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.

Análise da eficácia de um refrigerador doméstico com condensador modificado: revestimento com meio poroso dissipativo

The development of home refrigerators generally are compact and economic reasons for using simplified configuration. The thermodynamic coefficient of performance ( COP ) is limited mainly in the condenser design for reasons of size and arrangement ( layout ) of the project ( design ) and climatic characteristics of the region where it will operate. It is noteworthy that this latter limitation is very significant when it comes to a country of continental size like Brazil with diverse climatic conditions. The COP of the cycle depends crucially on the ability of heat dissipated in the condenser. So in hot climates like the northeast, north, and west-central dispel ability is highly attenuated compared to the south and southeast regions with tropical or subtropical climates when compared with other regions. The dissipation in compact capacitors for applications in domestic refrigeration has been the focus of several studies, that due to its impact on reducing costs and power consumption, and better use of the space occupied by the components of refrigeration systems. This space should be kept to a minimum to allow an increase in the useful storage volume of refrigerator without changing the external dimensions of the product. Due to its low cost manufacturing, wire on tube condensers continue to be the most advantageous option for domestic refrigeration. Traditionally, these heat exchangers are designed to operate under natural convection. Not always, the benefits of greater compactness of capacitors for forced outweigh the burden of pumping air through the external heat exchanger. In this work we propose an improvement in convective condenser changing it to a transfer mechanism combined in series with conductive pipes and wire to a moist convective porous medium and the porous medium to the environment. The porous media used in the coating was composed of a gypsum plaster impregnated fiber about a mesh of natural cellulosic molded tubular wire mesh about the original structure of the condenser , and then dried and calcined to greater adherence and increased porosity. The proposed configuration was installed in domestic refrigeration system ( trough ) and tested under the same conditions of the original configuration . Was also evaluated in the dry condition and humidified drip water under natural and forced with an electro - fan ( fan coil ) convection. Assays were performed for the same 134- refrigerant charge e under the same thermal cooling load. The performance was evaluated in various configurations, showing an improvement of about 72 % compared with the original configuration proposed in humidification and natural convection.

Constructal Design of Energy Systems

This dissertation shows the use of Constructal law to find the relation between the morphing of the system configuration and the improvements in the global performance of the complex flow system. It shows that the better features of both flow and heat transfer architecture can be found and predicted by using the constructal law in energy systems. Chapter 2 shows the effect of flow configuration on the heat transfer performance of a spiral shaped pipe embedded in a cylindrical conducting volume. Several configurations were considered. The optimal spacings between the spiral turns and spire planes exist, such that the volumetric heat transfer rate is maximal. The optimized features of the heat transfer architecture are robust. Chapter 3 shows the heat transfer performance of a helically shaped pipe embedded in a cylindrical conducting volume. It shows that the optimized features of the heat transfer architecture are robust with respect to changes in several physical parameters. Chapter 4 reports analytically the formulas for effective permeability in several configurations of fissured systems, using the closed-form description of tree networks designed to provide flow access. The permeability formulas do not vary much from one tree design to the next, suggesting that similar formulas may apply to naturally fissured porous media with unknown precise details, which occur in natural reservoirs. Chapter 5 illustrates a counterflow heat exchanger consists of two plenums with a core. The results show that the overall flow and thermal resistance are lowest when the core is absent. Overall, the constructal design governs the evolution of flow configuration in nature and energy systems.

