ/ano (86,16×018 J) e um consumo de energia nos sistemas de vapor de 32,75 EJ/ano. Evidenciou também nesses estudos que o potencial de poupança de energia nos sistemas de vapor era de 3,27 EJ/ano. Ou seja, quase tanto como a energia consumida nos sistemas de vapor da U.E. Não se encontraram números relativamente a Portugal, mas comparativamente com outros Países publicitados com alguma similaridade, o consumo de energia em vapor rondará 0,2 EJ/ano e por conseguinte um potencial de poupança de cerca 0,02 EJ/ano, ou 5,6 × 106 MWh/ano ou uma potência de 646 MW, mais do que a potência de cinco barragens Crestuma/Lever! Trata-se efetivamente de muita energia; interessa por isso perceber o onde e o porquê deste desperdício. De um modo muito modesto, pretende-se com este trabalho dar algum contributo neste sentido. Procurou-se evidenciar as possibilidades reais de os utilizadores de vapor de água na indústria reduzirem os consumos de energia associados à sua produção. Não estão em causa as diferentes formas de energia para a geração de vapor, sejam de origem fóssil ou renovável; interessou neste trabalho estudar o modo de como é manuseado o vapor na sua função de transporte de energia térmica, e de como este poderá ser melhorado na sua eficiência de cedência de calor, idealmente com menor consumo de energia. Com efeito, de que servirá se se optou por substituir o tipo de queima para uma mais sustentável se a jusante se continuarem a verificarem desperdícios, descarga exagerada nas purgas das caldeiras com perda de calor associada, emissões permanentes de vapor para a atmosfera em tanques de condensado, perdas por válvulas nos vedantes, purgadores avariados abertos, pressão de vapor exageradamente alta atendendo às temperaturas necessárias, “layouts” do sistema de distribuição mal desenhados, inexistência de registos de produção e consumos de vapor, etc. A base de organização deste estudo foi o ciclo de vapor: produção, distribuição, consumo e recuperação de condensado. Pareceu importante incluir também o tratamento de água, atendendo às implicações na transferência de calor das superfícies com incrustações. Na produção de vapor, verifica-se que os maiores problemas de perda de energia têm a ver com a falta de controlo, no excesso de ar e purgas das caldeiras em exagero. Na distribuição de vapor aborda-se o dimensionamento das tubagens, necessidade de purgas a v montante das válvulas de controlo, a redução de pressão com válvulas redutoras tradicionais; será de destacar a experiência americana no uso de micro turbinas para a redução de pressão com produção simultânea de eletricidade. Em Portugal não se conhecem instalações com esta opção. Fabricantes da República Checa e Áustria, têm tido sucesso em algumas dezenas de instalações de redução de pressão em diversos países europeus (UK, Alemanha, R. Checa, França, etc.). Para determinação de consumos de vapor, para projeto ou mesmo para estimativa em máquinas existentes, disponibiliza-se uma série de equações para os casos mais comuns. Dá-se especial relevo ao problema que se verifica numa grande percentagem de permutadores de calor, que é a estagnação de condensado - “stalled conditions”. Tenta-se também evidenciar as vantagens da recuperação de vapor de flash (infelizmente de pouca tradição em Portugal), e a aplicação de termocompressores. Finalmente aborda-se o benchmarking e monitorização, quer dos custos de vapor quer dos consumos específicos dos produtos. Esta abordagem é algo ligeira, por manifesta falta de estudos publicados. Como trabalhos práticos, foram efetuados levantamentos a instalações de vapor em diversos sectores de atividades; 1. ISEP - Laboratório de Química. Porto, 2. Prio Energy - Fábrica de Biocombustíveis. Porto de Aveiro. 3. Inapal Plásticos. Componentes de Automóvel. Leça do Balio, 4. Malhas Sonix. Tinturaria Têxtil. Barcelos, 5. Uma instalação de cartão canelado e uma instalação de alimentos derivados de soja. Também se inclui um estudo comparativo de custos de vapor usado nos hospitais: quando produzido por geradores de vapor com queima de combustível e quando é produzido por pequenos geradores elétricos. Os resultados estão resumidos em tabelas e conclui-se que se o potencial de poupança se aproxima do referido no início deste trabalho.

