Optimização energética dos fornos de uma indústria do sector cerâmico

Mestrado em Engenharia Química

HACCP numa indústria corticeira: implementação, identificação de pontos críticos e proposta de acções correctivas

Mestrado em Engenharia Química

Intra- and interspecific mineral composition variability of commercial instant coffees and coffee substitutes: contribution to mineral intake

The present paper reports the amount and estimated daily mineral intake of nine elements (Ca, Mg, K, Na, P, Fe, Mn, Cr and Ni) in commercial instant coffees and coffee substitutes (n = 49). Elements were quantified by high-resolution continuum source flame (HR-CS-FAAS) and graphite furnace (HR-CS-GFAAS) atomic absorption spectrometry, while phosphorous was evaluated by a standard vanadomolybdophosphoric acid colorimetric method. Instant coffees and coffee substitutes are rich in K, Mg and P (>100 mg/100 g dw), contain Na, Ca and Fe in moderate amounts (>1 mg/100 g), and trace levels of Cr and Ni. Among the samples analysed, plain instant coffees are richer in minerals (p < 0.001), except for Na and Cr. Blends of coffee substitutes (barley, malt, chicory and rye) with coffee (20–66%) present intermediate amounts, while lower quantities are found in substitutes without coffee, particularly in barley. From a nutritional point of view the results indicate that the mean ingestion of two instant beverages per day (total of 4 g instant powder), either with or without coffee, cannot be regarded as important sources of minerals to the human diet, although providing a supplementation of some minerals, particularly Mg and Mn in instant coffees. Additionally, and for authentication purposes, the correlations observed between some elements and the coffee percentage in the blends, with particular significance for Mg amounts, provides a potential tool for the estimation of coffee in substitute blends.

Polycyclic aromatic hydrocarbon levels in three pelagic fish species from Atlantic Ocean: inter-specific and inter-season comparisons and assessment of potential public health risks

The concentrations of 18 polycyclic aromatic hydrocarbons (PAHs) were determined in three commercially valuable fish species (sardine, Sardina pilchardus; chub mackerel, Scomber japonicus; and horse mackerel, Trachurus trachurus) from the Atlantic Ocean. Specimens were collected seasonally during 2007–2009. Only low molecular weight PAHs were detected, namely, naphthalene, acenaphthene, fluorene and phenanthrene. Chub mackerel (1.80–19.90 microg/kg ww) revealed to be significantly more contaminated than horse mackerel (2.73–10.0 microg/kg ww) and sardine (2.29–14.18 microg/kg ww). Inter-specific and inter-season comparisons of PAHs bioaccumulation were statistically assessed. The more relevant statistical correlations were observed between PAH amounts and total fat content (significant positive relationships, p < 0.05), and season (sardine displayed higher amounts in autumn–winter while the mackerel species showed globally the inverse behavior). The health risks by consumption of these species were assessed and shown to present no threat to public health concerning PAH intakes.

Lipid content of frozen fish: comparison of different extraction methods and variability during freezing storage

In this work, a microwave-assisted extraction (MAE) methodology was compared with several conventional extraction methods (Soxhlet, Bligh & Dyer, modified Bligh & Dyer, Folch, modified Folch, Hara & Radin, Roese-Gottlieb) for quantification of total lipid content of three fish species: horse mackerel (Trachurus trachurus), chub mackerel (Scomber japonicus), and sardine (Sardina pilchardus). The influence of species, extraction method and frozen storage time (varying from fresh to 9 months of freezing) on total lipid content was analysed in detail. The efficiencies of methods MAE, Bligh & Dyer, Folch, modified Folch and Hara & Radin were the highest and although they were not statistically different, differences existed in terms of variability, with MAE showing the highest repeatability (CV = 0.034). Roese-Gottlieb, Soxhlet, and modified Bligh & Dyer methods were very poor in terms of efficiency as well as repeatability (CV between 0.13 and 0.18).

A novel application of microwave-assisted extraction of polyphenols from brewer’s spent grain with HPLC-DAD-MS analysis

This paper reports a novel application of microwave-assisted extraction (MAE) of polyphenols from brewer’s spent grains (BSG). A 24 orthogonal composite design was used to obtain the optimal conditions of MAE. The influence of the MAE operational parameters (extraction time, temperature, solvent volume and stirring speed) on the extraction yield of ferulic acid was investigated through response surface methodology. The results showed that the optimal conditions were 15 min extraction time, 100 °C extraction temperature, 20 mL of solvent, and maximum stirring speed. Under these conditions, the yield of ferulic acid was 1.31±0.04% (w/w), which was fivefold higher than that obtained with conventional solid–liquid extraction techniques. The developed new extraction method considerably reduces extraction time, energy and solvent consumption, while generating fewer wastes. HPLC-DADMS analysis indicated that other hydroxycinnamic acids and several ferulic acid dehydrodimers, as well as one dehydrotrimer were also present, confirming that BSG is a valuable source of antioxidant compounds.

