Numerical Model of a Variable-Combined-Cycle Engine for Dual Subsonic and Supersonic Cruise

Efficient high speed propulsion requires exploiting the cooling capability of the cryogenic fuel in the propulsion cycle. This paper presents the numerical model of a combined cycle engine while in air turbo-rocket configuration. Specific models of the various heat exchanger modules and the turbomachinery elements were developed to represent the physical behavior at off-design operation. The dynamic nature of the model allows the introduction of the engine control logic that limits the operation of certain subcomponents and extends the overall engine operational envelope. The specific impulse and uninstalled thrust are detailed while flying a determined trajectory between Mach 2.5 and 5 for varying throttling levels throughout the operational envelope.

SolarPaces 2013: Innovations on direct steam generation in linear fresnel collectors

Direct Steam Generation (DSG) in Linear Fresnel (LF) solar collectors is being consolidated as a feasible technology for Concentrating Solar Power (CSP) plants. The competitiveness of this technology relies on the following main features: water as heat transfer fluid (HTF) in Solar Field (SF), obtaining high superheated steam temperatures and pressures at turbine inlet (500ºC and 90 bar), no heat tracing required to avoid HTF freezing, no HTF degradation, no environmental impacts, any heat exchanger between SF and Balance Of Plant (BOP), and low cost installation and maintenance. Regarding to LF solar collectors, were recently developed as an alternative to Parabolic Trough Collector (PTC) technology. The main advantages of LF are: the reduced collector manufacturing cost and maintenance, linear mirrors shapes versus parabolic mirror, fixed receiver pipes (no ball joints reducing leaking for high pressures), lower susceptibility to wind damages, and light supporting structures allowing reduced driving devices. Companies as Novatec, Areva, Solar Euromed, etc., are investing in LF DSG technology and constructing different pilot plants to demonstrate the benefits and feasibility of this solution for defined locations and conditions (Puerto Errado 1 and 2 in Murcia Spain, Lidellin Newcastle Australia, Kogran Creek in South West Queensland Australia, Kimberlina in Bakersfield California USA, Llo Solar in Pyrénées France,Dhursar in India,etc). There are several critical decisions that must be taken in order to obtain a compromise and optimization between plant performance, cost, and durability. Some of these decisions go through the SF design: proper thermodynamic operational parameters, receiver material selection for high pressures, phase separators and recirculation pumps number and location, pipes distribution to reduce the amount of tubes (reducing possible leaks points and transient time, etc.), etc. Attending to these aspects, the correct design parameters selection and its correct assessment are the main target for designing DSG LF power plants. For this purpose in the recent few years some commercial software tools were developed to simulatesolar thermal power plants, the most focused on LF DSG design are Thermoflex and System Advisor Model (SAM). Once the simulation tool is selected,it is made the study of the proposed SFconfiguration that constitutes the main innovation of this work, and also a comparison with one of the most typical state-of-the-art configuration. The transient analysis must be simulated with high detail level, mainly in the BOP during start up, shut down, stand by, and partial loads are crucial, to obtain the annual plant performance. An innovative SF configurationwas proposed and analyzed to improve plant performance. Finally it was demonstrated thermal inertia and BOP regulation mode are critical points in low sun irradiation day plant behavior, impacting in annual performance depending on power plant location.

