Methodology to create cost estimation models for engineer-to-order operations

This research addresses the problem of cost estimation for product development in engineer-to-order (ETO) operations. An ETO operation starts the product development process with a product specification and ends with delivery of a rather complicated, highly customized product. ETO operations are practiced in various industries such as engineering tooling, factory plants, industrial boilers, pressure vessels, shipbuilding, bridges and buildings. ETO views each product as a delivery item in an industrial project and needs to make an accurate estimation of its development cost at the bidding and/or planning stage before any design or manufacturing activity starts. ^ Many ETO practitioners rely on an ad hoc approach to cost estimation, with use of past projects as reference, adapting them to the new requirements. This process is often carried out on a case-by-case basis and in a non-procedural fashion, thus limiting its applicability to other industry domains and transferability to other estimators. In addition to being time consuming, this approach usually does not lead to an accurate cost estimate, which varies from 30% to 50%. ^ This research proposes a generic cost modeling methodology for application in ETO operations across various industry domains. Using the proposed methodology, a cost estimator will be able to develop a cost estimation model for use in a chosen ETO industry in a more expeditious, systematic and accurate manner. ^ The development of the proposed methodology was carried out by following the meta-methodology as outlined by Thomann. Deploying the methodology, cost estimation models were created in two industry domains (building construction and the steel milling equipment manufacturing). The models are then applied to real cases; the cost estimates are significantly more accurate than the actual estimates, with mean absolute error rate of 17.3%. ^ This research fills an important need of quick and accurate cost estimation across various ETO industries. It differs from existing approaches to the problem in that a methodology is developed for use to quickly customize a cost estimation model for a chosen application domain. In addition to more accurate estimation, the major contributions are in its transferability to other users and applicability to different ETO operations. ^

kit educacional para controle e supervisão aplicado a nível

PEREIRA, J. P. ; CASTRO, B. P. S. ; VALENTIM, R. A. M. . Kit Educacional para Controle e Supervisão Aplicado a Nível. Holos, Natal, v. 2, p. 68-72, 2009

kit educacional para controle e supervisão aplicado a nível

PEREIRA, J. P. ; CASTRO, B. P. S. ; VALENTIM, R. A. M. . Kit Educacional para Controle e Supervisão Aplicado a Nível. Holos, Natal, v. 2, p. 68-72, 2009

Chemistry of potassium halides and their role in corrosion in biomass and waste firing

Compared to the use of traditional fossil fuels (coal, oil, natural gas), combustion of biomass and waste fuels has several environmental and economic advantages for heat and power generation. However, biomass and waste fuels might contain halogens (Cl, Br, F), alkali metals (Na, K) and heavy metals (Zn, Pb), which may cause harmful emissions and corrosion problems. Hightemperature corrosion occurs typically on furnace waterwalls and superheaters. The corrosion of the boiler tube materials limits the increase of thermal efficiency of steam boilers and leads to costly shutdowns and repairs. In recent years, some concerns have been raised about halogen (Cl, Br, and F)-related hightemperature corrosion in biomass- and waste-fired boilers. Chlorine-related high-temperature corrosion has been studied extensively. The presence of alkali chlorides in the deposits is believed to play a major role in the corrosion observed in biomass and waste fired boilers. However, there is much less information found in literature on the corrosion effect of bromine and fluorine. According to the literature, bromine is only assumed to play a role similar to chlorine; the role of fluorine is even less understood. In this work, a series of bubbling fluidized bed (BFB) bench-scale tests were carried out to characterize the formation and sulfation behaviors of KCl and KBr in BFB combustion conditions. Furthermore, a series of laboratory tests were carried out to investigate the hightemperature corrosion behaviors of three different superheater steels (10CrMo9-10, AISI 347 and Sanicro 28) exposed to potassium halides in ambient air and wet air (containing 30% H2O). The influence of H2O and O2 on the high-temperature corrosion of steels both with and without a salt (KCl) in three gas atmospheres (2% H2O-30% O2-N2, 2% H2O-2% O2-N2 and 30% H2O-2% O2-N2) was also studied. From the bench-scale BFB combustion tests, it was found that HBr has a clearly higher affinity for the available K forming KBr than HCl forming KCl. The tests also indicated that KCl has a higher tendency for sulfation than KBr. From the laboratory corrosion tests in ambient air (also called “dry air” in Paper III and Paper IV), it was found that at relatively low temperatures (≤ 550 °C) the corrosivity of KBr and KF are similar to KCl. At 600 °C, KF showed much stronger corrosivity than KBr and KCl, especially for 10CrMo9-10 and AISI 347. When exposed to KBr or KF, 10CrMo9-10 was durable at least up to 450 °C, while AISI 347 and Sanicro 28 were durable at least up to 550 °C. From the laboratory corrosion tests in wet air (30% H2O), no obvious effect of water vapor was detected at 450 °C. At 550 °C, the influence of water vapor became significant in some cases, but the trend was not consistent. At 550 °C, after exposure with KBr, 10CrMo9-10 suffered from extreme corrosion; after exposure with KF and KCl, the corrosion was less severe, but still high. At 550 °C, local deep pitting corrosion occurred on AISI 347 and Sanicro 28 after exposure with KF. Some formation of K2CrO4 was observed in the oxide layer. At 550 °C, AISI 347 and Sanicro 28 suffered from low corrosion (oxide layer thickness of < 10 μm) after exposure with KBr and KCl. No formation of K2CrO4 was observed. Internal oxidation occurred in the cases of AISI 347 with KBr and KCl. From the laboratory corrosion tests in three different gas atmospheres (2% H2O-30% O2-N2, 2% H2O-2% O2-N2 and 30% H2O-2% O2-N2), it was found that in tests with no salt, no corrosion occurred on AISI 347 and Sanicro 28 up to 600 °C in both the “O2-rich” (2% H2O-30% O2-N2) and “H2O-rich” (30% H2O-2% O2-N2) gas atmospheres; only 10CrMo9-10 showed increased corrosion with increasing temperature. For 10CrMo9-10 in the “O2-rich” atmosphere, the presence of KCl significantly increased the corrosion compared to the “no salt” cases. For 10CrMo9-10 in the “H2O-rich” atmosphere, the presence or absence of KCl did not show any big influence on corrosion. The formation of K2CrO4 was observed only in the case with the “O2-rich” atmosphere. Considering both the results from the BFB tests and the laboratory corrosion tests, if fuels containing Br were to be combusted, the corrosion damage of superheaters would be expected to be higher than if the fuels contain only Cl. Information generated from these studies can be used to help the boiler manufacturers in selecting materials for the most demanding combustion systems.