A facilities maintenance management process based on degradation prediction using sensed data

Energy efficiency and user comfort have recently become priorities in the Facility Management (FM) sector. This has resulted in the use of innovative building components, such as thermal solar panels, heat pumps, etc., as they have potential to provide better performance, energy savings and increased user comfort. However, as the complexity of components increases, the requirement for maintenance management also increases. The standard routine for building maintenance is inspection which results in repairs or replacement when a fault is found. This routine leads to unnecessary inspections which have a cost with respect to downtime of a component and work hours. This research proposes an alternative routine: performing building maintenance at the point in time when the component is degrading and requires maintenance, thus reducing the frequency of unnecessary inspections. This thesis demonstrates that statistical techniques can be used as part of a maintenance management methodology to invoke maintenance before failure occurs. The proposed FM process is presented through a scenario utilising current Building Information Modelling (BIM) technology and innovative contractual and organisational models. This FM scenario supports a Degradation based Maintenance (DbM) scheduling methodology, implemented using two statistical techniques, Particle Filters (PFs) and Gaussian Processes (GPs). DbM consists of extracting and tracking a degradation metric for a component. Limits for the degradation metric are identified based on one of a number of proposed processes. These processes determine the limits based on the maturity of the historical information available. DbM is implemented for three case study components: a heat exchanger; a heat pump; and a set of bearings. The identified degradation points for each case study, from a PF, a GP and a hybrid (PF and GP combined) DbM implementation are assessed against known degradation points. The GP implementations are successful for all components. For the PF implementations, the results presented in this thesis find that the extracted metrics and limits identify degradation occurrences accurately for components which are in continuous operation. For components which have seasonal operational periods, the PF may wrongly identify degradation. The GP performs more robustly than the PF, but the PF, on average, results in fewer false positives. The hybrid implementations, which are a combination of GP and PF results, are successful for 2 of 3 case studies and are not affected by seasonal data. Overall, DbM is effectively applied for the three case study components. The accuracy of the implementations is dependant on the relationships modelled by the PF and GP, and on the type and quantity of data available. This novel maintenance process can improve equipment performance and reduce energy wastage from BSCs operation.

Medidas de eficiência energética numa indústria cerâmica

O presente relatório resulta de um estágio realizado no âmbito da eficiência energética assente no programa Galp 20-20-20 que tem por génese uma parceria entre a Universidade de Aveiro e a empresa de coberturas cerâmicas, CS – Coelho da Silva S.A. A Fábrica alvo de estudo é uma consumidora intensiva de energia, despendeu no ano de 2013 cerca de 3.768 tep. Devido aos seus processos de cozedura e secagem, apresenta uma elevada dependência de Gás Natural, representando pouco mais de 78% do consumo global da fábrica. Deste consumo de energia térmica, 83% respeita ao forno e os restantes 17% encontram-se alocados ao secador, pelo que as medidas de eficiência energética presentes neste relatório centram-se da redução deste vetor energético. São então propostas três medidas para a redução da dependência deste vetor. A primeira, incide na recuperação de calor residual presente nos gases de exaustão através da instalação de um permutador de calor. Esta medida permite uma redução do consumo na ordem dos 10% e conta com um payback de 2,3 anos resultante de uma economia anual de 150.000 €. Para este estudo foi desenvolvido um modelo dinâmico em excel que permite a simulação de diversos cenários. São também propostas mais duas intervenções que incidem na alteração do circuito térmico. Estas medidas têm um impacte mais reduzido no que respeita ao percentual de redução energético, ambas com menos de 1% de redução do consumo global da fábrica. Contudo são medidas bastante interessantes dada a sua simplicidade e contam com poupanças anuais na ordem dos 6.000 € que resultam num payback inferior a 2 meses. Paralelamente executaram-se dois estudos para a iluminação, o primeiro sugere a instalação de um modelador de tensão que reduz a potência de iluminação em 36%, implicando uma redução da iluminância de cerca de 5%. A redução da potência resulta numa economia energética na ordem dos 0,4% da energia global da instalação. Este equipamento poderá ser adquirido por completo ou em renting. Ao optar pela compra integral, o investimento será apenas ressarcido em 2,8 anos resultante de uma poupança anula de perto de 6.500 €. Caso seja por renting este não tem qualquer custo adicional e as economias monetárias são partilhadas entre a empresa que fornece o equipamento e a CS-Coelho da Silva, S.A. Por fim é sugerida a substituição de parte da iluminação atual da fábrica por tecnologia LED, com esta medida reduz-se o consumo global em 0,76%. Esta medida gera uma economia monetária na ordem dos 11.500 € sendo ressarcida em 2,1 anos.

