Obtaining data to validate a model of an induction skull melting furnace

A casting route is often the most cost-effective means of producing engineering components. However, certain materials, particularly those based on Ti, TiAl and Zr alloy systems, are very reactive in the molten condition and must be melted in special furnaces. Induction Skull Melting (ISM) is the most widely-used process for melting these alloys prior to casting components such as turbine blades, engine valves, turbocharger rotors and medical prostheses. A major research project is underway with the specific target of developing robust techniques for casting TiAl components. The aims include increasing the superheat in the molten metal to allow thin section components to be cast, improving the quality of the cast components and increasing the energy efficiency of the process. As part of this, the University of Greenwich (UK) is developing a computer model of the ISM process in close collaboration with the University of Birmingham (UK) where extensive melting trials are being undertaken. This paper describes the experimental measurements to obtain data to feed into and to validate the model. These include measurements of the true RMS current applied to the induction coil, the heat transfer from the molten metal to the crucible cooling water, and the shape of the column of semi-levitated molten metal. Data are presented for Al, Ni and TiAl.

Sandstone response to salt weathering following simulated fire damage: a comparison of furnace heating and fire.

Fire has long been recognized as an agent of rock weathering. Our understanding of the impact of fire on stone comes either from early anecdotal evidence, or from more recent laboratory simulation studies, using furnaces to simulate the effects of fire. This paper suggests that knowledge derived from simulated heating experiments is based on the preconceptions of the experiment designer – when using a furnace to simulate fire, the operator decides on the maximum temperature and the duration of the experiment. These are key factors in determining the response of the stone to fire, and if these are removed from realworld observations then knowledge based on these simulations must be questioned. To explore the differences between heating sandstone in a furnace and a real fire, sample blocks of Peakmoor Sandstone were subjected to different stress histories in combination (lime rendering and removal, furnace heating or fire, frost and salt weathering). Block response to furnace heating and fire is discussed, with emphasis placed on the non-uniformity of the fire and of block response to fire in contrast to the uniform response to surface heating in a furnace. Subsequent response to salt weathering (by a 10% solution of sodium chloride and magnesium sulphate) was then monitored by weight loss. Blocks that had experienced fire showed a more unpredictable response to salt weathering than those that had undergone furnace heating – spalling of corners and rapid catastrophic weight loss were evidenced in blocks that had been subjected to fire, after periods of relative quiescence. An important physical side-effect of the fire was soot accumulation, which created a waxy, relatively impermeable layer on some blocks. This layer repelled water and hindered salt ingress, but eventually detached when salt, able to enter the substrate through more permeable areas, concentrated and crystallized behind it, resulting in rapid weight loss and accelerated decay. Copyright ©2007 John Wiley & Sons, Ltd.

Char oxidation of torrefied biomass at high temperatures and high heating rates

The char oxidation of a torrefied biomass and its parent material was carried out in an isothermal plug flow reactor (IPFR), which is able to rapidly heat the biomass particles to a maximum temperature of 1400 °C at a heating rate of 104 °C/s, similar to the real conditions found in power plant furnaces. During each char oxidation test, the residues of biomass particles were collected and analyzed to determine the weight loss based on the ash tracer method. According to the experimental results, it can be concluded that chars produced from a torrefied biomass are less reactive than the ones produced, under the same conditions, from its raw material. The apparent kinetics of the torrefied biomass and its parent material are determined by minimizing the difference between the modeled and the experimental results. The predicted weight loss during char oxidation, using the determined kinetics, agrees well with experimental results

Melhoria da eficiência energética do processo de produção de molas para a indústria automóvel

Trabalho Final de Mestrado para obtenção do grau de Mestre em Engenharia Química e Biológica

Behaviour of laterised normal and self compacting concrete subjected to elevated temperatures

