Process intensification: From optimised flow patterns to microprocess technology

This thesis is focused on process intensification. Several significant problems and applications of this theme are covered. Process intensification is nowadays one of the most popular trends in chemical engineering and attempts have been made to develop a general, systematic methodology for intensification. This seems, however, to be very difficult, because intensified processes are often based on creativity and novel ideas. Monolith reactors and microreactors are successful examples of process intensification. They are usually multichannel devices in which a proper feed technique is important for creating even fluid distribution into the channels. Two different feed techniques were tested for monoliths. In the first technique a shower method was implemented by means of perforated plates. The second technique was a dispersion method using static mixers. Both techniques offered stable operation and uniform fluid distribution. The dispersion method enabled a wider operational range in terms of liquid superficial velocity. Using dispersion method, a volumetric gas-liquid mass transfer coefficient of 2 s-1 was reached. Flow patterns play a significant role in terms of the mixing performance of micromixers. Although the geometry of a T-mixer is simple, channel configurations and dimensions had a clear effect on mixing efficiency. The flow in the microchannel was laminar, but the formation of vortices promoted mixing in micro T-mixers. The generation of vortices was dependent on the channel dimensions, configurations and flow rate. Microreactors offer a high ratio of surface area to volume. Surface forces and interactions between fluids and surfaces are, therefore, often dominant factors. In certain cases, the interactions can be effectively utilised. Different wetting properties of solid materials (PTFE and stainless steel) were applied in the separation of immiscible liquid phases. A micro-scale plate coalescer with hydrophilic and hydrophobic surfaces was used for the continuous separation of organic and aqueous phases. Complete phase separation occurred in less than 20 seconds, whereas the separation time by settling exceeded 30 min. Fluid flows can be also intensified in suitable conditions. By adding certain additives into turbulent fluid flow, it was possible to reduce friction (drag) by 40 %. Drag reduction decreases frictional pressure drop in pipelines which leads to remarkable energy savings and decreases the size or number of pumping facilities required, e.g., in oil transport pipes. Process intensification enables operation often under more optimal conditions. The consequent cost savings from reduced use of raw materials and reduced waste lead to greater economic benefits in processing.

Control of permanent magnet linear synchronous motor in motion control applications

The aim of the thesis is to study the principles of the permanent magnet linear synchronous motor (PMLSM) and to develop a simulator model of direct force controlled PMLSM. The basic motor model is described by the traditional two-axis equations. The end effects, cogging force and friction model are also included into the final motor model. Direct thrust force control of PMLSM is described and modelled. The full system model is proven by comparison with the data provided by the motor manufacturer.

Drag force and frictional resistances in vertically vibrated dense granular media

The objective of this thesis is to shed light on the vertical vibration of granular materials for potential interest in the power generation industry. The main focus is investigating the drag force and frictional resistance that influence the movement of a granular material (in the form of glass beads) contained in a vessel, which is subjected to sinusoidal oscillation. The thesis is divided into three parts: theoretical analysis, experiments and computer simulations. The theoretical part of this study presents the underlying physical phenomena of the vibration of granular materials. Experiments are designed to determine fundamental parameters that contribute to the behavior of vibrating granular media. Numerical simulations include the use of three different software applications: FLUENT, LS-DYNA and ANSYS Workbench. The goal of these simulations is to test theoretical and semiempirical models for granular materials in order to validate their compatibility with the experimental findings, to assist in predicting their behavior, and to estimate quantities that are hard to measure in laboratory.