Supercritical Steam power cycle for Line-Focus Solar Power Plants

The supercritical Rankine power cycle offers a net improvement in plant efficiency compared with a subcritical Rankine cycle. For fossil power plants the minimum supercritical steam turbine size is about 450MW. A recent study between Sandia National Laboratories and Siemens Energy, Inc., published on March 2013, confirmed the feasibility of adapting the Siemens turbine SST-900 for supercritical steam in concentrated solar power plants, with a live steam conditions 230-260 bar and output range between 140-200 MWe. In this context, this analysis is focused on integrating a line-focus solar field with a supercritical Rankine power cycle. For this purpose two heat transfer fluids were assessed: direct steam generation and molten salt Hitec XL. To isolate solar field from high pressure supercritical water power cycle, an intermediate heat exchanger was installed between linear solar collectors and balance of plant. Due to receiver selective coating temperature limitations, turbine inlet temperature was fixed 550ºC. The design-point conditions were 550ºC and 260 bar at turbine inlet, and 165 MWe Gross power output. Plant performance was assessed at design-point in the supercritical power plant (between 43-45% net plant efficiency depending on balance of plantconfiguration), and in the subcritical plant configuration (~40% net plant efficiency). Regarding the balance of plant configuration, direct reheating was adopted as the optimum solution to avoid any intermediate heat exchanger. One direct reheating stage between high pressure turbine and intermediate pressure turbine is the common practice; however, General Electric ultrasupercritical(350 bar) fossil power plants also considered doubled-reheat applications. In this study were analyzed heat balances with single-reheat, double-reheat and even three reheating stages. In all cases were adopted the proper reheating solar field configurations to limit solar collectors pressure drops. As main conclusion, it was confirmed net plant efficiency improvements in supercritical Rankine line-focus (parabolic or linear Fresnel) solar plant configurations are mainly due to the following two reasons: higher number of feed-water preheaters (up to seven)delivering hotter water at solar field inlet, and two or even three direct reheating stages (550ºC reheating temperature) in high or intermediate pressure turbines. However, the turbine manufacturer should confirm the equipment constrains regarding reheating stages and number of steam extractions to feed-water heaters.

Investigación sobre la aplicación de energía solar a una depuradora convencional de fangos activos

El consumo de energía es responsable de una parte importante de las emisiones a la atmósfera de CO2, que es uno de los principales causantes del efecto invernadero en nuestro planeta. El aprovechamiento de la energía solar para la producción de agua caliente, permite economizar energía y disminuir el impacto del consumo energético sobre el medio ambiente y por tanto un menor impacto medioambiental. El objetivo de la presente investigación consiste en estudiar el aprovechamiento solar para el calentamiento de los fangos en los digestores anaerobios mediante agua caliente circulando en el interior de un serpentín que rodea la superficie de dicho digestor, como apoyo a los métodos convencionales del calentamiento de fangos como la resistencia eléctrica o el intercambiador de calor mediante la energía obtenida por el gas metano producido en la digestión anaerobia. Para el estudio se utilizaron 3 digestores, dos delos cuales se calentaron con agua caliente en el interior de un serpentín (uno aislado mediante una capa de fibra de vidrio y poliuretano y otro sin aislar).El tercer digestor no tenía calentamiento exterior con el objetivo de observar su comportamiento y comparar su evolución con el resto de los digestores .La comparación de los digestores 1 y 2 nos permitió estudiar la conveniencia de proveer de aislamiento al digestor. La transferencia de calor mediante serpentín de cobre dio valores comprendidos entre 83 y 92%. La aplicación de la instalación a una depuradora a escala real para mantenimiento en el interior del digestor a T=32ºC en diferentes climas: climas templados, cálidos y fríos, consistió en el cálculo de la superficie de colectores solares y superficie de serpentín necesario para cubrir las necesidades energéticas anuales de dicho digestor, así como el estudio de rentabilidad de la instalación, dando los mejores resultados para climas cálidos con períodos de retorno de 12 años y una tasa interna de rentabilidad (TIR) del 16% obteniendo una cobertura anual del 79% de las necesidades energéticas con energía solar térmica. Energy consumption accounts for a significant part of the emissions of CO2, which is one of the main causes of the greenhouse effect on our planet. The use of solar energy for hot water production. can save energy and reduce the impact of energy consumption on the environment and therefore a reduced environmental impact. The objective of this research is to study the solar utilization for heating the sludge in anaerobic digesters by hot water circulating inside a coil surrounding the surface of digester, to support conventional heating methods sludge as the electrical resistance or heat exchanger by energy generated by the methane gas produced in the anaerobic digestion. To study 3 digesters used two models which are heated with hot water within a coil (one insulated by a layer of fiberglass and polyurethane and other uninsulated) .The third digester had no external heating in order to observe their behavior and compare their evolution with the rest of the .The comparison digesters digesters 1 and 2 allowed us to study the advisability of providing insulation to the digester. Heat transfer through copper coil gave values between 83 and 92%. The installation application to a treatment for maintaining full scale within the digester at T = 32ºC in different climates: temperate, warm and cold climates, consisted of calculating the surface area of solar collectors and coil required to cover the annual energy needs of the digester, and the study of profitability of the installation, giving the best results for hot climates with return periods of 12 years and an internal rate of return (IRR) of 16% achieving an annual coverage of 79 % of energy needs with solar energy.