Concrete is a universal material in the construction industry. With natural resources like sand and aggregate, fast depleting, it is time to look for alternate materials to substitute these in the process of making concrete. There are instances like exposure to solar radiation, fire, furnaces, and nuclear reactor vessels, special applications like missile launching pads etc., where concrete is exposed to temperature variations In this research work, an attempt has been made to understand the behaviour of concrete when weathered laterite aggregate is used in both conventional and self compacting normal strength concrete. The study has been extended to understand the thermal behaviour of both types of laterised concretes and to check suitability as a fire protection material. A systematic study of laterised concrete considering parameters like source of laterite aggregate, grades of Ordinary Portland Cement (OPC) and types of supplementary cementitious materials (fly ash and GGBFS) has been carried out to arrive at a feasible combination of various ingredients in laterised concrete. A mix design methodology has been proposed for making normal strength laterised self compacting concrete based on trial mixes and the same has also been validated. The physical and mechanical properties of laterised concretes have been studied with respect to different variables like exposure temperature (200°C, 400°C and 600°C) and cooling environment (air cooled and water cooled). The behaviour of ferrocement elements with laterised self compacting concrete has also been studied by varying the cover to mesh reinforcement (10mm to 50mm at an interval of 10mm), exposure temperature and cooling environment.

Behavior of geopolymer concrete exposed to elevated temperatures

The research in the area of geopolymer is gaining momentum during the past 20 years. Studies confirm that geopolymer concrete has good compressive strength, tensile strength, flexural strength, modulus of elasticity and durability. These properties are comparable with OPC concrete.There are many occasions where concrete is exposed to elevated temperatures like fire exposure from thermal processor, exposure from furnaces, nuclear exposure, etc.. In such cases, understanding of the behaviour of concrete and structural members exposed to elevated temperatures is vital. Even though many research reports are available about the behaviour of OPC concrete at elevated temperatures, there is limited information available about the behaviour of geopolymer concrete after exposure to elevated temperatures. A preliminary study was carried out for the selection of a mix proportion. The important variable considered in the present study include alkali/fly ash ratio, percentage of total aggregate content, fine aggregate to total aggregate ratio, molarity of sodium hydroxide, sodium silicate to sodium hydroxide ratio, curing temperature and curing period. Influence of different variables on engineering properties of geopolymer concrete was investigated. The study on interface shear strength of reinforced and unreinforced geopolymer concrete as well as OPC concrete was also carried out. Engineering properties of fly ash based geopolymer concrete after exposure to elevated temperatures (ambient to 800 °C) were studied and the corresponding results were compared with those of conventional concrete. Scanning Electron Microscope analysis, Fourier Transform Infrared analysis, X-ray powder Diffractometer analysis and Thermogravimetric analysis of geopolymer mortar or paste at ambient temperature and after exposure to elevated temperature were also carried out in the present research work. Experimental study was conducted on geopolymer concrete beams after exposure to elevated temperatures (ambient to 800 °C). Load deflection characteristics, ductility and moment-curvature behaviour of the geopolymer concrete beams after exposure to elevated temperatures were investigated. Based on the present study, major conclusions derived could be summarized as follows. There is a definite proportion for various ingredients to achieve maximum strength properties. Geopolymer concrete with total aggregate content of 70% by volume, ratio of fine aggregate to total aggregate of 0.35, NaOH molarity 10, Na2SiO3/NaOH ratio of 2.5 and alkali to fly ash ratio of 0.55 gave maximum compressive strength in the present study. An early strength development in geopolymer concrete could be achieved by the proper selection of curing temperature and the period of curing. With 24 hours of curing at 100 °C, 96.4% of the 28th day cube compressive strength could be achieved in 7 days in the present study. The interface shear strength of geopolymer concrete is lower to that of OPC concrete. Compared to OPC concrete, a reduction in the interface shear strength by 33% and 29% was observed for unreinforced and reinforced geopolymer specimens respectively. The interface shear strength of geopolymer concrete is lower than ordinary Portland cement concrete. The interface shear strength of geopolymer concrete can be approximately estimated as 50% of the value obtained based on the available equations for the calculation of interface shear strength of ordinary portland cement concrete (method used in Mattock and ACI). Fly ash based geopolymer concrete undergoes a high rate of strength loss (compressive strength, tensile strength and modulus of elasticity) during its early heating period (up to 200 °C) compared to OPC concrete. At a temperature exposure beyond 600 °C, the unreacted crystalline materials in geopolymer concrete get transformed into amorphous state and undergo polymerization. As a result, there is no further strength loss (compressive strength, tensile strength and modulus of elasticity) in geopolymer concrete, whereas, OPC concrete continues to lose its strength properties at a faster rate beyond a temperature exposure of 600 °C. At present no equation is available to predict the strength properties of geopolymer concrete after exposure to elevated temperatures. Based on the study carried out, new equations have been proposed to predict the residual strengths (cube compressive strength, split tensile strength and modulus of elasticity) of geopolymer concrete after exposure to elevated temperatures (upto 800 °C). These equations could be used for material modelling until better refined equations are available. Compared to OPC concrete, geopolymer concrete shows better resistance against surface cracking when exposed to elevated temperatures. In the present study, while OPC concrete started developing cracks at 400 °C, geopolymer concrete did not show any visible cracks up to 600 °C and developed only minor cracks at an exposure temperatureof 800 °C. Geopolymer concrete beams develop crack at an early load stages if they are exposed to elevated temperatures. Even though the material strength of the geopolymer concrete does not decrease beyond 600 °C, the flexural strength of corresponding beam reduces rapidly after 600 °C temperature exposure, primarily due to the rapid loss of the strength of steel. With increase in temperature, the curvature at yield point of geopolymer concrete beam increases and thereby the ductility reduces. In the present study, compared to the ductility at ambient temperature, the ductility of geopolymer concrete beams reduces by 63.8% at 800 °C temperature exposure. Appropriate equations have been proposed to predict the service load crack width of geopolymer concrete beam exposed to elevated temperatures. These equations could be used to limit the service load on geopolymer concrete beams exposed to elevated temperatures (up to 800 °C) for a predefined crack width (between 0.1mm and 0.3 mm) or vice versa. The moment-curvature relationship of geopolymer concrete beams at ambient temperature is similar to that of RCC beams and this could be predicted using strain compatibility approach Once exposed to an elevated temperature, the strain compatibility approach underestimates the curvature of geopolymer concrete beams between the first cracking and yielding point.

