Planejamento e controle da produção de cilindros para laminação: um estudo de caso quantitativo

Este trabalho apresenta um modelo de otimização-simulação aplicado em um estudo de caso real no setor de cilindros para laminação de uma siderúrgica, buscando melhorar o gerenciamento da área/equipamento gargalo da linha de produção. A simulação atuou em conjunto com um modelo de otimização da programação linear inteira (PLI) para melhorar o atendimento de prazo junto aos clientes em uma produção não seriada. Como resultado deste procedimento combinado da PLI e simulação, o processo produtivo foi otimizado e as filas de espera e o lead-time foram reduzidos, melhorando o atendimento aos clientes.

Remote Sensing Detection of atmospheric pollutants using Lidar, Sodar and correlation with air quality data in an industrial area

Optical remote sensing techniques have obvious advantages for monitoring gas and aerosol emissions, since they enable the operation over large distances, far from hostile environments, and fast processing of the measured signal. In this study two remote sensing devices, namely a Lidar (Light Detection and Ranging) for monitoring the vertical profile of backscattered light intensity, and a Sodar (Acoustic Radar, Sound Detection and Ranging) for monitoring the vertical profile of the wind vector were operated during specific periods. The acquired data were processed and compared with data of air quality obtained from ground level monitoring stations, in order to verify the possibility of using the remote sensing techniques to monitor industrial emissions. The campaigns were carried out in the area of the Environmental Research Center (Cepema) of the University of São Paulo, in the city of Cubatão, Brazil, a large industrial site, where numerous different industries are located, including an oil refinery, a steel plant, as well as fertilizer, cement and chemical/petrochemical plants. The local environmental problems caused by the industrial activities are aggravated by the climate and topography of the site, unfavorable to pollutant dispersion. Results of a campaign are presented for a 24- hour period, showing data of a Lidar, an air quality monitoring station and a Sodar. © 2011 SPIE.

Analise das emissões de CO2 e de energia - simulação com novas tecnologias siderúrgicas

The process of steel production emits a large quantity of greenhouse gases, specifically carbon dioxide (CO2), and the reduction of such emissions is one of the main challenges for the industry in the 21st. Century. To quantify these emissions, the Worldsteel Association (association of the 170 large steel manufacturers of the world) published a methodology (CO2 Emission Data Collection) for calculation and comparison of CO2 emissions among its members. After that, in 2010, this methodology became an ISO (International Organization for Standardization) norm. Today, the calculation of the CO2 emissions in steel making companies follow the ISO 14404-1 for units with blast furnaces and the ISO 14404-2 for units with electric furnaces. In the last years, new technologies were and continue to be developed for the steel making sector aiming at energetic improvements and greenhouse gas reductions (mainly CO2) by the several processes involved in the production of steel. This work had the objective of producing a tool to calculate the CO2 emissions for the steel making sector. An Excel spreadsheet was developed to calculate the emission intensities of CO2 of a steel plant, the Usina Presidente Vargas, of the Companhia Siderúrgica Nacional (CSN). The spreadsheet furnishes results of CO2 emissions and energetic fluxes, and simulates the benefits that some of the new technologies can give to the company. The spreadsheet calculates the emissions in two ways: a) based on the carbon fluxes that enter the unit, and b) based on the emissions of each specific process within the unit (coking, sinterization, blast furnace, among others)

Riesgo biomecánico y dolor lumbar en operarios y personal administrativo en una fábrica de jabón en Bogotá 2016