Anisotropic surface properties of micro/nanostructured a-C:H:F thin films with self-assembly applications

The singular properties of hydrogenated amorphous carbon (a-C:H) thin filmsdeposited by pulsed DC plasma enhanced chemical vapor deposition (PECVD), such as hardness and wear resistance, make it suitable as protective coating with low surface energy for self-assembly applications. In this paper, we designed fluorine-containing a-C:H (a-C:H:F) nanostructured surfaces and we characterized them for self-assembly applications. Sub-micron patterns were generated on silicon through laser lithography while contact angle measurements, nanotribometer, atomic force microscopy (AFM), and scanning electron microscopy (SEM) were used to characterize the surface. a-C:H:F properties on lithographied surfaces such as hydrophobicity and friction were improved with the proper relative quantity of CH4 and CHF3 during deposition, resulting in ultrahydrophobic samples and low friction coefficients. Furthermore, these properties were enhanced along the direction of the lithographypatterns (in-plane anisotropy). Finally, self-assembly properties were tested with silicananoparticles, which were successfully assembled in linear arrays following the generated patterns. Among the main applications, these surfaces could be suitable as particle filter selector and cell colony substrate.

Real-Time Simulation of Mobile and Industrial Machines Using the Multibody Simulation Approach

This thesis introduces a real-time simulation environment based on the multibody simulation approach. The environment consists of components that are used in conventional product development, including computer aided drawing, visualization, dynamic simulation and finite element software architecture, data transfer and haptics. These components are combined to perform as a coupled system on one platform. The environment is used to simulate mobile and industrial machines at different stages of a product life time. Consequently, the demands of the simulated scenarios vary. In this thesis, a real-time simulation environment based on the multibody approach is used to study a reel mechanism of a paper machine and a gantry crane. These case systems are used to demonstrate the usability of the real-time simulation environment for fault detection purposes and in the context of a training simulator. In order to describe the dynamical performance of a mobile or industrial machine, the nonlinear equations of motion must be defined. In this thesis, the dynamical behaviour of machines is modelled using the multibody simulation approach. A multibody system may consist of rigid and flexible bodies which are joined using kinematic joint constraints while force components are used to describe the actuators. The strength of multibody dynamics relies upon its ability to describe nonlinearities arising from wearing of the components, friction, large rotations or contact forces in a systematic manner. For this reason, the interfaces between subsystems such as mechanics, hydraulics and control systems of the mechatronic machine can be defined and analyzed in a straightforward manner.

Percepció de dificultat i esforç en la mobilització de persones dependents, en el seu entorn domiciliari, per part dels seus cuidadors, abans i després de la utilització de llençols lliscants

Les persones amb dependència necessiten ajuda en la mobilització al llit, que suposa un esforç per a la persona cuidadora. La percepció de dificultat en dur a terme aquestes tasques pot afectar negativament la qualitat de vida de les persones cuidadores i també la de les persones dependents. L’objectiu d’aquest estudi va ser investigar si la utilització de superfícies de reducció de la fricció (tipus llençols lliscants) redueix la dificultat percebuda per les persones cuidadores i les persones dependents en la mobilització al llit. Mètodes: es va dur a terme un estudi quasi experimental a domicili en una mostra seleccionada a conveniència de 12 persones amb dependència i els seus cuidadors en diverses localitats. Es va avaluar la percepció de dificultat en la mobilització per part dels cuidadors i les persones dependents abans i després d’una intervenció formativa simultània a la utilització de llençols lliscants. Resultats: el perfil del cuidador és el d’una dona de mitjana edat amb una relació filial amb la persona dependent i sense formació específica en mètodes de mobilització de persones dependents. El perfil de la persona dependent és el d’una dona major de 80 anys amb una gran dependència que necessita ajuda de la persona que la cuida en les maniobres de redreçament i trasllat al llit. En una escala de percepció de la dificultat de 0 a 10, les mitjanes de les puntuacions observades en els cuidadors abans de la intervenció van ser de 6,9 (DE: 3,1) en el redreçament cap amunt i de 7,1 (DE: 3,1) en el trasllat lateral; després de la intervenció van ser d’1,25 (DE: 1,8) en el redreçament cap amunt i d’1,45 (DE: 1,6) en la mobilització lateral. En la mateixa escala, les mitjanes de les puntuacions observades en les persones dependents abans de la intervenció van ser de 8,6 (DE: 2,3) en el redreçament cap amunt i de 8,6 (DE: 2,3) en el trasllat cap als costats, i després de la intervenció van ser de 2 (DE: 2,6) en els redreçaments cap amunt i de 2 (DE: 2,6) en els trasllats cap als costats. Comparant les puntuacions d’abans i després de la intervenció, observem que la dificultat percebuda per part dels cuidadors de les persones dependents va disminuir de manera significativa (p < 0,001); en les persones dependents també va disminuir, però la disminució no va arribar a ser significativa (p = 0,057). Conclusions: els resultats observats mostren que la utilització de llençols lliscants millora la qualitat de vida dels cuidadors, mesurada per la percepció de la dificultat en les maniobres de mobilització al llit. Així mateix, la seva utilització pot contribuir a un millor envelliment actiu. Caldria fer estudis que permetin quantificar l’esforç físic necessari i el cost-benefici que suposa la utilització d’aquests dispositius.