Balanço energético da operação de uma caldeira a biomassa

A pressão causada sobre os recursos energéticos é impulsionada pela evolução demográfica e pelo crescimento económico, que se vem registando principalmente nos países em desenvolvimento. Segundo várias estatísticas, a procura pela energia incide principalmente sobre os combustíveis fósseis, os quais, representam cerca de do mix de consumo mundial de energia primária. A incerteza sobre as reservas das fontes energéticas não renováveis, e os problemas ambientais derivados da sua conversão noutros tipos de energia, levaram a uma implementação de medidas com rumo à sustentabilidade e eficiência energética. Desta forma, o aumento da utilização sobre as fontes energéticas renováveis é de extrema importância. A biomassa é uma das fontes energéticas de maior relevo. A utilização de biomassa em caldeiras, oferece benefícios económicos, sociais e ambientais, tais como poupança financeira no combustível, conservação dos recursos fósseis e redução de emissões poluentes. As caldeiras desenvolvidas por empresas como a Ventil, são uma solução para a produção de energia térmica pela combustão da biomassa. Estes sistemas caracterizam-se por serem energeticamente eficientes nas várias componentes da sua operação. Assim, pretende-se fazer uma caracterização dos consumos energéticos associados à operação de uma caldeira Ventil de, nomeadamente o consumo de energia elétrica de equipamentos associados. Também será considerado um balanço energético da caldeira e determinado o seu rendimento. Desta forma, concluiu-se que a potência do sistema é de MJ/s, apresentando um rendimento de. Foram detetados motores mal dimensionados e apresentadas alternativas de substituição. Com um investimento de seria possível reduzir a fatura energética em, obtendo um payback de anos. No entanto, a fatura energética do sistema ultrapassa os anuais, sendo que do investimento é na compra do combustível e os restantes são relativos ao consumo de energia elétrica.

Alternativas de uso da borra de café através de hidrólise ácida, enzimática, ou como substrato para a produção das enzimas: lacase e celulase