Structural, physical, and chemical modifications induced by microwave heating on native agar-like galactans

Native agars from Gracilaria vermiculophylla produced in sustainable aquaculture systems (IMTA) were extracted under conventional (TWE) and microwave (MAE) heating. The optimal extracts from both processes were compared in terms of their properties. The agars’ structure was further investigated through Fourier transform infrared and NMR spectroscopy. Both samples showed a regular structure with an identical backbone, β-D-galactose (G) and 3,6-anhydro-α-L-galactose (LA) units; a considerable degree of methylation was found at C6 of the G units and, to a lesser extent, at C2 of the LA residues. The methylation degree in the G units was lower for MAEopt agar; the sulfate content was also reduced. MAE led to higher agar recoveries with drastic extraction time and solvent volume reductions. Two times lower values of [η] and Mv obtained for the MAEopt sample indicate substantial depolymerization of the polysaccharide backbone; this was reflected in its gelling properties; yet it was clearly appropriate for commercial application in soft-texture food products.

Analysis of polycyclic aromatic hydrocarbons in fish: optimisation and validation of microwave-assisted extraction

An accurate and sensitive method for determination of 18 polycyclic aromatic hydrocarbons (PAHs) (16 PAHs considered by USEPA as priority pollutants, dibenzo[a,l]pyrene and benzo[j]fluoranthene) in fish samples was validated. Analysis was performed by microwave-assisted extraction and liquid chromatography with photodiode array and fluorescence detection. Response surface methodology was used to find the optimal extraction parameters. Validation of the overall methodology was performed by spiking assays at four levels and using SRM 2977. Quantification limits ranging from 0.15–27.16 ng/g wet weight were obtained. The established method was applied in edible tissues of three commonly consumed and commercially valuable fish species (sardine, chub mackerel and horse mackerel) originated from Atlantic Ocean. Variable levels of naphthalene (1.03–2.95 ng/g wet weight), fluorene (0.34–1.09 ng/g wet weight) and phenanthrene (0.34–3.54 ng/g wet weight) were detected in the analysed samples. None of the samples contained detectable amounts of benzo[a]pyrene, the marker used for evaluating the occurrence and carcinogenic effects of PAHs in food.

Development of polyaniline microarray electrodes for cadmium analysis

Disposable screen-printed electrodes (SPCE) were modified using a cosmetic product to partially block the electrode surface in order to obtain a microelectrode array. The microarrays formed were electropolymerized with aniline. Scanning electron microscopy was used to evaluate the modified and polymerized electrode surface. Electrochemical characteristics of the constructed sensor for cadmium analysis were evaluated by cyclic and square-wave voltammetry. Optimized stripping procedure in which the preconcentration of cadmium was achieved by depositing at –1.20 V (vs. Ag/AgCl) resulted in a well defined anodic peak at approximately –0.7 V at pH 4.6. The achieved limit of detection was 4 × 10−9 mol dm−3. Spray modified and polymerized microarray electrodes were successfully applied to quantify cadmium in fish sample digests.

Metal accumulation and oxidative stress biomarkers in octopus (Octopus vulgaris) from Northwest Atlantic

Metals are ubiquitous in the environment and accumulate in aquatic organisms and are known for their ability to enhance the production of reactive oxygen species (ROS). In aquatic species, oxidative stress mechanisms have been studied by measuring antioxidant enzyme activities and oxidative damages in tissues. The aim of this study was to apply and validate a set of oxidative stress biomarkers and correlate responses with metal contents in tissues of common octopus (Octopus vulgaris). Antioxidant enzyme activity (catalase — CAT, superoxide dismutase — SOD and glutathione S-transferases — GST), oxidative damages (lipid peroxidation — LPO and protein carbonyl content — PCO) andmetal content (Cu, Zn, Pb, Cd and As) in the digestive gland and armof octopus, collected in the NWPortuguese coast in different periods, were assessed after capture and after 14 days in captivity. CAT and SOD activitieswere highly responsive to fluctuations inmetal concentrations and able to reduce oxidative damage, LPO and PCO in the digestive gland. CAT activity was also positively correlated with SOD and GST activities, which emphasizes that the three enzymes respond in a coordinated way to metal induced oxidative stress. Our results validate the use of oxidative stress biomarkers to assess metal pollution effects in this ecological and commercial relevant species.Moreover, octopus seems to have the ability to control oxidative damage by triggering an antioxidant enzyme coordinated response in the digestive gland.