Putkien päittäishitsaaminen orbitaali-TIG-hitsauksella

Tämän kandidaatintyön tavoitteena oli esitellä orbitaali-TIG-hitsauksen käyttämistä putkien päittäishitsaamiseen. Työssä esitellään Suomesta saatavia orbitaali-TIG-laitteita ja TIG-hitsausprosessi pääperiaatteiltaan sekä prosessin käyttämistä orbitaalihitsaukseen. Myös orbitaali-TIG-hitsauksen tuottavuuteen ja laatuun liittyviä asioita käydään läpi. Suomesta saatavilla olevista laitteista valittiin toiminnallisten mittojen kannalta sopivimmat kandidaatintyötä varten suunniteltuun ripaputkilämmönvaihtimen hitsaukseen. Työ on pääasiallisesti tehty kirjallisuustutkimuksena käyttäen apuna orbitaalilaitteistojen valmistajien ja jälleenmyyjien haastatteluja. Kirjalliset lähteet koostuvat kotimaisesta ja kansainvälisestä hitsauksen alan kirjallisuudesta ja teksti on pyritty sitomaan yhteen käyttäen useaa eri lähdettä. Laitekohtaiset tiedot saatiin laitevalmistajien tuotetiedotteista ja sähköpostihaastatteluna laitteiden jälleenmyyjiltä ja laitevalmistajilta. Suomessa orbitaali-TIG-laitteita maahantuo ja jälleenmyy Masino Welding Oy ja Suomen Teknohaus Oy. Suomessa laitteita valmistaa Kemppi Oy, jonka orbitaalilaitteilla on useita jälleenmyyjiä. Masino Welding Oy myy saksalaisia Orbitalum GmbH:n laitteita ja Suomen Teknohaus Oy ranskalaisia Polysoude S.A.S.:n laitteita. Näiden laitevalmistajien joukosta suunnitellun ripaputkilämmönvaihtimen hitsaukseen soveltuu Orbitalumilta ja Polysoudelta yhdet sekä Kempiltä kaksi umpipihtimallista orbitaalihitsauspäätä. Orbitaali-TIG-hitsauslaitteissa virtalähteet ovat kehittyneet eniten vuosien aikana ja eri laitevalmistajien laitteistojen erot ovat pääasiassa virtalähteisiin liittyviä. Ripaputkilämmönvaihtimen hitsaamiseen sopivin hitsauspäämalli on umpipihti, sillä lämmönvaihtimen päädyt ovat hyvin ahtaita ja umpipihdit ovat orbitaalihitsauspäistä kaikkein kompakteimmat. Suomessa orbitaali-TIG-laitteita ei ole kauheasti tarjolla ja laitteiden markkinointi on jossain määrin kannattamatonta. Orbitaalihitsaus on kuitenkin varteenotettava vaihtoehto TIG-käsinhitsaukselle, jos hitsataan paljon samankaltaisia hitsejä.

Estudo do Sujamento da Superfície de Transferência de Calor do Evaporador de uma Bomba de Calor aquecido pelo efluente de uma fábrica de pasta para papel

O presente trabalho tem como principal objectivo a avaliação do sujamento da superfície de transferência de calor do evaporador de uma bomba de calor, quando se utiliza o efluente da fábrica de pasta e papel da Portucel Soporcel em Cacia como fluido de aquecimento. Para a realização deste estudo montou-se uma instalação, composta por uma bomba de calor, um circuito de água de arrefecimento do condensador da bomba de calor e um circuito de água residual quente para o aquecimento do evaporador da bomba de calor. O ensaio decorreu durante um período de 84 dias, durante o qual foram registadas as temperaturas em vários pontos dos circuitos e os caudais de circulação. A evolução temporal da quantidade de calor transferida no evaporador, assim como, a comparação do coeficiente global de transferência de calor em condições ideias e experimentais, permitiu verificar que a razão U/U0 para o evaporador da bomba de calor não teve um comportamento decrescente ao longo do período de ensaio, permitindo concluir que, nas condições operatórias da experiência, não ocorreu sujamento na superfície do evaporador. No estudo de corrosão do cobre quando exposto à água residual em questão, obteve-se, para a velocidade de corrosão, o valor de 1,56 mg/(dm2 .dia), indicando assim que a corrosão do cobre naquele meio é praticamente inexistente.