Introducción: El dolor lumbar y los desórdenes músculo esqueléticos comprometen la salud y la calidad de vida de los trabajadores, pueden poner en riesgo el futuro laboral de las personas. bjetivo: Estimar la prevalencia de dolor lumbar y los posibles factores biomecánicos asociados en el personal operativo y administrativo en una empresa manufacturera de jabón en Bogotá, en el año 2016 Metodología: Estudio de corte transversal donde se evaluó el riesgo biomecánico y la prevalencia del dolor lumbar en personal administrativo (138) y operativo (165); se utilizó como instrumento el ERGOPAR validado en España. Se revisó la asociación utilizando la prueba Chi Cuadrado de Pearson, con un nivel de significación α 0.05 Resultados: 303 trabajadores de una empresa manufacturera de jabón en Bogotá, donde predominó el género masculino (51,82%) y la población adulta media entre 30-39 años (57,42%). La prevalencia del dolor lumbar en la población fue de 61,39% (186). La edad no se asoció estadísticamente al dolor lumbar. Se encontró asociación estadística entre el síntoma dolor lumbar y extensión de cuello (p=0,05 OR1.95 IC 1.33-2.88), así como con agarrar o sujetar objetos (p= 0,036. OR 2.3 IC 1.59-3.51) y con las exigencias físicas laborales (p= 0.001 OR 1.99 IC 1.31-3.02). Conclusiones: La población estudiada presentó una alta prevalencia de dolor lumbar, con predominio en personal que realiza labores operativas, y del género femenino. La adopción de posturas de extensión del cuello y la sujeción o agarre de objetos son factores asociados directamente con la aparición de lumbalgia.

Bending fatigue of stainless steel shear pins belonging to a hydroelectric plant

Coaracy Nunes was the first hydroelectric power plant in the Amazon region, being located in Araguari River, Amapa State, Brazil. The plant operates since 1976, presenting now a nominal capacity of 78 MW. The shear pins, which are installed in the turbine hydraulic arms to control the wicket gate and regulate the water flow into the turbine blades, suffered several breakdowns since 2004. These shear pins are made of an ASTM 410 stainless steel and were designed to break by a shear overload of 120 kN. Fractographic investigation of the pins, however, revealed two types of fracture topographies: a region of stable crack propagation area, with non-pronounced striation and secondary cracks; and a region of unstable propagation, featuring elongated dimples. These results indicated that the stable crack propagation occurred by fatigue (bidirectional bending), which was nucleated at machining marks under high nominal load. Finite element analysis was carried out using two loading conditions (pure shear and a combination of shear and bending) and the results indicated that the presence of a bending stress strongly increased the stress concentration factor (85% rise in the shear stress and 130% rise in the Von Mises stress). Misalignment during shear pins assembly associated with vibration might have promoted the premature failure of the shear by bending fatigue. (C) 2008 Elsevier Ltd. All rights reserved.

Stainless steel information manual for the Savannah River Plant /

"Metals, Ceramics, and Materials (TID-4500, 20th Ed.)."

Fish screen head loss, perforated 16-gage steel plate (5/32-inch holes staggered on 7/32-inch centers) versus 5-mesh, 19-gage galvanized wire, Tracy Pumping Plant intake, Central Valley Project /

Mode of access: Internet.

Hoover Steel Ball Company Plant, Ann Arbor, Michigan

Image from publication: The evolution of the steel ball industry. Hoover Steel Ball Company (Ann Arbor, Mich.), [1917]

A knowledge-based system for process planning in a seamless steel tube plant

The thesis describes the work carried out to develop a prototype knowledge-based system 'KBS-SETUPP' to generate process plans for the manufacture of seamless tubes. The work is specifically related to a plant in which hollows are made from solid billets using a rotary piercing process and then reduced to required size and finished properties using the fixed plug cold drawing process. The thesis first discusses various methods of tube production in order to give a general background of tube manufacture. Then a review of the automation of the process planning function is presented in terms of its basic sub-tasks and the techniques and suitability of a knowledge-based system is established. In the light of such a review and a case study, the process planning problem is formulated in the domain of seamless tube manufacture, its basic sub-tasks are identified and capabilities and constraints of the available equipment in the specific plant are established. The task of collecting and collating the process planning knowledge in seamless tube manufacture is discussed and is mostly fulfilled from domain experts, analysing of existing manufacturing records specific to plant, textbooks and applicable Standards. For the cold drawing mill, tube-drawing schedules have been rationalised to correspond with practice. The validation of such schedules has been achieved by computing the process parameters and then comparing these with the drawbench capacity to avoid over-loading. The existing models cannot be simulated in the computer program as such, therefore a mathematical model has been proposed which estimates the process parameters which are in close agreement with experimental values established by other researchers. To implement the concepts, a Knowledge-Based System 'KBS- SETUPP' has been developed on Personal Computer using Turbo- Prolog. The system is capable of generating process plans, production schedules and some additional capabilities to supplement process planning. The system generated process plans have been compared with the actual plans of the company and it has been shown that the results are satisfactory and encouraging and that the system has the capabilities which are useful.

