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.

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.

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.

The Humidity in a Drager Primus Anesthesia Workstation Using Low or High Fresh Gas Flow and With or Without a Heat and Moisture Exchanger in Pediatric Patients

Fundação de Amparo à Pesquisa do Estado de São Paulo (FAPESP)

Quantum heat engines: A thermodynamic analysis of power and efficiency

We show that the operation and the output power of a quantum heat engine that converts incoherent thermal energy into coherent cavity photons can be optimized by manipulating quantum coherences. The gain or loss in the efficiency at maximum power depends on the details of the output power optimization. Quantum effects tend to enhance the output power and the efficiency as the photon occupation in the cavity is decreased.

Heat source modelling and natural ventilation efficiency

We compare natural ventilation flows established by a range of heat source distributions at floor level. Both evenly distributed and highly localised line and point source distributions are considered. We demonstrate that modelling the ventilation flow driven by a uniformly distributed heat source is equivalent to the flow driven by a large number of localised sources. A model is developed for the transient flow development in a room with a uniform heat distribution and is compared with existing models for localised buoyancy inputs. For large vent areas the flow driven by localised heat sources reaches a steady state more rapidly than the uniformly distributed case. For small vent areas there is little difference in the transient development times. Our transient model is then extended to consider the time taken to flush a neutrally buoyant pollutant from a naturally ventilated room. Again comparisons are drawn between uniform and localised (point and line) heat source geometries. It is demonstrated that for large vent areas a uniform heat distribution provides the fastest flushing. However, for smaller vent areas, localised heat sources produce the fastest flushing. These results are used to suggest a definition for the term 'natural ventilation efficiency', and a model is developed to estimate this efficiency as a function of the room and heat source geometries. © 2006 Elsevier Ltd. All rights reserved.

Low heat and high efficiency Nd:GdVO4 laser pumped by 913 nm

A Nd:GdVO4 crystal is pumped directly into its emitting level at 913 nm for the first time to the best of our knowledge. 3.35 W output laser emitting at 1063 nm is achieved in a 1.1 at.% Nd-doped Nd:GdVO4. The crystal absorbs pumping light of 4.30 W at 913 nm and produces a very low quantity of heat with the opto-optic conversion efficiency of 77.2%. The average slope efficiency is 81.2% from 0.21 W, at the threshold, to 4.30 W of absorbed pump power. Because of the very weakly thermal effect, the near-diffraction-limit beam is easily obtained with beam quality factor of M-2 approximate to 1.1.

Combined Effects of Hot Curing Conditions and Reaction Heat on Rubber Vulcanization Efficiency and Vulcanizate Uniformity

A mathematical model of the chemical kinetics of silicone rubber Vulcanization is developed, with the thermal effects being computed using the increment method, and the hot Vulcanization process estimated with the finite element method. The results show that the reaction heat of rubber vulcanization is important for energy saving, and that a proper curing medium temperature is important when considering both vulcanization efficiency and vulcanizate uniformity. The results also indicate that increases in the forced convective heat transfer coefficient have no significant effect above a certain level. The validity of the numerical model is indirectly proven by comparison with existing data.

Heat Dissipation And Energetic Efficiency In Animal Anoxibiosis - Economy Contra Power

This survey on calorimetry and thermodynamics of anoxibiosis applies classical and irreversible thermodynamics to interpret experimental, direct calorimetric results in order to elucidate the sequential activation of various biochemical pathways. First, the concept of direct and indirect calorimetry is expanded to incorporate the thermochemistry of aerobic and anoxic metabolism in living cells and organisms. Calorimetric studies done under normoxia as well as under physiological and environmental anoxia are presented and assessed in terms of ATP turnover rate. Present evidence suggests that unknown sources of energy in freshwater and marine invertebrates under long-term anoxia may be important. During physiological hypoxia, thermodynamically grossly inefficient pathways sustain high metabolic rates for brief periods. On the contrary, under long-term environmental anoxia, low steady-state heat dissipation is linked to the more efficient succinate, propionate, and acetate pathways. In the second part of this paper these relationships are discussed in the context of linear, irreversible thermodynamics. The calorimetric and biochemical trends during aerobic-anoxic transitions are consistent with thermodynamic optimum functions of catabolic pathways. The theory predicts a decrease of rate with an increase of thermodynamic efficiency; therefore maximum rate and maximum efficiency are mutually exclusive. Cellular changes of pH and adenylate phosphorylation potential are recognized as regulatory mechanisms in the energetic switching to propionate production. While enzyme kinetics provides one key for understanding metabolic regulation, our insight remains incomplete without a complementary thermodynamic analysis of kinetic control in energetically coupled pathways.