Residential energy resources management by a SCADA system in case of excess wind generation

The end consumers in a smart grid context are seen as active players. The distributed generation resources applied in smart home system as a micro and small-scale systems can be wind generation, photovoltaic and combine heat and power facility. The paper addresses the management of domestic consumer resources, i.e. wind generation, solar photovoltaic, combined heat and power, electric vehicle with gridable capability and loads, in a SCADA system with intelligent methodology to support the user decision in real time. The main goal is to obtain the better management of excess wind generation that may arise in consumer’s distributed generation resources. The optimization methodology is performed in a SCADA House Intelligent Management context and the results are analyzed to validate the SCADA system.

Biofiltration of Air/Styrene and Air/Styrene/Acetone mixtures in a bubble column reactor

The goal of this work was the treatment of polluted waste gases in a bubble column reactor (BCR), in order to determinate the maximum value of reactor’s efficiency (RE), varying the inlet concentration (C in) of the pollutants. The gaseous mixtures studied were: (i) air with styrene and (ii) air with styrene and acetone. The liquid phase used to contain the biomass in the reactor was a basal salt medium (BSM), fundamental for the microorganisms’ development. The reactor used in this project consists of a glass column of 620mm height and inside diameter 75mm. In all essays there were continually measured: pH, dissolved oxygen and liquid’s temperature. Temperature and pH were controlled (T=24ºC, 7.0 ≤ pH ≤ 7.7). In all experiments the liquid volume (including the biomass) used in the reactor was kept constant (1.5L) as well as the total gas flowrate (1 L/min). Concerning the goal of the work, some parameters were calculated: the organic load (OL), removal efficiency (RE), elimination capacity (EC), biomass concentration (xf) and dry biomass concentration (Xdw). In a first series of experiments, the gas mixture used was air with styrene, varying its concentration from 191 mg.m-3 to 6500 mg.m-3.It was concluded that the RE maximum value (97%) was obtained for C in Sty = 4200 mg.m-3. For the maximum tested value of C in Sty, RE obtained was 20%. In a second step, the gaseous mixture included acetone, varying C in Sty between 225 mg.m-3 and 2659 mg.m-3 and C in Ac between 153mg.m-3 and 1389 mg.m-3. The aim of these tests was the determination of C in Ac for which RE was maximum, obtaining C in Ac = 750 mg.m-3. A third series of experiments was performed, in which C in Ac was maintained equal to that value and C in Sty was varied until higher values (5422 mg.m-3). RE maximum values obtained in this last series were 100% for styrene and 40% for acetone. One important conclusion is the fact that the microorganisms available degrade better styrene than acetone. On the ambit of this study, it was possible to identify the species available in biomass: Xanthobacter antotrophicus py2, Enterobacter aerogenes, Nocardia, Corynebacterium Spp., Rhodococcus rhodochrous e Pseudomonas Sp.

Air pollution from traffic emissions in Oporto, Portugal: health and environmental implications

Air pollution represents a serious risk not only to environment and human health, but also to historical heritage. In this study, air pollution of the Oporto Metropolitan Area and its main impacts were characterized. The results showed that levels of CO, PM10 and SO2 have been continuously decreasing in the respective metropolitan area while levels of NOx and NO2 have not changed significantly. Traffic emissions were the main source of the determined polycyclic aromatic hydrocarbons (PAHs; 16 PAHs considered by U.S. EPA as priority pollutants, dibenzo[a,l]pyrene and benzo[j]fluoranthene) in air of the respective metropolitan area. The mean concentration of 18 PAHs in air was 69.9±39.7 ng m−3 with 3–4 rings PAHs accounting for 75% of the total ΣPAHs. The health risk analysis of PAHs in air showed that the estimated values of lifetime lung cancer risks considerably exceeded the health-based guideline level. Analytical results also confirm that historical monuments in urban areas act as passive repositories for air pollutants present in the surrounding atmosphere. FTIR and EDX analyses showed that gypsum was the most important constituent of black crusts of the characterized historical monument Monastery of Serra do Pilar classified as “UNESCO World Cultural Heritage”. In black crusts, 4–6 rings compounds accounted approximately for 85% of ΣPAHs. The diagnostic ratios confirmed that traffic emissions were the major source of PAHs in black crusts; PAH composition profiles were very similar for crusts and PM10 and PM2.5.