Kehittyneiden hitsausprosessien soveltuvuus alumiinin ja hiiliterästen hitsaukseen

Diplomityössä tutkitaan hitsausprosessien kehitystä. Työn kirjallisen osan alku kuvaa hitsauksen nykypäivää ja tulevaisuutta sekä millainen on hitsaava Suomi. Kehittyneiden hitsausprosessien tarkastelu on jaettu hiiliterästen ja alumiinien hitsausprosesseihin. Hiiliteräksien hitsauksen osalta työssä esitellään kitkahitsaus pyörivällä työkalulla, muunnettu lyhytkaarihitsaus, laserhitsaus, laser-hybridihitsaus ja kapearailohitsaus. Alumiinien hitsauksen osalta työssä esitellään laserhitsaus, muunnettu lyhytkaarihitsaus, kitkahitsaus pyörivällä työkalulla ja vaihtovirta MIG hitsaus. Diplomityön käytännönosuudessa todennettiin hitsausprosessien kehitys. Ensimmäisissä hitsauskokeissa hitsattiin merialumiinia eri kaarityypeillä. Vertailua tehdään pulssihitsauksen, lankapulssihitsauksen sekä CMT-kaarihitsauksen välillä. Koehitsaukset osoittavat CMT-hitsauksen tuottavan MIG-pulssihitsausta pienemmät hitsausmuodonmuutokset. CMT-hitsauksessa alumiinin oksidikerros aiheuttaa MIGpulssihitsausta vähemmän ongelmia, sillä kaari syttyy varmemmin suurillakin hitsausnopeuksilla, eikä hitsiin synny huokosia. Hitsausnopeudella 40 cm/min lankapulssihitsauksella ja MIG-pulssihitsauksella päittäisliitoksena hitsattujen vesileikattujen alumiinikappaleiden hitseihin ei syntynyt huokosia. Kokeen perusteella voidaan todeta, ettei oksidikerroksella ollut vaikutusta hitsin onnistumiseen. Hitsauskokeiden toinen osio tutkii hiilimangaaniteräksisen T-palkin kuitulaserhitsausta. Viiden kilowatin laserteholla hitsattiin onnistuneesti viisi metriä pitkiä T-palkkeja hitsausnopeudella 2 m/min. Takymetrimittauksella ja Tritop 3D-koordinaattimittauksella todennettiin laserhitsatun T-palkin hitsausmuodonmuutosten olevan huomattavasti Twin-jauhekaarihitsauksella hitsattua T-palkkia pienemmät.