Extraction of ochratoxin A in bread samples by the QuEChERS methodology

A QuEChERS method for the extraction of ochratoxin A (OTA) from bread samples was evaluated. A factorial design (23) was used to find the optimal QuEChERS parameters (extraction time, extraction solvent volume and sample mass). Extracts were analysed by LC with fluorescence detection. The optimal extraction conditions were: 5 g of sample, 15 mL of acetonitrile and 3 min of agitation. The extraction procedure was validated by systematic recovery experiments at three levels. The recoveries obtained ranged from 94.8% (at 1.0 μg kg -1) to 96.6% (at 3.0 μg kg -1). The limit of quantification of the method was 0.05 μg kg -1. The optimised procedure was applied to 20 samples of different bread types (‘‘Carcaça’’, ‘‘Broa de Milho’’, and ‘‘Broa de Avintes’’) highly consumed in Portugal. None of the samples exceeded the established European legal limit of 3 μg kg -1.

Auditoria e optimização energética à secção de impregnação de uma indústria têxtil

Mestrado em Engenharia Química

Espresso coffee residues: a valuable source of unextracted compounds

Espresso spent coffee grounds were chemically characterized to predict their potential, as a source of bioactive compounds, by comparison with the ones from the soluble coffee industry. Sampling included a total of 50 samples from 14 trademarks, collected in several coffee shops and prepared with distinct coffee machines. A high compositional variability was verified, particularly with regard to such water-soluble components as caffeine, total chlorogenic acids (CGA), and minerals, supported by strong positive correlations with total soluble solids retained. This is a direct consequence of the reduced extraction efficiency during espresso coffee preparation, leaving a significant pool of bioactivity retained in the extracted grounds. Besides the lipid (12.5%) and nitrogen (2.3%) contents, similar to those of industrial coffee residues, the CGA content (478.9 mg/100 g), for its antioxidant capacity, and its caffeine content (452.6 mg/100 g), due to its extensive use in the food and pharmaceutical industries, justify the selective assembly of this residue for subsequent use.

Auditoria energética à indústria têxtil do Ave

A Indústria Têxtil do Ave S.A. (ITA) dedica-se, desde 1948, à produção de componentes têxteis para pneus em forma de fio torcido (corda) e tela. Estes componentes são quimicamente activados e impregnados em estufas, possibilitando assim a posterior adesão ao pneu. A máquina de impregnar corda Single End é composta pelos grupos de estiragem, por um recipiente contendo a solução química e por 4 estufas em série. A máquina de impregnar tela Zell é composta pelos grupos de estiragem, pelos acumuladores de saída e entrada, pelos recipientes com as soluções químicas e por um grupo de 7 estufas em série. O aquecimento das estufas é feito através da queima de gás natural. O presente trabalho teve como objectivo a realização de uma auditoria energética à ITA com um especial destaque às máquinas de impregnar corda (Single End) e tela (Zell). As correntes de entrada que contribuem para a potência térmica de impregnação são a combustão do gás natural, o ar de combustão, o ar fresco, o artigo em verde e as soluções químicas. As correntes de saída correspondem aos gases de combustão e exaustão, ao artigo impregnado e às perdas térmicas. A auditoria à máquina Single End mostrou que a potência térmica de impregnação é de 413,1 kW. Dessa potência térmica, 77,2% correspondem à combustão do gás natural, 6,7% ao ar de combustão, 15% ao ar fresco, 0,7% às cordas em verde e 0,4% à solução química. Da potência térmica de saída, 88,4% correspondem aos gases de combustão e exaustão, 3,2% às cordas impregnadas e 8,4% às perdas térmicas. Da auditoria à máquina Zell observou-se que a potência térmica de impregnação é de 5630,7 kW. Dessa potência, 73,3% corresponde à combustão do gás natural, 1,6% ao ar de combustão, 24,5% ao ar fresco, 0,3% à tela em verde e 0,3% às soluções químicas. Da potência térmica de saída, 65,2% correspondem aos gases de combustão e exaustão, 3,1% à tela impregnada e 31,7% às perdas térmicas. Foram sugeridas como medidas de optimização a redução dos caudais de exaustão das estufas e o aumento de temperatura do ar fresco. O aumento da temperatura do ar fresco da máquina de impregnar Single End para 50 ºC, usando ar quente dos torcedores, leva a uma poupança de 0,22 €/h, com um período de retorno do investimento de 13 anos e 4 meses enquanto o aumento para 120 ºC, usando o calor dos gases de combustão e exaustão, reduz os custos em 0,88 €/h, sendo o período de retorno para esse investimento de 2 anos e 6 meses. Na máquina de impregnar Zell, uma redução de 15% no caudal de exaustão numa das estufas leva a ganhos de 3,43 €/h. O aumento de temperatura do ar fresco para 45 ºC, usando o calor de gases de combustão e exaustão, leva a uma poupança de 9,93 €/h sendo o período de retorno para cada uma das duas sugestões de investimento de 5 meses e 9 meses.

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.