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.

Avaliação de um chiller de absorção numa unidade de cogeração e trigeração

Portugal é um país dependente da energia do exterior, devido à elevada percentagem de consumo de energia a partir de fontes primárias, como por exemplo o gasóleo. Para colmatar este cenário, têm vindo a criar-se incentivos para o uso de energias renováveis e para intensificação de medidas de eficiência energética, como os sistemas de cogeração, de forma a tornar os processos industriais nacionais mais autónomos e mais competitivos. O presente trabalho, centra-se na avaliação do chiller de absorção na central de trigeração da empresa Monteiro, Ribas-Indústria, SA, com a finalidade de identificar algum problema no funcionamento do chiller. Após efetuado o estudo do chiller, verificou-se que o coeficiente de performance do chiller apresenta valores que variam entre 0,75 e 0,81, que comparado com o valor especificado, não apresenta grande diferença. No que toca à potência do chiller, esta apresentou valores entre 948 e 1045 kW. Estes valores estavam bem abaixo da potência especificada pelos fornecedores. Assim, pretendeu-se propor medidas para melhor a potência obtida. Para o efeito foi sugerido o aquecimento da corrente que atua como fonte de calor para o chiller, a corrente de água quente. Embora a empresa apresente a solução para o problema, um permutador de vapor para o aquecimento da corrente de água quente, este não se encontra em funcionamento contínuo, levando a uma potência mais baixa.

Caracterização da tecnologia de frio comercial e profissional

Hoje em dia a preocupação ambiental e a economia são fatores de sustentabilidade que são tidos em conta em países desenvolvidos, especialmente no seio da União Europeia. Reduzir os consumos de energia é, portanto, um ponto-chave para a redução das emissões de gases com efeito de estufa e aumentar a dependência das energias renováveis. Consequentemente surge então a necessidade de aumentar a eficiência dos equipamentos, em particular no presente caso, equipamentos de refrigeração. Para isso foi adotado pela Comissão Europeia uma rotulagem nos produtos consumidores de energia, em particular na refrigeração, os frigoríficos e congeladores domésticos permitindo informar o consumidor para os equipamentos mais eficientes. Mais recentemente, frigoríficos comerciais e profissionais também terão obrigatoriedade de incluir um rótulo energético na parte externa dos mesmos. Nesses rótulos estão incluídas várias informações técnicas do aparelho representadas de uma forma compreensível e lúdica aos olhos do consumidor mais leigo, entre as quais as classes de eficiência energética. As classes de eficiência energética caracterizam-se pela componente tecnológica dos frigoríficos. Perceber quais os componentes e materiais em particular que promovem uma melhor eficiência, quantificar a sua influência e avaliar os seus custos de integração torna-se assim essencial para toda a cadeia envolvida na produção destes equipamentos. Os fluídos frigorigénios e compressores aparentam ser os que mais exercem influência na eficiência de frigoríficos de baixa potência. Tubos capilares com trocador de calor são uma escolha mais eficiente comparado com o tubo capilar padrão que é utilizado nestes frigoríficos. Por forma a obter informação adicional e relevante do ponto de vista da análise energética realizaram-se simulações para determinação do consumo elétrico anual com recurso ao software Pack Calculation Pro. Entre os fluídos frigorigénios R-134a, R-22 e R-410a, os compressores scroll apresentaram consumos mais reduzidos (no máximo de 16%) do que os compressores alternativos. No caso do amoníaco (R-717) os compressores alternativos consumiram em média 14% menos do que os compressores parafuso. O recurso a velocidade variável em compressores permite reduzir o consumo na ordem dos 25%. Válvulas de expansão eletrónicas trazem reduções no consumo de 1,5% quando comparadas com válvulas de expansão termostáticas em compressores de velocidade variável. O propano (R-290) é um gás que mostra ter um melhor desempenho do que o R-134a e R404a em vários compressores, consumindo 16% menos do que o R-404a. Em função da temperatura exterior, o R-290 também apresentou um bom desempenho consumindo em climas quentes (Belém, Brasil) 24% menos do que o R-404a.