Computational and Experimental Investigation of the Grooved Roll in Paper Machine Environment

In the paper machine, it is not a desired feature for the boundary layer flows in the fabric and the roll surfaces to travel into the closing nips, creating overpressure. In this thesis, the aerodynamic behavior of the grooved roll and smooth rolls is compared in order to understand the nip flow phenomena, which is the main reason why vacuum and grooved roll constructions are designed. A common method to remove the boundary layer flow from the closing nip is to use the vacuum roll construction. The downside of the use of vacuum rolls is high operational costs due to pressure losses in the vacuum roll shell. The deep grooved roll has the same goal, to create a pressure difference over the paper web and keep the paper attached to the roll or fabric surface in the drying pocket of the paper machine. A literature review revealed that the aerodynamic functionality of the grooved roll is not very well known. In this thesis, the aerodynamic functionality of the grooved roll in interaction with a permeable or impermeable wall is studied by varying the groove properties. Computational fluid dynamics simulations are utilized as the research tool. The simulations have been performed with commercial fluid dynamics software, ANSYS Fluent. Simulation results made with 3- and 2-dimensional fluid dynamics models are compared to laboratory scale measurements. The measurements have been made with a grooved roll simulator designed for the research. The variables in the comparison are the paper or fabric wrap angle, surface velocities, groove geometry and wall permeability. Present-day computational and modeling resources limit grooved roll fluid dynamics simulations in the paper machine scale. Based on the analysis of the aerodynamic functionality of the grooved roll, a grooved roll simulation tool is proposed. The smooth roll simulations show that the closing nip pressure does not depend on the length of boundary layer development. The surface velocity increase affects the pressure distribution in the closing and opening nips. The 3D grooved roll model reveals the aerodynamic functionality of the grooved roll. With the optimal groove size it is possible to avoid closing nip overpressure and keep the web attached to the fabric surface in the area of the wrap angle. The groove flow friction and minor losses play a different role when the wrap angle is changed. The proposed 2D grooved roll simulation tool is able to replicate the grooved aerodynamic behavior with reasonable accuracy. A small wrap angle predicts the pressure distribution correctly with the chosen approach for calculating the groove friction losses. With a large wrap angle, the groove friction loss shows too large pressure gradients, and the way of calculating the air flow friction losses in the groove has to be reconsidered. The aerodynamic functionality of the grooved roll is based on minor and viscous losses in the closing and opening nips as well as in the grooves. The proposed 2D grooved roll model is a simplification in order to reduce computational and modeling efforts. The simulation tool makes it possible to simulate complex paper machine constructions in the paper machine scale. In order to use the grooved roll as a replacement for the vacuum roll, the grooved roll properties have to be considered on the basis of the web handling application.

Inovação para a sustentabilidade

The transition to sustainable standards of production and consumption within a scenario of decreased availability of natural resources, growing population and climate change is essential to meet current challenges facing mankind. A strategy to meet these challenges should contain elements different from current approaches for industrial production. This work concentrates on the possibilities for the intensive use of sustainable biomass, abundant minerals and every type of residue, a task that can largely benefit from the application of nanotechnology and biotechnology platforms for material design and transformation. This strategy cannot be solely based on existing knowledge and requires new science, new knowledge including supposedly well-known themes, like the tribochemistry of electrostatic charging and friction. It is especially relevant within the Brazilian context, where many recent successful innovations are related to biomass production and transformation. Implementation of this strategy requires converging efforts by personnel from many different organizations and professions, while making sound risk assessment to produce significant innovation leading to sustainable development.

The Effects of Some Furnish and Paper Structure Related Factors on Wet Web Tensile and Relaxation Characteristics