Evidence of different thermoregulatory mechanisms between two sympatric Scarabaeus species using infrared thermography and micro-computer tomography

In endotherms insects, the thermoregulatory mechanisms modulate heat transfer from the thorax to the abdomen to avoid overheating or cooling in order to obtain a prolonged flight performance. Scarabaeus sacer and S. cicatricosus, two sympatric species with the same habitat and food preferences, showed daily temporal segregation with S. cicatricosus being more active during warmer hours of the day in opposition to S. sacer who avoid it. In the case of S. sacer, their endothermy pattern suggested an adaptive capacity for thorax heat retention. In S. cicatricosus, an active ‘heat exchanger’ mechanism was suggested. However, no empirical evidence had been documented until now. Thermographic sequences recorded during flight performance showed evidence of the existence of both thermoregulatory mechanisms. In S. sacer, infrared sequences showed a possible heat insulator (passive thermal window), which prevents heat transfer from meso- and metathorax to the abdomen during flight. In S. cicatricosus, infrared sequences revealed clear and effective heat flow between the thorax and abdomen (abdominal heat transfer) that should be considered the main mechanism of thermoregulation. This was related to a subsequent increase in abdominal pumping (as a cooling mechanism) during flight. Computer microtomography scanning, anatomical dissections and internal air volume measurements showed two possible heat retention mechanisms for S. sacer; the abdominal air sacs and the development of the internal abdominal sternites that could explain the thermoregulation between thorax and abdomen. Our results suggest that interspecific interactions between sympatric species are regulated by very different mechanisms. These mechanisms create unique thermal niches for the different species, thereby preventing competition and modulating spatio-temporal distribution and the composition of dung beetle assemblages.

Large scale optimization of a sour water stripping plant using surrogate models

In this work, we propose a new methodology for the large scale optimization and process integration of complex chemical processes that have been simulated using modular chemical process simulators. Units with significant numerical noise or large CPU times are substituted by surrogate models based on Kriging interpolation. Using a degree of freedom analysis, some of those units can be aggregated into a single unit to reduce the complexity of the resulting model. As a result, we solve a hybrid simulation-optimization model formed by units in the original flowsheet, Kriging models, and explicit equations. We present a case study of the optimization of a sour water stripping plant in which we simultaneously consider economics, heat integration and environmental impact using the ReCiPe indicator, which incorporates the recent advances made in Life Cycle Assessment (LCA). The optimization strategy guarantees the convergence to a local optimum inside the tolerance of the numerical noise.

On minimal models of process systems

Minimal representations are known to have no redundant elements, and are therefore of great importance. Based on the notions of performance and size indices and measures for process systems, the paper proposes conditions for a process model being minimal in a set of functionally equivalent models with respect to a size norm. Generalized versions of known procedures to obtain minimal process models for a given modelling goal, model reduction based on sensitivity analysis and incremental model building are proposed and discussed. The notions and procedures are illustrated and compared on a simple example, that of a simple nonlinear fermentation process with different modelling goals and on a case study of a heat exchanger modelling. (C) 2004 Elsevier Ltd. All rights reserved.

Diagnostic goal driven modelling and simulation of multiscale process systems

A systematic goal-driven top-down modelling methodology is proposed that is capable of developing a multiscale model of a process system for given diagnostic purposes. The diagnostic goal-set and the symptoms are extracted from HAZOP analysis results, where the possible actions to be performed in a fault situation are also described. The multiscale dynamic model is realized in the form of a hierarchical coloured Petri net by using a novel substitution place-transition pair. Multiscale simulation that focuses automatically on the fault areas is used to predict the effect of the proposed preventive actions. The notions and procedures are illustrated on some simple case studies including a heat exchanger network and a more complex wet granulation process.