Remediation efficiency of vapour extraction of sandy soils contaminated with cyclohexane: influence of air flow rate, water and natural organic matter content

Abstract This work reports the analysis of the efficiency and time of soil remediation using vapour extraction as well as provides comparison of results using both, prepared and real soils. The main objectives were: (i) to analyse the efficiency and time of remediation according to the water and natural organic matter content of the soil; and (ii) to assess if a previous study, performed using prepared soils, could help to preview the process viability in real conditions. For sandy soils with negligible clay content, artificially contaminated with cyclohexane before vapour extraction, it was concluded that (i) the increase of soil water content and mainly of natural organic matter content influenced negatively the remediation process, making it less efficient, more time consuming, and consequently more expensive; and (ii) a previous study using prepared soils of similar characteristics has proven helpful for previewing the process viability in real conditions.

PAH air pollution at a Portuguese urban area: carcinogenic risks and sources identification

This study aimed to characterize air pollution and the associated carcinogenic risks of polycyclic aromatic hydrocarbon (PAHs) at an urban site, to identify possible emission sources of PAHs using several statistical methodologies, and to analyze the influence of other air pollutants and meteorological variables on PAH concentrations.The air quality and meteorological data were collected in Oporto, the second largest city of Portugal. Eighteen PAHs (the 16 PAHs considered by United States Environment Protection Agency (USEPA) as priority pollutants, dibenzo[a,l]pyrene, and benzo[j]fluoranthene) were collected daily for 24 h in air (gas phase and in particles) during 40 consecutive days in November and December 2008 by constant low-flow samplers and using polytetrafluoroethylene (PTFE) membrane filters for particulate (PM10 and PM2.5 bound) PAHs and pre-cleaned polyurethane foam plugs for gaseous compounds. The other monitored air pollutants were SO2, PM10, NO2, CO, and O3; the meteorological variables were temperature, relative humidity, wind speed, total precipitation, and solar radiation. Benzo[a]pyrene reached a mean concentration of 2.02 ngm−3, surpassing the EU annual limit value. The target carcinogenic risks were equal than the health-based guideline level set by USEPA (10−6) at the studied site, with the cancer risks of eight PAHs reaching senior levels of 9.98×10−7 in PM10 and 1.06×10−6 in air. The applied statistical methods, correlation matrix, cluster analysis, and principal component analysis, were in agreement in the grouping of the PAHs. The groups were formed according to their chemical structure (number of rings), phase distribution, and emission sources. PAH diagnostic ratios were also calculated to evaluate the main emission sources. Diesel vehicular emissions were the major source of PAHs at the studied site. Besides that source, emissions from residential heating and oil refinery were identified to contribute to PAH levels at the respective area. Additionally, principal component regression indicated that SO2, NO2, PM10, CO, and solar radiation had positive correlation with PAHs concentrations, while O3, temperature, relative humidity, and wind speed were negatively correlated.

Numerical solution of a PDE system with non-linear steady state conditions that translates the air stripping pollutants removal

This work deals with the numerical simulation of air stripping process for the pre-treatment of groundwater used in human consumption. The model established in steady state presents an exponential solution that is used, together with the Tau Method, to get a spectral approach of the solution of the system of partial differential equations associated to the model in transient state.

Project, modelling and simulation of air stripping columns for the treatment of groundwater contaminated with volatile organic compounds

Volatile organic compounds are a common source of groundwater contamination that can be easily removed by air stripping in columns with random packing and using a counter-current flow between the phases. This work proposes a new methodology for the column design for any particular type of packing and contaminant avoiding the necessity of a pre-defined diameter used in the classical approach. It also renders unnecessary the employment of the graphical Eckert generalized correlation for pressure drop estimates. The hydraulic features are previously chosen as a project criterion and only afterwards the mass transfer phenomena are incorporated, in opposition to conventional approach. The design procedure was translated into a convenient algorithm using C++ as programming language. A column was built in order to test the models used either in the design or in the simulation of the column performance. The experiments were fulfilled using a solution of chloroform in distilled water. Another model was built to simulate the operational performance of the column, both in steady state and in transient conditions. It consists in a system of two partial non linear differential equations (distributed parameters). Nevertheless, when flows are steady, the system became linear, although there is not an evident solution in analytical terms. In steady state the resulting system of ODE can be solved, allowing for the calculation of the concentration profile in both phases inside the column. In transient state the system of PDE was numerically solved by finite differences, after a previous linearization.

