Incorporação de novas tecnologias no setor sucroalcooleiro: produção de hidrogênio e aumento da oferta de eletricidade

This work studies the incorporation of new technologies in the sugarcane sector. Are considered the ethanol steam reforming and the gasification of sugarcane bagasse(by-product) processes associated with combined cycle systems (Gas Turbine + Steam Turbine), aggregating hydrogen production and increased electricity supply in the sector, respectively. To verify the technical feasibility of the incorporation processes was performed a thermodynamic analysis, considering data from a typical Brazilian Sugar Cane Industry. In another step the economic viability study of the hydrogen production process was made, with consideration on hydrated and anhydrous ethanol steam reform, comparing the cost of hydrogen production. Also considered studies of economic engineering of the gasification process and the generation of electricity associated. As conclusions, it follows that the ethanol steam reforming is a great alternative for hydrogen production, presenting production cost relatively low, especially when is considered the steam reforming of hydrated ethanol. For the gasification process associated with combined cycle, can be observed an increase of 8.56 times of the electricity production in the sugar cane industry, indicating a positive annual saving when the sales price of the supply electricity is greater than 0.070 US$/kWh. Finally it can be concluded that the incorporation of these new processes allow greater profitability and operational flexibility of Brazilian sugarcane mills

Studio e sviluppo di un motore a 2 tempi diesel veloce di nuova concezione per applicazioni automobilistiche

The Department of Mechanical and Civil Engineering (DIMeC) of the University of Modena and Reggio Emilia is developing a new type of small capacity HSDI 2-Stroke Diesel engine (called HSD2), featuring a specifically designed combustion system, aimed to reduce weight, size and manufacturing costs, and improving pollutant emissions at partial load. The present work is focused on the analysis of the combustion and the scavenging process, investigated by means of a version of the KIVA-3V code customized by the University of Chalmers and modified by DIMeC. The customization of the KIVA-3V code includes a detailed combustion chemistry approach, coupled with a comprehensive oxidation mechanism for diesel oil surrogate and the modeling of turbulence/chemistry interaction through the PaSR (Partially Stirred Reactor) model. A four stroke automobile Diesel engine featuring a very close bore size is taken as a reference, for both the numerical models calibration and for a comparison with the 2-Stroke engine. Analysis is carried out trough a comparison between HSD2 and FIAT 1300 MultiJet in several operating conditions, at full and partial load. Such a comparison clearly demonstrates the effectiveness of the two stroke concept in terms of emissions reduction and high power density. However, HSD2 is still a virtual engine, and experimental results are needed to assume the reliability of numerical results.

Modellizzazione numerica e caratterizzazione sperimentale di macchine e componenti oleodinamici

Nella prima parte di questa tesi di dottorato sono presentate le attività svolte, di carattere numerico, ai fini della modellizzazione di macchine volumetriche ad ingranaggi esterni. In particolare viene dapprima presentato un modello a parametri concentrati utilizzato per l’analisi dei fenomeni che coinvolgono l’area di ingranamento della macchina; un codice di calcolo associato al modello è stato sviluppato ed utilizzato per la determinazione dell’influenza delle condizioni di funzionamento e delle caratteristiche geometriche della macchina sulle sovra-pressioni e sull’eventuale instaurarsi della cavitazione nei volumi tra i denti che si trovano nell’area di ingranamento. In seguito vengono presentati i risultati ottenuti dall’analisi del bilanciamento assiale di diverse unità commerciali, evidenziando l’influenza delle caratteristiche geometriche delle fiancate di bilanciamento; a questo proposito, viene presentato anche un semplice modello a parametri concentrati per valutare il rendimento volumetrico della macchina ad ingranaggi esterni, con l’intenzione di usare tale parametro quale indice qualitativo della bontà del bilanciamento assiale. Infine, viene presentato un modello completo della macchina ad ingranaggi esterni, realizzato in un software commerciale a parametri concentrati, che permette di analizzare nel dettaglio il funzionamento della macchina e di studiare anche l’interazione della stessa con il circuito idraulico in cui è inserita. Nella seconda parte della tesi si presentano le attività legate alla messa in funzione di due banchi prova idraulici per la caratterizzazione sperimentale di macchine volumetriche e componenti di regolazione, con particolare attenzione dedicata alla messa a punto del sistema di acquisizione e gestione dei dati sperimentali; si presentano infine i risultati di alcune prove eseguite su componenti di regolazione e macchine volumetriche.