A neural network-based preset generation tool for a steel tandem cold mill

This paper traces the development of a software tool, based oil a combination of artificial neural networks (ANN) and a few process equations. aiming to serve as a backup operation instrument in the reference generation for real-time controllers of a steel tandem cold mill By emulating the mathematical model responsible for generating presets under normal operational conditions, the system works as ail option to maintain plant operation in the event of a failure in the processing unit that executes the mathematical model. The system, built from the production data collected over six years of plant operation, steered to the replacement of the former backup operation mode (based oil a lookup table). which degraded both product quality and plant productivity. The study showed that ANN are appropriated tools for the intended purpose and that by this instrument it is possible to achieve nearly the totality of the presets needed by this land of process. The text characterizes the problem, relates the investigated options to solve it. justifies the choice of the ANN approach, describes the methodology and system implementation and, finally, shows and discusses the attained results. (C) 2009 Elsevier Ltd. All rights reserved

Development of an innovative pyrolysis plant for the production of secondary raw materials

This project was born with the aim of developing an environmentally and financially sustainable process to dispose of end-life tires. In this perspective was devised an innovative static bed batch pilot reactor where pyrolysis can be carried out on the whole tires in order to recover energy and materials and simultaneously save the energy costs of their shredding. The innovative plant is also able to guarantee a high safety of the process thanks to the presence of a hydraulic guard. The pilot plant was used to pyrolyze new and end-life tires at temperatures from 400 to 600°C with step of 50°C in presence of steam. The main objective of this research was to evaluate the influence of the maximum process temperature on yields and chemical-physics properties of pyrolysis products. In addition, in view of a scale-up of the plant in continuous mode, the influence of the nature of several different tires as well as the effects of the aging on the final products were studied. The same pilot plant was also used to carry out pyrolysis on polymeric matrix composites in order to obtain chemical feedstocks from the resin degradation together with the recovery of the reinforcement in the form of fibers. Carbon fibers reinforced composites ad fiberglass was treated in the 450-600°C range and the products was fully characterized. A second oxidative step was performed on the pyrolysis solid residue in order to obtain the fibers in a suitable condition for a subsequent re-impregnation in order to close the composite Life Cycle in a cradle-to-cradle approach. These investigations have demonstrated that steel wires, char, carbon and glass fibers recovered in the prototypal plant as solid residues can be a viable alternative to pristine materials, making use of them to obtain new products with a commercial added value.

Stress relaxation losses of prestressing steel wires

Prestressed structures are susceptible to relaxation losses which are of significant importance in structural design. After being manufactured, prestressing wires are coiled to make their storage and transportation easier. The possible deleterious effects of this operation on the stress relaxation behavior of prestressing steel wires are usually neglected, though it has been noticed by manufacturers and contractors that when relaxation tests are carried out after a long-time storage, on occasions relaxation losses are higher than those measured a short time after manufacturing. The influence of coiling on the relaxation losses is checked by means of experimental work and confirmed with a simple analytical model. The results show that some factors like initial residual stresses, excessively long-time storage or storage at high temperatures, can trigger or accentuate this damage. However, it is also shown that if the requirements of standards are fulfilled (minimum coiling diameters) these effects can be neglected.