In the industrial production of soluble coffee, huge amounts of extracted coffee residues are generated; onaverage, for eachtonne of green coffee extracted, 480 kg of coffee ground waste is produced. This is a solid residue currently used to generate energy at the steam boilers from the soluble coffee industry. Some is also used or as fertilizer on agriculture fields. Seeking a better end use, the work reported here aimed to study the viability of hydrolyzing the coffee ground residue for the production of carbohydrates. Hydrolysis was undertaken with hydrochloric acid at different temperatures and pressures, using a water bath or autoclave.An enzymatic hydrolysis with Viscozyme Lwas developed using Whatman filter paper No1 and the optimal conditions were determined using a rotational central composite experimental design (DCCR).The best conditions to hydrolyze filter paper cellulose were 50 FBG (Fungal β-glucanase) of Viscozyme L at pH 4.0 for 1.0 h and 45 ºC. The ground coffee was hydrolyzed under the same conditions as described above for filter paper, however this enzymatic hydrolysis was not efficient. A combination of enzymatic hydrolysis as a pre-treatment for the ground coffee followed by acid hydrolysis using HCl conducted in an autoclave (120 C for 2.0 h) resulted in higher production of glucose as analyzed by HPLC. Another end use of the ground coffee evaluated was as source of substrate in the culture medium to grow Botryosphaeria rhodina MAMB-05 to produce the enzymes laccase and cellulase. Highest enzyme titres obtained were with 8% (w/v) coffee grounds to which was added a minimum salts medium(Vogel), under agitation conditions (180 rpm) at 28ºC. The phenolic compounds present in the coffee grounds appear to have induced laccase by Botryosphaeria rhodina.

Silagem do bagaço de sorgo sacarino

Brazilian sweet sorghum is used to generate ethanol and the bagasse is burned in industrial boilers or deposited on soil polluting the environment. This study evaluated the performance of sorghum plants and its bagasse silage nutritional value aiming to use it in the ruminant nutrition. Experiments were set up on the UTFPR campus at Dois Vizinhos-PR. The first trial was established on October 2nd, 2012 using the genotypes ADV 2010, Hunnigreen, Sugargraze, Volumax, BR 505, 503, 501 and the second trial at 2013 on November 27th assessing the materials ADV 2010, Sugargraze, Hunnigreen, EX 5110, BR 506, 508, 509 and 511. Experimental was laid out as a randomized block design with three replications. Results were analyzed through ANOVA comparing the averages by Duncan test at 5% error probability. As field variables were evaluated: plant height (Pl hei), green mass production (GM Prod), percentage of leaves, stems and panicles in relation to the plant, stems production without straw (Prod stems with straw), whole stems production (Who stems Prod), stem diameter (Stem diam), juice production (Juice prod) and Brix degree (oBrix). After juice plant extraction, forage bagasse was crushed and packed in silos for 60 days and green matter yield was estimated (GM). In bagasse silage gauged to buffer capacity (BC), dry matter (DM), mineral matter (MM), crude protein (CP), ether extract (EE), total carbohydrates (TC), non-fibrous carbohydrates (NFCH), neutral detergent fiber (NDF), acid detergent fiber (ADF), lignin (LIG ) and digestibility "in vitro" (DIGIV). There was no significant difference (P> 0.05) between genotypes regarding to green matter production and on average, the second crop yield was lower and reflected in the reduction of bagasse production. Bagasse silage DM was of 32.3% and 33.1%; NDF 73% and 65.8%, crude protein 3.8% and 5.9; pH 3.7 and 3.7; TC and 9.8 and 10.7. mg MS-1; the amount of NFCH was 11.1 and 13.5%; DIG of DM 36.9 and 62.4% for the respectively to the bagasse produced from materials grown in the 2012/2013 and 2013/2014 seasons. Hybrid genotypes had a better agronomic performance while the varieties were more efficient in bromatological indexes. And despite the high percentage of NDF and the low protein level, it is possible to feed ruminants with this coproduct.