Erosion-corrosion of mild steel in hot caustic. Part I: NaOH solution

A novel apparatus, high-pressure/high-temperature nickel flow loop, was constructed to study the effect of the flow on the rate of erosion-corrosion of mild steel in hot caustic. It has been successfully used to measure the corrosion rate of 1020 steel in 2.75 M NaOH solution at a temperature of 160 degrees C and velocities of 0.32 and 2.5 m/s. In situ electrochemical methods were used to measure the corrosion rate such as the potentiodynamic sweep, the polarization resistance method, and electrochemical impedance spectroscopy (EIS). Also used were the weight-loss method and scanning electron microscopy (SEM). Eight electrodes/coupons were used to monitor the metal loss rate, four were placed at the low velocity section, while the other four were placed in the high velocity section. The first three coupons in each section were placed within the disturbed flow region, while the fourth was placed in a fully developed flow region. The corrosion rate of the coupons in the high velocity section was generally higher than that of the coupons in the low velocity section. One coupon in the disturbed flow region had a significantly higher corrosion rate than the others. (c) 2005 Elsevier Ltd. All rights reserved.

Erosion-corrosion of mild steel in hot caustic. Part II: The effect of acid cleaning

Corrosion rates of 1020 steel in 2.75 M NaOH solution at a temperature of 160 degrees C and velocities of 0.32 and 2.5 m/s were studied. The focus was on the effect of the acid cleaning which was performed by using strong, inhibited sulphuric acid in between the exposures to caustic. In situ electrochemical methods were used to measure the corrosion rate such as the potentiodynamic sweep and the polarization resistance method. Also used were the weight-loss method and scanning electron microscopy (SEM). Eight electrodes/coupons were used to monitor the metal loss rate, four were placed at the low velocity section, while the other four were placed in the high velocity section of a high temperature flow. The first three coupons in each section were placed within the disturbed flow region, while the fourth was placed in a fully developed flow region. During the exposure of mild steel to the inhibited acid, following the first caustic period, the corrosion rate increased significantly to between 3 and 10mm/y with a few electrodes experiencing as high as 50 mm/y. The second caustic period following the acidic period typically started with very high corrosion rates (20-80 mm/y). The length of this corrosion period was typically 2-3 h with a few exceptions when the high corrosion period lasted 7-10 h. Following the very high corrosion rates experienced at the beginning of the second caustic period, the corrosion rates were reduced sharply (as the corrosion potential increased) to nearly the same levels as those observed during the passive part of the first caustic period. (c) 2005 Elsevier Ltd. All rights reserved.

Using computational fluid dynamics in combating erosion-corrosion

Computational fluid dynamics was used to search for the links between the observed pattern of attack seen in a bauxite refinery's heat exchanger headers and the hydrodynamics inside the header. Validation of the computational fluid dynamics results was done by comparing then with flow parameters measured in a 1:5 scale model of the first pass header in the laboratory. Computational fluid dynamics simulations were used to establish hydrodynamic similarity between the 1:5 scale and full scale models of the first pass header. It was found that the erosion-corrosion damage seen at the tubesheet of the first pass header was a consequence of increased levels of turbulence at the tubesheet caused by a rapidly turning flow. A prismatic flow corrections device introduced in the past helped in rectifying the problem at the tubesheet but exaggerated the erosion-corrosion problem at the first pass header shell. A number of alternative flow correction devices were tested using computational fluid dynamics. Axial ribbing in the first pass header and an inlet flow diffuser have shown the best performance and were recommended for implementation. Computational fluid dynamics simulations have revealed a smooth orderly low turbulence flow pattern in the second, third and fourth pass as well as the exit headers where no erosion-corrosion was seen in practice. This study has confirmed that near-wall turbulence intensity, which can be successfully predicted by using computational fluid dynamics, is a good hydrodynamic predictor of erosion-corrosion damage in complex geometries. (c) 2006 Published by Elsevier Ltd.