Sensoriamento óptico quase-distribuído aplicado ao monitoramento de trocadores de calor de usinas hidrelétricas

This work aims to develop optical sensors for temperature monitoring in hydroelectric power plant heat exchangers. The proposed sensors are based on the Fiber Bragg Gratings technology. First of all, a prototype with three sensors inscribed in a same fiber was developed. This fiber was then fixed to a conventional Pt100 sensor rod and inserted in a thermowell. The ensemble was then calibrated in a workbench, presenting a maximum combined uncertainty of 2,06 °C. The sensor was installed in one of the heat exchangers of the Salto Osório’s hydroelectric power plant. This power plant is situated in the Iguaçu river, at the Paraná state. Despite the satisfactory results, the sensor was improved to a second version. In this, fifteen optical Bragg sensors were inscribed in a same fiber. The fixation with a conventional sensor was no longer necessary, because the first version results comproved the efficiency and response time in comparison to a conventional sensor. For this reason, it was decided to position the fiber inside a stainless steel rod, due to his low thermal expansion coefficient and high corrosion immunity. The utilization of fifteen fiber Bragg gratings aims to improve the sensor spatial resolution. Therefore, measurements every ten centimeters with respect to the heat exchanger’s height are possible. This provides the generation of a thermal map of the heat exchanger’s surface, which can be used for determination of possible points of obstruction in the hydraulic circuit of the heat exchanger. The heat exchanger’s obstruction in hydroelectric power plants usually occur by bio-fouling, and has direct influence in the generator’s cooling system efficiency. The obtained results have demonstrated the feasibility in application of the optical sensors technology in hydroelectric power plants.

A geometric study of liquid retention in open-cell metal foams

Open-cell metal foams show promise as an emerging novel material for heat exchanger applications. The high surface-area-to-volume ratio suggests increased compactness and decrease in weight of heat exchanger designs. However, the metal foam structure appears conducive to condensate retention, which would degenerate heat transfer performance. This research investigates the condensate retention behavior of aluminum open-cell metal foams through the use of static dip tests and geometrical classification via X-ray Micro-Computed Tomography. Aluminum open-cell metal foam samples of 5, 10, 20, and 40 pores per inch (PPI), all having a void fraction greater than 90%, were included in this investigation. In order to model the condensate retention behavior of metal foams, a clearer understanding of the geometry was required. After exploring the ideal geometries presented in the open literature, X-ray Micro-Computed Tomography was employed to classify the actual geometry of the metal foam samples. The images obtained were analyzed using specialized software from which geometric information including strut length and pore shapes were extracted. The results discerned a high variability in ligament length, as well as features supporting the ideal geometry known as the Weaire-Phelan unit cell. The static dip tests consisted of submerging the metal foam samples in a liquid, then allowing gravity-induced drainage until steady-state was reached and the liquid remaining in the metal foam sample was measured. Three different liquids, water, ethylene glycol, and 91% isopropyl alcohol, were employed. The behaviors of untreated samples were compared to samples subjected to a Beomite surface treatment process, and no significant differences in retention behavior were discovered. The dip test results revealed two distinct regions of condensate retention, each holding approximately half of the total liquid retained by the sample. As expected, condensate retention increased as the pores sizes decreased. A model based on surface tension was developed to predict the condensate retention in the metal foam samples and verified using a regular mesh. Applying the model to both the ideal and actual metal foam geometries showed good agreement with the dip test results in this study.