Effect of boiling on deposition of metallic colloids

In this study the relationship between heterogeneous nucleate boiling surfaces and deposition of suspended metallic colloidal particles, popularly known as crud or corrosion products in process industries, on those heterogeneous sites is investigated. Various researchers have reported that hematite is a major constituent of crud which makes it the primary material of interest; however the models developed in this work are irrespective of material choice. Qualitative hypotheses on the deposition process under boiling as proposed by previous researchers have been tested, which fail to provide explanations for several physical mechanisms observed and analyzed. In this study a quantitative model of deposition rate has been developed on the basis of bubble dynamics and colloid-surface interaction potential. Boiling from a heating surface aids in aggregation of the metallic particulates viz. nano-particles, crud particulate, etc. suspended in a liquid, which helps in transporting them to heating surfaces. Consequently, clusters of particles deposit onto the heating surfaces due to various interactive forces, resulting in formation of porous or impervious layers. The deposit layer grows or recedes depending upon variations in interparticle and surface forces, fluid shear, fluid chemistry, etc. This deposit layer in turn affects the rate of bubble generation, formation of porous chimneys, critical heat flux (CHF) of surfaces, activation and deactivation of nucleation sites on the heating surfaces. Several problems are posed due to the effect of boiling on colloidal deposition, which range from research initiatives involving nano-fluids as a heat transfer medium to industrial applications such as light water nuclear reactors. In this study, it is attempted to integrate colloid and surface science with vapor bubble dynamics, boiling heat transfer and evaporation rate. Pool boiling experiments with dilute metallic colloids have been conducted to investigate several parameters impacting the system. The experimental data available in the literature is obtained by flow experiments, which do not help in correlating boiling mechanism with the deposition amount or structure. With the help of experimental evidences and analysis, previously proposed hypothesis for particle transport to the contact line due to hydrophobicity has been challenged. The experimental observations suggest that deposition occurs around the bubble surface contact line and extends underneath area of the bubble microlayer as well. During the evaporation the concentration gradient of a non-volatile species is created, which induces osmotic pressure. The osmotic pressure developed inside the microlayer draws more particles inside the microlayer region or towards contact line. The colloidal escape time is slower than the evaporation time, which leads to the aggregation of particles in the evaporating micro-layer. These aggregated particles deposit onto or are removed from the heating surface, depending upon their total interaction potential. Interaction potential has been computed with the help of surface charge and van der Waals potential for the materials in aqueous solutions. Based upon the interaction-force boundary layer thickness, which is governed by debye radius (or ionic concentration and pH), a simplified quantitative model for the attachment kinetics is proposed. This attachment kinetics model gives reasonable results in predicting attachment rate against data reported by previous researchers. The attachment kinetics study has been done for different pH levels and particle sizes for hematite particles. Quantification of colloidal transport under boiling scenarios is done with the help of overall average evaporation rates because generally waiting times for bubbles at the same position is much larger than growth times. In other words, from a larger measurable scale perspective, frequency of bubbles dictates the rate of collection of particles rather than evaporation rate during micro-layer evaporation of one bubble. The combination of attachment kinetics and colloidal transport kinetics has been used to make a consolidated model for prediction of the amount of deposition and is validated with the help of high fidelity experimental data. In an attempt to understand and explain boiling characteristics, high speed visualization of bubble dynamics from a single artificial large cavity and multiple naturally occurring cavities is conducted. A bubble growth and departure dynamics model is developed for artificial active sites and is validated with the experimental data. The variation of bubble departure diameter with wall temperature is analyzed with experimental results and shows coherence with earlier studies. However, deposit traces after boiling experiments show that bubble contact diameter is essential to predict bubble departure dynamics, which has been ignored previously by various researchers. The relationship between porosity of colloid deposits and bubbles under the influence of Jakob number, sub-cooling and particle size has been developed. This also can be further utilized in variational wettability of the surface. Designing porous surfaces can having vast range of applications varying from high wettability, such as high critical heat flux boilers, to low wettability, such as efficient condensers.

Utilização de sondas lambda em caldeiras de biomassa

Nos dias que correm a eficiência energética está na ordem do dia, havendo um esforço significativo para obter-se equipamentos cada vez mais eficientes. Uma parte significativa do consumo global de energia, bem como da emissão de gases nocivos e de efeito de estufa, está associado à climatização, quer doméstica quer industrial. Assim, é importante desenvolver tecnologias mais eficientes neste domínio. O principal objetivo deste trabalho consiste no desenvolvimento de um módulo de interface a uma sonda lambda para monitorização de combustão em caldeiras de biomassa. Este módulo permitirá medir a concentração de oxigénio presente na saída das caldeiras, possibilitando o ajuste dinâmico dos parâmetros de combustão por forma a maximizar o seu rendimento e minimizar a emissão de gases poluentes. O módulo desenvolvido é de baixo custo e apresenta uma interface bastante simples, facilitando a sua incorporação em equipamentos já existentes. Os resultados obtidos revelaram-se consistentes com os valores teóricos fornecidos pelo fabricante da sonda utilizada, podendo assim concluir-se que o trabalho foi realizado com sucesso.

Geothermal district heating networks: modelling novel operational strategies incorporating heat storage