Experimental assessment of pressure drop in air stripping columns

One important step in the design of air stripping operations for the removal of VOC is the choice of operating conditions, which are based in the phase ratio. This parameter sets on directly the stripping factor and the efficiency of the operation. Its value has an upper limit determined by the flooding regime, which is previewed using empirical correlations, namely the one developed by Eckert. This type of approach is not suitable for the development of algorithms. Using a pilot scale column and a convenient solution, the pressure drop was determined in different operating conditions and the experimental values were compared with the estimations. This particular research will be incorporated in a global model for simulating the dynamics of air stripping using a multi variable distributed parameter system.

Practical software improve design and performance of a randomly packed air stripping column for removing volatile organic compounds from water

STRIPPING is a software application developed for the automatic design of a randomly packing column where the transfer of volatile organic compounds (VOCs) from water to air can be performed and to simulate it’s behaviour in a steady-state. This software completely purges any need of experimental work for the selection of diameter of the column, and allows a choice, a priori, of the most convenient hydraulic regime for this type of operation. It also allows the operator to choose the model used for the calculation of some parameters, namely between the Eckert/Robbins model and the Billet model for estimating the pressure drop of the gaseous phase, and between the Billet and Onda/Djebbar’s models for the mass transfer. Illustrations of the graphical interface offered are presented.

Spectral solution for the air stripping pollutants removal dynamic model with non linear steady state conditions

This work deals with the numerical simulation of air stripping process for the pre-treatment of groundwater used in human consumption. The model established in steady state presents an exponential solution that is used, together with the Tau Method, to get a spectral approach of the solution of the system of partial differential equations associated to the model in transient state.

A New Approach in the Design of Air Stripping Columns for the Treatment of Groundwater Contaminated With Volatile Organic Compounds

Volatile organic compounds are a common source of groundwater contamination that can be easily removed by air stripping in columns with random packing and using a counter-current flow between the phases. This work proposes a new methodology for column design for any type of packing and contaminant which avoids the necessity of an arbitrary chosen diameter. It also avoids the employment of the usual graphical Eckert correlations for pressure drop. The hydraulic features are previously chosen as a project criterion. The design procedure was translated into a convenient algorithm in C++ language. A column was built in order to test the design, the theoretical steady-state and dynamic behaviour. The experiments were conducted using a solution of chloroform in distilled water. The results allowed for a correction in the theoretical global mass transfer coefficient previously estimated by the Onda correlations, which depend on several parameters that are not easy to control in experiments. For best describe the column behaviour in stationary and dynamic conditions, an original mathematical model was developed. It consists in a system of two partial non linear differential equations (distributed parameters). Nevertheless, when flows are steady, the system became linear, although there is not an evident solution in analytical terms. In steady state the resulting ODE can be solved by analytical methods, and in dynamic state the discretization of the PDE by finite differences allows for the overcoming of this difficulty. To estimate the contaminant concentrations in both phases in the column, a numerical algorithm was used. The high number of resulting algebraic equations and the impossibility of generating a recursive procedure did not allow the construction of a generalized programme. But an iterative procedure developed in an electronic worksheet allowed for the simulation. The solution is stable only for similar discretizations values. If different values for time/space discretization parameters are used, the solution easily becomes unstable. The system dynamic behaviour was simulated for the common liquid phase perturbations: step, impulse, rectangular pulse and sinusoidal. The final results do not configure strange or non-predictable behaviours.

Comparison of contaminant removal effectiveness and air change efficiency as indicator of air diffusion quality.

The ventilation efficiency concept is an attempt to quantify a parameter that can easily distinguish the different options for air diffusion in the building spaces. Thirteen strategies of air diffusion were measured in a test chamber through the application of the tracer gas method, with the objective to validate the calculation by Computational fluid dynamics (CFD). Were compared the Air Change Efficiency (ACE) and the Contaminant Removal Effectiveness (CRE), the two indicators most internationally accepted. The main results from this work shows that the values of the numerical simulations are in good agreement with experimental measurements and also, that the solutions to be adopted for maximizing the ventilation efficiency should be the schemes that operate with low speeds of supply air and small differences between supply air temperature and the room temperature.