The objective of this thesis was to identify the effects of different factors on the tension and tension relaxation of wet paper web after high-speed straining. The study was motivated by the plausible connection between wet web mechanical properties and wet web runnability on paper machines shown by previous studies. The mechanical properties of wet paper were examined using a fast tensile test rig with a strain rate of 1000%/s. Most of the tests were carried out with laboratory handsheets, but samples from a pilot paper machine were also used. The tension relaxation of paper was evaluated as the tension remaining after 0.475 s of relaxation (residual tension). The tensile and relaxation properties of wet webs were found to be strongly dependent on the quality and amount of fines. With low fines content, the tensile strength and residual tension of wet paper was mainly determined by the mechanical interactions between fibres at their contact points. As the fines strengthen the mechanical interaction in the network, the fibre properties also become important. Fibre deformations caused by the mechanical treatment of pulp were shown to reduce the mechanical properties of both dry and wet paper. However, the effect was significantly higher for wet paper. An increase of filler content from 10% to 25% greatly reduced the tensile strength of dry paper, but did not significantly impair wet web tensile strength or residual tension. Increased filler content in wet web was shown to increase the dryness of the wet web after the press section, which partly compensates for the reduction of fibrous material in the web. It is also presumable that fillers increase entanglement friction between fibres, which is beneficial for wet web strength. Different contaminants present in white water during sheet formation resulted in lowered surface tension and increased dryness after wet pressing. The addition of different contaminants reduced the tensile strength of the dry paper. The reduction of dry paper tensile strength could not be explained by the reduced surface tension, but rather on the tendency of different contaminants to interfere with the inter-fibre bonding. Additionally, wet web strength was not affected by the changes in the surface tension of white water or possible changes in the hydrophilicity of fibres caused by the addition of different contaminants. The spraying of different polymers on wet paper before wet pressing had a significant effect on both dry and wet web tensile strength, whereas wet web elastic modulus and residual tension were basically not affected. We suggest that the increase of dry and wet paper strength could be affected by the molecular level interactions between these chemicals and fibres. The most significant increases in dry and wet paper strength were achieved with a dual application of anionic and cationic polymers. Furthermore, selectively adding papermaking chemicals to different fibre fractions (as opposed to adding chemicals to the whole pulp) improved the wet web mechanical properties and the drainage of the pulp suspension.

Improving the calculation of rate of stratification in APROS

APROS (Advanced Process Simulation Environment) is a computer simulation program developed to simulate thermal hydraulic processes in nuclear and conventional power plants. Earlier research at VTT Technological Research Centre of Finland had found the current version of APROS to produce inaccurate simulation results for a certain case of loop seal clearing. The objective of this Master’s thesis is to find and implement an alternative method for calculating the rate of stratification in APROS, which was found to be the reason for the inaccuracies. Brief literature study was performed and a promising candidate for the new method was found. The new method was implemented into APROS and tested against experiments and simulations from two test facilities and the current version of APROS. Simulation results with the new version were partially conflicting; in some cases the new method was more accurate than the current version, in some the current method was better. Overall, the new method can be assessed as an improvement.

Rasitusten älykäs seuranta

Tässä diplomityössä käsitellään monikappalesysteeminä mallinnetun toimilaitteen tai mekaanisen systeemin kappaleissa vaikuttavien rasitusten, siirtymien ja jännitysten laskentamenetelmiä. Työhön sisällytettyjen menetelmien valinta on toteutettu 2000-luvulla virtuaalisuunnittelua käsittelevissä tiedelehdissä julkaistujen artikkelien pohjalta. Työn tarkoituksena on muodostaa kirjallisuuskatsaus uusien laskentamenetelmien ominaisuuksista ja metodiikasta, mitä voidaan tarvittaessa soveltaa virtuaalisuunnittelun tarpeisiin. Kaksi esiteltävistä menetelmistä on optimointimenetelmiä (RBDO ja ESL). Muissa menetelmissä käsitellään muun muassa venymien rekonstruointia ja hankauskitkasta komponentteihin kohdistuvia jännityksiä. Moving frame-menetelmässä sovelletaan kelluvan koordinaatiston periaatetta, yksi menetelmistä perustuu selkeästi osarakennetekniikkaan ja yhdessä kappaleiden joustokäyttäytymistä mallinnetaan muotofunktioiden avulla. Lisäksi on kolme soveltavaa esimerkkiä rasitusten seurannasta teollisuuskoneissa. Laskentamenetelmät ovat luonteeltaan ja sovelluskelpoisuudeltaan erilaisia. Optimointimenetelmät ovat parhaimmillaan rakenteiden jatkokehitystyössä, siinä missä muut menetelmät soveltuvat joko olemassa olevien rakenteiden mallintamiseen tai kokonaan uusien systeemien suunnittelutyökaluiksi. Tätä eroavuutta voidaan pitää hyvänä asiana, jotta voidaan valita parhaiten omiin tarkoituksiin soveltuva menetelmä.