The value of integrating a heat storage into a geothermal district heating system has been investigated. The behaviour of the system under a novel operational strategy has been simulated focusing on the energetic, economic and environmental effects of the new strategy of incorporation of the heat storage within the system. A typical geothermal district heating system consists of several production wells, a system of pipelines for the transportation of the hot water to end-users, one or more re-injection wells and peak-up devices (usually fossil-fuel boilers). Traditionally in these systems, the production wells change their production rate throughout the day according to heat demand, and if their maximum capacity is exceeded the peak-up devices are used to meet the balance of the heat demand. In this study, it is proposed to maintain a constant geothermal production and add heat storage into the network. Subsequently, hot water will be stored when heat demand is lower than the production and the stored hot water will be released into the system to cover the peak demands (or part of these). It is not intended to totally phase-out the peak-up devices, but to decrease their use, as these will often be installed anyway for back-up purposes. Both the integration of a heat storage in such a system as well as the novel operational strategy are the main novelties of this thesis. A robust algorithm for the sizing of these systems has been developed. The main inputs are the geothermal production data, the heat demand data throughout one year or more and the topology of the installation. The outputs are the sizing of the whole system, including the necessary number of production wells, the size of the heat storage and the dimensions of the pipelines amongst others. The results provide several useful insights into the initial design considerations for these systems, emphasizing particularly the importance of heat losses. Simulations are carried out for three different cases of sizing of the installation (small, medium and large) to examine the influence of system scale. In the second phase of work, two algorithms are developed which study in detail the operation of the installation throughout a random day and a whole year, respectively. The first algorithm can be a potentially powerful tool for the operators of the installation, who can know a priori how to operate the installation on a random day given the heat demand. The second algorithm is used to obtain the amount of electricity used by the pumps as well as the amount of fuel used by the peak-up boilers over a whole year. These comprise the main operational costs of the installation and are among the main inputs of the third part of the study. In the third part of the study, an integrated energetic, economic and environmental analysis of the studied installation is carried out together with a comparison with the traditional case. The results show that by implementing heat storage under the novel operational strategy, heat is generated more cheaply as all the financial indices improve, more geothermal energy is utilised and less fuel is used in the peak-up boilers, with subsequent environmental benefits, when compared to the traditional case. Furthermore, it is shown that the most attractive case of sizing is the large one, although the addition of the heat storage most greatly impacts the medium case of sizing. In other words, the geothermal component of the installation should be sized as large as possible. This analysis indicates that the proposed solution is beneficial from energetic, economic, and environmental perspectives. Therefore, it can be stated that the aim of this study is achieved in its full potential. Furthermore, the new models for the sizing, operation and economic/energetic/environmental analyses of these kind of systems can be used with few adaptations for real cases, making the practical applicability of this study evident. Having this study as a starting point, further work could include the integration of these systems with end-user demands, further analysis of component parts of the installation (such as the heat exchangers) and the integration of a heat pump to maximise utilisation of geothermal energy.

Avaliação do potencial energético de cana (Arundo donax L.) no Algarve

Dissertação de Mestrado, Energias Renováveis e Gestão de Energia, Faculdade de Ciências e Tecnologia, Universidade do Algarve, 2016

Added value from biomass by broader utilization of fuels and CHP plants

The present work, where additional value-creating processes in existing combined heat and power (CHP) structures have been examined, is motivated by a political- and consumer-driven strive towards a bioeconomy and a stagnation for the existing business models in large parts of the CHP sector. The research is based on cases where the integration of flash pyrolysis for co-production of bio-oil, co-gasification for production of fuel gas and synthetic biofuels as well as leaching of extractable fuel components in existing CHP plants have been simulated. In particular, this work has focused on the CHP plants that utilize boilers of fluidized bed (FB) type, where the concept of coupling a separate FB reactor to the FB of the boiler forms an important basis for the analyses. In such dual fluidized bed (DFB) technology, heat is transferred from the boiler to the new rector that is operating with other fluidization media than air, thereby enabling other thermochemical processes than combustion to take place. The result of this work shows that broader operations at existing CHP plants have the potential to enable production of significant volumes of chemicals and/or fuels with high efficiency, while maintaining heat supply to external customers. Based on the insight that the technical preconditions for a broader operation are favourable, the motivation and ability among the incumbents in the Swedish CHP sector to participate in a transition of their operation towards a biorefinery was examined. The result of this assessment showed that the incumbents believe that a broader operation can create significant values for their own operations, the society and the environment, but that they lack both a strong motivation as well as important abilities to move into the new technological fields. If the concepts of broader production are widely implemented in the Swedish FB based CHP sector, this can substantially contribute in the transition towards a bioeconomy.

Characterization of Chimney Flue Gas Flows : Flow Rate Measurements with Averaging Pitot Probes

Performance testing methods of boilers in transient operating conditions (start, stop and combustion power modulation sequences) need the combustion rate quantified to allow for the emissions to be quantified. One way of quantifying the combustion rate of a boiler during transient operating conditions is by measuring the flue gas flow rate. The flow conditions in chimneys of single family house boilers pose a challenge however, mainly because of the low flow velocity. The main objectives of the work were to characterize the flow conditions in residential chimneys, to evaluate the use of the Pitot-static method and the averaging Pitot method, and to develop and test a calibration method for averaging Pitot probes for low