Sviluppo di algoritmi avanzati di analisi e diagnosi combustione in tempo reale per motori endotermici alternativi

Increasingly stringent exhaust emission limits and higher fuel economy are the main drivers of the engine development process. As a consequence, the complexity of the propulsion units and its subsystems increase, due to the extensive use of sensors and actuators needed to obtain a precise control over the combustion phase. Since engine calibration process consumes most of the development time, new tools and methodologies are needed to shorten the development time and increase the performance attainable. Real time combustion analysis, based on the in-cylinder pressure signal, can significantly improve the calibration of the engine control strategies and the development of new algorithms, giving instantaneous feedback on the engine behavior. A complete combustion analysis and diagnosis system has been developed, capable of evaluating the most important indicators about the combustion process, such as indicated mean effective pressure, heat release, mass fraction burned and knock indexes. Such a tool is built on top of a flexible, modular and affordable hardware platform, capable of satisfying the requirements needed for accuracy and precision, but also enabling the use directly on-board the vehicle, due to its small form factor.

Sintesi e caratterizzazione di La0.4Sr0.4TiO3 (LST) come anodo innovativo per celle a combustibile ad ossido solido (SOFC)

Le celle a combustibile ad ossido solido (SOFC) sono reattori elettrochimici che convertono l’energia chimica di un gas combustibile direttamente in energia elettrica con un’alta efficienza e con basse emissioni. Il materiale più comunemente usato come anodo, il Ni/YSZ cermet, mostra però numerosi svantaggi nell’applicazione quali la suscettibilità all’avvelenamento da zolfo e la deposizione di coke per cracking degli idrocarburi usati come combustibile. E’ perciò necessario sviluppare materiali alternativi che sopperiscano a questi problemi. Il titanato di stronzio drogato con lantanio con stechiometria La0.4Sr0.4TiO3 (LST) è stato scelto come anodo alternativo per le ottime proprietà possedute. Lo scopo del lavoro di tesi è stato quindi lo studio dell’influenza della natura dei precursori, delle condizioni di sintesi e dell’aggiunta di agenti porizzanti necessari per l’ottenimento della fase perovskitica pura e con porosità controllata. In un primo tempo è stata verificata la possibilità di ottenere la fase La0.4Sr0.4TiO3 pura mediante sintesi allo stato solido, trattando termicamente miscele di precursori diversi. I risultati ottenuti hanno evidenziato che l’utilizzo di nitrati metallici porta a risultati migliori rispetto all’utilizzo di carbonati ed ossidi poiché permette la formazione della fase perovskite a temperature inferiori e con una purezza maggiore. Poiché l’analisi elementare sui materiali preparati in questa prima fase ha evidenziato un problema sulla stechiometria, il metodo di sintesi è stato ottimizzato solubilizzando preventivamente i precursori di lantanio e stronzio e determinandone il titolo mediante ICP. Inoltre, sono state effettuate delle sintesi utilizzando TiO2 a diversa area superficiale, per verificare l’effetto sulle fasi formate di una maggior reattività di questo componente. Per completezza la perovskite è stata sintetizzata anche tramite sintesi sol-gel, utilizzando il metodo Pechini, ottenendo a 700°C la fase pura. L’analisi morfologica ha evidenziato che le polveri con caratteristiche migliori per la formatura sono quelle ottenute tramite sintesi allo stato solido. Le pastiglie prodotte, miscelando tali polveri e agenti porizzanti opportuni, hanno evidenziato la stabilità della fase perovskitica voluta ma anche la necessità di ottimizzare l’aggiunta del porizzante per avere una porosità adeguata all’applicazione del sistema quale anodo SOFC.

Sviluppo di modelli motore e veicolo per l'analisi di strategie di controllo in applicazioni Software e Hardware In the Loop