Protótipo de um microgerador termoelétrico de estado sólido: cogeração a gás

The thermoelectric energy conversion can be performed directly on generators without moving parts, using the principle of SEEBECK effect, obtained in junctions of drivers' thermocouples and most recently in semiconductor junctions type p-n which have increased efficiency of conversion. When termogenerators are exposed to the temperature difference (thermal gradient) eletromotriz a force is generated inducing the appearance of an electric current in the circuit. Thus, it is possible to convert the heat of combustion of a gas through a burner in power, being a thermoelectric generator. The development of infrared burners, using porous ceramic plate, is possible to improve the efficiency of heating, and reduce harmful emissions such as CO, CO2, NOx, etc.. In recent years the meliorate of thermoelectric modules semiconductor (TEG's) has stimulated the development of devices generating and recovery of thermal irreversibility of thermal machines and processes, improving energy efficiency and exergy these systems, especially processes that enable the cogeneration of energy. This work is based on the construction and evaluation of a prototype in a pilot scale, for energy generation to specific applications. The unit uses a fuel gas (LPG) as a primary energy source. The prototype consists of a porous plate burner infrared, an adapter to the module generator, a set of semiconductor modules purchased from Hi-Z Inc. and a heat exchanger to be used as cold source. The prototype was mounted on a test bench, using a system of acquisition of temperature, a system of application of load and instrumentation to assess its functioning and performance. The prototype had an efficiency of chemical conversion of 0.31% for electrical and heat recovery for cogeneration of about 33.2%, resulting in an overall efficiency of 33.51%. The efficiency of energy exergy next shows that the use of primary energy to useful fuel was satisfactory, although the proposed mechanism has also has a low performance due to underuse of the area heated by the small number of modules, as well as a thermal gradient below the ideal informed by the manufacturer, and other factors. The test methodology adopted proved to be suitable for evaluating the prototype

Abstraction and use of groundwater for heating buildings in a hard rock environment

In order to turn more efficient the heating of class rooms in the lower floor of the old building of the University of Évora (a XVI century building), five drillings were organised inside the area of the university (Figure 1). The purpose was to use the temperature differential of groundwater in relation to air, by means of a heat exchanger, and use this process to heat the rooms using less energy, turning the heating process less expensive. The wells were drilled in fractured rocks (gneisses), and the purpose was to locate them at least around 100 m one from each other, whilst trying to have a hydraulic connection in-between. From the five initial wells, four were successful in terms of productivity, but just two of them (RA1 and RA2) proved to be hydraulically connected. The wells were equipped with screens for all their drilled depth (100 m), except for the first six meters and some two or three pipes of six meters each, to allow space for the installation for submersible pumps. The length of the installed screens guarantees a good efficiency of the system. In the wells with no connection, the heating system can work using each single well for abstraction and injection, but the process is much less efficient than in the cases where interaction between wells is possible through the rock’s fracture network.

Safety of combined heat and moisture exchanger filters in long-term mechanical ventilation.

STUDY OBJECTIVE: To evaluate the safety of a combined heat and moisture exchanger filter (HMEF) for the conditioning of inspired gas in long-term mechanical ventilation (MV). DESIGN: Randomized controlled trial. SETTING: Medical ICU in a large teaching hospital. PATIENTS: One hundred fifteen consecutive patients who required > or = 48 h of MV. INTERVENTIONS: Patients were randomized at intubation time (day 1) to receive inspired gas conditioned either by a water-bath humidifier heated at 32 degrees C (HWBH) or by an HMEF (Hygroster; DAR; Mirandola, Italy). MEASUREMENTS AND MAIN RESULTS: The two study groups were comparable in terms of primary pathologic condition at the time of hospital admission, disease severity as measured by the Simplified Acute Physiology Score, and ICU mortality. They did not differ with respect to ventilator days per patient (mean +/- SD: HMEF, 7.6 +/- 6.5; HWBH, 7.8 +/- 5.8), incidence of endotracheal tube obstruction (HMEF, 0/59; HWBH, 1/56), and incidence of hypothermic episodes (HMEF, five; HWBH, two). In 41 patients receiving MV for > or = 5 days, the morphologic integrity of respiratory epithelium was evaluated on day 1 and day 5, using a cytologic examination of tracheal aspirate smears. The state of ciliated epithelium was scored on a scale from 0 (poorest integrity) to 1,200 (maximum integrity), according to a well-described method. In both patient groups, the scores slightly but significantly decreased from day 1 to day 5 (mean +/- SD: HWBH, from 787 +/- 104 to 745 +/- 88; HMEF, from 813 +/- 79 to 739 +/- 62; p < 0.01 for both groups); there were no statistically significant differences between groups. CONCLUSIONS: These data indicate acceptable safety of HMEFs of the type used in the present study for long-term mechanical ventilation.