Local shell-side coefficients in shell and tube exchanges the use of a mass transfer technique

A diffusion-controlled electrochemical mass transfer technique has been employed in making local measurements of shell-side coefficients in segmentally baffled shell and tube heat exchangers. Corresponding heat transfer data are predicted through the Chilton and Colburn heat and mass transfer analogy. Mass transfer coefficients were measured for baffle spacing lengths of individual tubes in an internal baffle compartment. Shell-side pressure measurements were also made. Baffle compartment average coefficients derived from individual tube coefficients are shown to be in good agreement with reported experimental bundle average heat transfer data for a heat exchanger model of similar geometry. Mass transfer coefficients of individual tubes compare favourably with those obtained previously by another mass transfer technique. Experimental data are reported for a variety of segmental baffle configurations over the shell-side Reynolds number range 100 to 42 000. Baffles with zero clearances were studied at three baffle cuts and two baffle spacings. Baffle geometry is shown to have a large effect on the distribution of tube coefficients within the baffle compartment. Fluid "jetting" is identified with some baffle configurations. No simple characteristic velocity is found to correlate zonal or baffle compartment average mass transfer data for the effect of both baffle cut and baffle spacing. Experiments with baffle clearances typical of commercial heat exchangers are also reported. The effect of leakage streams associated with these baffles is identified. Investigations were extended to double segmental baffles for which no data had previously been published. The similarity in the shell-side characteristics of this baffle arrangement and two parallel single segmental baffle arrangements is demonstrated. A general relationship between the shell-side mass transfer performance and pressure drop was indicated by the data for all the baffle configurations examined.

Energy conservation in the steel industry

The last few years have witnessed an unprecedented increase in the price of energy available to industry in the United Kingdom and worldwide. The steel industry, as a major consumer of energy delivered in U.K. (8% of national total and nearly 25% of industrial total) and whose energy costs currently form some 28% of the total manufacturing cost, is very much aware of the need to conserve energy. Because of the complexities of steelmaking processes it is imperative that a full understanding of each process and its interlinking role in an integrated steelworks is understood. An analysis of energy distribution shows that as much as 70% of heat input is dissipated to the environment in a variety of forms. Of these, waste gases offer the best potential for energy conservation. The study identifies areas for and discusses novel methods of energy conservation in each process. Application of these schemes in BSC works is developed and their economic incentives highlighted. A major part of this thesis describes design, development and testing of a novel ceramic rotary regenerator for heat recovery from high temperature waste gases, where no such system is available. The regenerator is a compact, efficient heat exchanger. Application of such a system to a reheating furnace provides a fuel saving of up to 40%. A mathematical model developed is verified on the pilot plant. The results obtained confirm the success of the concept and material selection and outlines the work needed to develop an industrial unit. Last, but not least, the key position of an energy manager in an energy conservation programme is identified and a new Energy Management Model for the BSC is developed.

Coupling of Heck and hydrogenation reactions in a continuous compact reactor

A continuous multi-step synthesis of 1,2-diphenylethane was performed sequentially in a structured compact reactor. This process involved a Heck C-C coupling reaction followed by the addition of hydrogen to perform reduction of the intermediate obtained in the first step. Both of the reactions were catalysed by microspherical carbon-supported Pd catalysts. Due to the integration of the micro-heat exchanger, the static mixer and the mesoscale packed-bed reaction channel, the compact reactor was proven to be an intensified tool for promoting the reactions. In comparison with the batch reactor, this flow process in the compact reactor was more efficient as: (i) the reaction time was significantly reduced (ca. 7 min versus several hours), (ii) no additional ligands were used and (iii) the reaction was run at lower operational pressure and temperature. Pd leached in the Heck reaction step was shown to be effectively recovered in the following hydrogenation reaction section and the catalytic activity of the system can be mostly retained by reverse flow operation. © 2009 Elsevier Inc. All rights reserved.

Solar pond powered liquid desiccant evaporative cooling

Liquid desiccant cooling systems (LDCS) are energy efficient means of providing cooling, especially when powered by low-grade thermal sources. In this paper, the underlying principles of operation of desiccant cooling systems are examined, and the main components (dehumidifier, evaporative cooler and regenerator) of the LDCS are reviewed. The evaporative cooler can take the form of direct, indirect or semi-indirect. Relative to the direct type, the indirect type is generally less effective. Nonetheless, a certain variant of the indirect type - namely dew-point evaporative cooler - is found to be the most effective amongst all. The dehumidifier and the regenerator can be of the same type of equipment: packed tower and falling film are popular choices, especially when fitted with an internal heat exchanger. The energy requirement of the regenerator can be supplied from solar thermal collectors, of which a solar pond is an interesting option especially when a large scale or storage capability is desired.