This work describes the development of a simulation tool which allows the simulation of the Internal Combustion Engine (ICE), the transmission and the vehicle dynamics. It is a control oriented simulation tool, designed in order to perform both off-line (Software In the Loop) and on-line (Hardware In the Loop) simulation. In the first case the simulation tool can be used in order to optimize Engine Control Unit strategies (as far as regard, for example, the fuel consumption or the performance of the engine), while in the second case it can be used in order to test the control system. In recent years the use of HIL simulations has proved to be very useful in developing and testing of control systems. Hardware In the Loop simulation is a technology where the actual vehicles, engines or other components are replaced by a real time simulation, based on a mathematical model and running in a real time processor. The processor reads ECU (Engine Control Unit) output signals which would normally feed the actuators and, by using mathematical models, provides the signals which would be produced by the actual sensors. The simulation tool, fully designed within Simulink, includes the possibility to simulate the only engine, the transmission and vehicle dynamics and the engine along with the vehicle and transmission dynamics, allowing in this case to evaluate the performance and the operating conditions of the Internal Combustion Engine, once it is installed on a given vehicle. Furthermore the simulation tool includes different level of complexity, since it is possible to use, for example, either a zero-dimensional or a one-dimensional model of the intake system (in this case only for off-line application, because of the higher computational effort). Given these preliminary remarks, an important goal of this work is the development of a simulation environment that can be easily adapted to different engine types (single- or multi-cylinder, four-stroke or two-stroke, diesel or gasoline) and transmission architecture without reprogramming. Also, the same simulation tool can be rapidly configured both for off-line and real-time application. The Matlab-Simulink environment has been adopted to achieve such objectives, since its graphical programming interface allows building flexible and reconfigurable models, and real-time simulation is possible with standard, off-the-shelf software and hardware platforms (such as dSPACE systems).

A model for diffusive and displacive phase transitions in steels

Heat treatment of steels is a process of fundamental importance in tailoring the properties of a material to the desired application; developing a model able to describe such process would allow to predict the microstructure obtained from the treatment and the consequent mechanical properties of the material. A steel, during a heat treatment, can undergo two different kinds of phase transitions [p.t.]: diffusive (second order p.t.) and displacive (first order p.t.); in this thesis, an attempt to describe both in a thermodynamically consistent framework is made; a phase field, diffuse interface model accounting for the coupling between thermal, chemical and mechanical effects is developed, and a way to overcome the difficulties arising from the treatment of the non-local effects (gradient terms) is proposed. The governing equations are the balance of linear momentum equation, the Cahn-Hilliard equation and the balance of internal energy equation. The model is completed with a suitable description of the free energy, from which constitutive relations are drawn. The equations are then cast in a variational form and different numerical techniques are used to deal with the principal features of the model: time-dependency, non-linearity and presence of high order spatial derivatives. Simulations are performed using DOLFIN, a C++ library for the automated solution of partial differential equations by means of the finite element method; results are shown for different test-cases. The analysis is reduced to a two dimensional setting, which is simpler than a three dimensional one, but still meaningful.

Sviluppo di algoritmi di RCP per la stima della coppia indicata erogata da un motore a combustione interna.

Combustion control is one of the key factors to obtain better performances and lower pollutant emissions for diesel, spark ignition and HCCI engines. An algorithm that allows estimating, as an example, the mean indicated torque for each cylinder, could be easily used in control strategies, in order to carry out cylinders trade-off, control the cycle to cycle variation, or detect misfires. A tool that allows evaluating the 50% of Mass Fraction Burned (MFB50), or the net Cumulative Heat Release (CHRNET), or the ROHR peak value (Rate of Heat Release), could be used to optimize spark advance or to detect knock in gasoline engines and to optimize injection pattern in diesel engines. Modern management systems are based on the control of the mean indicated torque produced by the engine: they need a real or virtual sensor in order to compare the measured value with the target one. Many studies have been performed in order to obtain an accurate and reliable over time torque estimation. The aim of this PhD activity was to develop two different algorithms: the first one is based on the instantaneous engine speed fluctuations measurement. The speed signal is picked up directly from the sensor facing the toothed wheel mounted on the engine for other control purposes. The engine speed fluctuation amplitudes depend on the combustion and on the amount of torque delivered by each cylinder. The second algorithm processes in-cylinder pressure signals in the angular domain. In this case a crankshaft encoder is not necessary, because the angular reference can be obtained using a standard sensor wheel. The results obtained with these two methodologies are compared in order to evaluate which one is suitable for on board applications, depending on the accuracy required.