The Temperature and Humidity in a Low-Flow Anesthesia Workstation With and Without a Heat and Moisture Exchanger

Coordenação de Aperfeiçoamento de Pessoal de Nível Superior (CAPES)

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)

Effect of heat and moisture exchangers on the prevention of ventilator-associated pneumonia in critically ill patients

Ventilator-associated pneumonia (VAP) remains one of the major causes of infection in the intensive care unit (ICU) and is associated with the length of hospital stay, duration of mechanical ventilation, and use of broad-spectrum antibiotics. We compared the frequency of VAP 10 months prior to (pre-intervention group) and 13 months after (post-intervention group) initiation of the use of a heat and moisture exchanger (HME) filter. This is a study with prospective before-and-after design performed in the ICU in a tertiary university hospital. Three hundred and fourteen patients were admitted to the ICU under mechanical ventilation, 168 of whom were included in group HH (heated humidifier) and 146 in group HME. The frequency of VAP per 1000 ventilator-days was similar for both the HH and HME groups (18.7 vs 17.4, respectively; P = 0.97). Duration of mechanical ventilation (11 vs 12 days, respectively; P = 0.48) and length of ICU stay (11 vs 12 days, respectively; P = 0.39) did not differ between the HH and HME groups. The chance of developing VAP was higher in patients with a longer ICU stay and longer duration of mechanical ventilation. This finding was similar when adjusted for the use of HME. The use of HME in intensive care did not reduce the incidence of VAP, the duration of mechanical ventilation, or the length of stay in the ICU in the study population.

Comparative study of the performance of the M-cycle counter-flow and cross-flow heat exchangers for indirect evaporative cooling - paving the path towards sustainable cooling of buildings

This paper provides a comparative study of the performance of cross-flow and counter-flow M-cycle heat exchangers for dew point cooling. It is recognised that evaporative cooling systems offer a low energy alternative to conventional air conditioning units. Recently emerged dew point cooling, as the renovated evaporative cooling configuration, is claimed to have much higher cooling output over the conventional evaporative modes owing to use of the M-cycle heat exchangers. Cross-flow and counter-flow heat exchangers, as the available structures for M-cycle dew point cooling processing, were theoretically and experimentally investigated to identify the difference in cooling effectiveness of both under the parallel structural/operational conditions, optimise the geometrical sizes of the exchangers and suggest their favourite operational conditions. Through development of a dedicated computer model and case-by-case experimental testing and validation, a parametric study of the cooling performance of the counter-flow and cross-flow heat exchangers was carried out. The results showed the counter-flow exchanger offered greater (around 20% higher) cooling capacity, as well as greater (15%–23% higher) dew-point and wet-bulb effectiveness when equal in physical size and under the same operating conditions. The cross-flow system, however, had a greater (10% higher) Energy Efficiency (COP). As the increased cooling effectiveness will lead to reduced air volume flow rate, smaller system size and lower cost, whilst the size and cost are the inherent barriers for use of dew point cooling as the alternation of the conventional cooling systems, the counter-flow system is considered to offer practical advantages over the cross-flow system that would aid the uptake of this low energy cooling alternative. In line with increased global demand for energy in cooling of building, largely by economic booming of emerging developing nations and recognised global warming, the research results will be of significant importance in terms of promoting deployment of the low energy dew point cooling system, helping reduction of energy use in cooling of buildings and cut of the associated carbon emission.