Luistonestojärjestelmän ja elektronisen tasauspyörästön suunnittelu ja implementointi hybridityökoneympäristöön

Ympäristörasituksen vähentäminen, tiukkenevat päästörajat ja ehtyvät öljyvarat ovat ajaneet kulkuvälineteollisuuden hakemaan uusia vaihtoehtoja ajoneuvojen energiatehokkuuden kehittämiseksi. Hybriditeknologia tarjoaa ratkaisuja kustannustehokkuuden ja ympäristöystävällisyyden parantamiseksi. Hybriditeknologian yleistyessä myös työkoneympäristössä saadaan paitsi kehitettyä energiatehokkaampia ja pienemmillä käyttökustannuksilla olevia työkoneita, niin myös tuotua siviiliajoneuvoista tuttuja turvallisuusominaisuuksia työkoneympäristöön. Perinteisten diesel-moottorien korvaaminen nopeavasteisilla ja tarkasti säädettävillä sähkömoottoreilla tarjoaa mahdollisuuksia toteuttaa tarkempia ja monipuolisempia säätöjärjestelmiä kuin perinteisessä ympäristössä. Tässä diplomityössä suunnitellaan luistonestojärjestelmä ja elektroninen tasauspyörästö hybridityökoneympäristöön. Järjestelmä voi käyttökohteesta riippuen pienentää huomattavasti käyttökustannuksia ja mahdollistaa uusien sovellusten tuomista markkinoille, kuten esimerkiksi kääntymisen avustaminen differentiaalisella ohjauksella.

Broadband excitation in the system identification of active magnetic bearing rotor systems

One of the targets of the climate and energy package of the European Union is to increase the energy efficiency in order to achieve a 20 percent reduction in primary energy use compared with the projected level by 2020. The energy efficiency can be improved for example by increasing the rotational speed of large electrical drives, because this enables the elimination of gearboxes leading to a compact design with lower losses. The rotational speeds of traditional bearings, such as roller bearings, are limited by mechanical friction. Active magnetic bearings (AMBs), on the other hand, allow very high rotational speeds. Consequently, their use in large medium- and high-speed machines has rapidly increased. An active magnetic bearing rotor system is an inherently unstable, nonlinear multiple-input, multiple-output system. Model-based controller design of AMBs requires an accurate system model. Finite element modeling (FEM) together with the experimental modal analysis provides a very accurate model for the rotor, and a linearized model of the magneticactuators has proven to work well in normal conditions. However, the overall system may suffer from unmodeled dynamics, such as dynamics of foundation or shrink fits. This dynamics can be modeled by system identification. System identification can also be used for on-line diagnostics. In this study, broadband excitation signals are adopted to the identification of an active magnetic bearing rotor system. The broadband excitation enables faster frequency response function measurements when compared with the widely used stepped sine and swept sine excitations. Different broadband excitations are reviewed, and the random phase multisine excitation is chosen for further study. The measurement times using the multisine excitation and the stepped sine excitation are compared. An excitation signal design with an analysis of the harmonics produced by the nonlinear system is presented. The suitability of different frequency response function estimators for an AMB rotor system are also compared. Additionally, analytical modeling of an AMB rotor system, obtaining a parametric model from the nonparametric frequency response functions, and model updating are discussed in brief, as they are key elements in the modeling for a control design. Theoretical methods are tested with a laboratory test rig. The results conclude that an appropriately designed random phase multisine excitation is suitable for the identification of AMB rotor systems.