Caratterizzazione tecnica e fisiologica della Muay Thai

La Muay Thai, comunemente detta “Boxe Thailandese” è un'arte marziale che rientra nella classificazione delle attività intermittenti con entrambi i sistemi energetici reclutati, aerobico e anaerobico, è inoltre caratterizzata dal fatto che il combattimento alla distanza si alterna alla lotta, denominata “clinch”. Nonostante la popolarità della Muay Thai, in ambito mondiale, stia progressivamente aumentando così come è in aumento il numero di atleti che la praticano, le ricerche incentrate su questa arte marziale e gli studi relativi agli aggiustamenti cardiometabolici nonché alle modalità temporali con cui gli specifici gesti atletici si possono succedere nel tempo durante un match, sono ancora estremamente esigui. L’oggetto del nostro studio è stato l’analisi della struttura temporale del combattimento, tramite la Match Analysis off line (analisi visiva del combattimento), con comparazione dei dati ottenuti tra il vincitore (winner) e il perdente (loser) e la valutazione dell’andamento di alcuni importanti parametri metabolici attraverso la misurazione del lattato e della HR, durante un incontro reale di Boxe Thailandese. La sperimentazione è stata condotta su un gruppo di dieci soggetti di sesso maschile, praticanti la disciplina ad un alto livello nazionale, la cui media ± deviazione standard (DS), di età, peso e altezza è di 24,6 ±4,01 anni, 69,4 ±7 kg e 174,1 ±4,3 cm. Gli atleti sono stati sottoposti, in due diverse giornate separate da almeno tre giorni, a due test; durante una prima seduta sperimentale preliminare abbiamo determinato il massimo consumo di ossigeno (VO2max) nel corso di un test sul nastro trasportare, con concomitante stima della Soglia anaerobica (SA) e misura della massima frequenza cardiaca (HR max). In una seconda seduta sperimentale abbiamo effettuato i test di combattimento in palestra e infine abbiamo analizzato i video degli incontri attraverso la Match Analysis. Dai risultati della Match - Analysis è scaturito che i vincitori hanno eseguito un numero più elevato di azioni efficaci (p < 0,05) rispetto ai non-vincitori, grazie ad un numero maggiore di combinazioni (C ) e di attacchi singoli (A) e un numero minore di difese (D) e di tecniche inefficaci. È così emerso come il livello delle realizzazioni sia quasi esclusivamente dovuto all’efficacia della tecnica e alla tattica delle azioni. Abbiamo quindi focalizzato la nostra attenzione sul clinch e sulle azioni di attacco perché si ipotizzava che potessero essere attività dispendiose e probabilmente responsabili dell’incremento di lattato durante il combattimento, dall’ analisi dei dati però non è stata riscontrata nessuna significativa correlazione tra l’andamento dei dati metabolici e le fasi di attacco e di lotta. Dai nostri risultati emerge in maniera interessante come durante le fasi attive del combattimento si siano raggiunti alti valori di lattato ematico e di frequenza cardiaca, rispettivamente di 12,55 mmol/L e di 182,68 b/min, ben oltre la SA rilevata nel test incrementale dove la HR si posizionava a 168,2 b/min. In conclusione si evidenzia come la Boxe Thailandese sia una disciplina caratterizzata da un considerevole impegno energetico-metabolico, sia aerobico che anaerobico. La predominanza del metabolismo lattacido è dimostrata dagli elevati valori di lattato osservati nel presente studio e dalla frequenza degli attacchi (8,6 ± 3,5 sec.). Questo studio potrà essere utilizzato dagli allenatori per la predisposizione di allenamenti specifici che inducano gli adattamenti propri della Muay Thai.

Comparative Analysis of Alternative Hybrid Systems for Automotive Applications

The main objective of this work was to investigate the impact of different hybridization concepts and levels of hybridization on fuel economy of a standard road vehicle where both conventional and non-conventional hybrid architectures are treated exactly in the same way from the point of view of overall energy flow optimization. Hybrid component models were developed and presented in detail as well as the simulations results mainly for NEDC cycle. The analysis was performed on four different parallel hybrid powertrain concepts: Hybrid Electric Vehicle (HEV), High Speed Flywheel Hybrid Vehicle (HSF-HV), Hydraulic Hybrid Vehicle (HHV) and Pneumatic Hybrid Vehicle (PHV). In order to perform equitable analysis of different hybrid systems, comparison was performed also on the basis of the same usable system energy storage capacity (i.e. 625kJ for HEV, HSF and the HHV) but in the case of pneumatic hybrid systems maximal storage capacity was limited by the size of the systems in order to comply with the packaging requirements of the vehicle. The simulations were performed within the IAV Gmbh - VeLoDyn software simulator based on Matlab / Simulink software package. Advanced cycle independent control strategy (ECMS) was implemented into the hybrid supervisory control unit in order to solve power management problem for all hybrid powertrain solutions. In order to maintain State of Charge within desired boundaries during different cycles and to facilitate easy implementation and recalibration of the control strategy for very different hybrid systems, Charge Sustaining Algorithm was added into the ECMS framework. Also, a Variable Shift Pattern VSP-ECMS algorithm was proposed as an extension of ECMS capabilities so as to include gear selection into the determination of minimal (energy) cost function of the hybrid system. Further, cycle-based energetic analysis was performed in all the simulated cases, and the results have been reported in the corresponding chapters.

Sviluppo di metodologie per la Stima in Tempo Reale delle Grandezze Indicate in Motori a Combustione Interna

Modern Internal Combustion Engines are becoming increasingly complex in terms of their control systems and strategies. The growth of the algorithms’ complexity results in a rise of the number of on-board quantities for control purposes. In order to improve combustion efficiency and, simultaneously, limit the amount of pollutant emissions, the on-board evaluation of two quantities in particular has become essential; namely indicated torque produced by the engine and the angular position where 50% of fuel mass injected over an engine cycle is burned (MFB50). The above mentioned quantities can be evaluated through the measurement of in-cylinder pressure. Nonetheless, at the time being, the installation of in-cylinder pressure sensors on vehicles is extremely uncommon mainly because of measurement reliability and costs. This work illustrates a methodological approach for the estimation of indicated torque and MFB50 that is based on the engine speed fluctuation measurement. This methodology is compatible with the typical on-board application restraints. Moreover, it requires no additional costs since speed can be measured using the system already mounted on the vehicle, which is made of a magnetic pick-up faced to a toothed wheel. The estimation algorithm consists of two main parts: first, the evaluation of indicated torque fluctuation based on speed measurement and secondly, the evaluation of the mean value of the indicated torque (over an engine cycle) and MFB50 by using the relationship with the indicated torque harmonic and other engine quantities. The procedure has been successfully applied to an L4 turbocharged Diesel engine mounted on-board a vehicle.

Development of control-oriented models of Dual Clutch Transmission systems

A control-oriented model of a Dual Clutch Transmission was developed for real-time Hardware In the Loop (HIL) applications, to support model-based development of the DCT controller. The model is an innovative attempt to reproduce the fast dynamics of the actuation system while maintaining a step size large enough for real-time applications. The model comprehends a detailed physical description of hydraulic circuit, clutches, synchronizers and gears, and simplified vehicle and internal combustion engine sub-models. As the oil circulating in the system has a large bulk modulus, the pressure dynamics are very fast, possibly causing instability in a real-time simulation; the same challenge involves the servo valves dynamics, due to the very small masses of the moving elements. Therefore, the hydraulic circuit model has been modified and simplified without losing physical validity, in order to adapt it to the real-time simulation requirements. The results of offline simulations have been compared to on-board measurements to verify the validity of the developed model, that was then implemented in a HIL system and connected to the TCU (Transmission Control Unit). Several tests have been performed: electrical failure tests on sensors and actuators, hydraulic and mechanical failure tests on hydraulic valves, clutches and synchronizers, and application tests comprehending all the main features of the control performed by the TCU. Being based on physical laws, in every condition the model simulates a plausible reaction of the system. The first intensive use of the HIL application led to the validation of the new safety strategies implemented inside the TCU software. A test automation procedure has been developed to permit the execution of a pattern of tests without the interaction of the user; fully repeatable tests can be performed for non-regression verification, allowing the testing of new software releases in fully automatic mode.

High-Speed Laser Processing of Thin Single and Multi-Layer Films

Theoretical models are developed for the continuous-wave and pulsed laser incision and cut of thin single and multi-layer films. A one-dimensional steady-state model establishes the theoretical foundations of the problem by combining a power-balance integral with heat flow in the direction of laser motion. In this approach, classical modelling methods for laser processing are extended by introducing multi-layer optical absorption and thermal properties. The calculation domain is consequently divided in correspondence with the progressive removal of individual layers. A second, time-domain numerical model for the short-pulse laser ablation of metals accounts for changes in optical and thermal properties during a single laser pulse. With sufficient fluence, the target surface is heated towards its critical temperature and homogeneous boiling or "phase explosion" takes place. Improvements are seen over previous works with the more accurate calculation of optical absorption and shielding of the incident beam by the ablation products. A third, general time-domain numerical laser processing model combines ablation depth and energy absorption data from the short-pulse model with two-dimensional heat flow in an arbitrary multi-layer structure. Layer removal is the result of both progressive short-pulse ablation and classical vaporisation due to long-term heating of the sample. At low velocity, pulsed laser exposure of multi-layer films comprising aluminium-plastic and aluminium-paper are found to be characterised by short-pulse ablation of the metallic layer and vaporisation or degradation of the others due to thermal conduction from the former. At high velocity, all layers of the two films are ultimately removed by vaporisation or degradation as the average beam power is increased to achieve a complete cut. The transition velocity between the two characteristic removal types is shown to be a function of the pulse repetition rate. An experimental investigation validates the simulation results and provides new laser processing data for some typical packaging materials.