Estudio de la aplicación de sistemas basados en el conocimiento a la operación de una planta de tratamiento de residuos sólidos urbanos por valorización energética

Una de las actuaciones posibles para la gestión de los residuos sólidos urbanos es la valorización energética, es decir la incineración con recuperación de energía. Sin embargo es muy importante controlar adecuadamente el proceso de incineración para evitar en lo posible la liberación de sustancias contaminantes a la atmósfera que puedan ocasionar problemas de contaminación industrial.Conseguir que tanto el proceso de incineración como el tratamiento de los gases se realice en condiciones óptimas presupone tener un buen conocimiento de las dependencias entre las variables de proceso. Se precisan métodos adecuados de medida de las variables más importantes y tratar los valores medidos con modelos adecuados para transformarlos en magnitudes de mando. Un modelo clásico para el control parece poco prometedor en este caso debido a la complejidad de los procesos, la falta de descripción cuantitativa y la necesidad de hacer los cálculos en tiempo real. Esto sólo se puede conseguir con la ayuda de las modernas técnicas de proceso de datos y métodos informáticos, tales como el empleo de técnicas de simulación, modelos matemáticos, sistemas basados en el conocimiento e interfases inteligentes. En [Ono, 1989] se describe un sistema de control basado en la lógica difusa aplicado al campo de la incineración de residuos urbanos. En el centro de investigación FZK de Karslruhe se están desarrollando aplicaciones que combinan la lógica difusa con las redes neuronales [Jaeschke, Keller, 1994] para el control de la planta piloto de incineración de residuos TAMARA. En esta tesis se plantea la aplicación de un método de adquisición de conocimiento para el control de sistemas complejos inspirado en el comportamiento humano. Cuando nos encontramos ante una situación desconocida al principio no sabemos como actuar, salvo por la extrapolación de experiencias anteriores que puedan ser útiles. Aplicando procedimientos de prueba y error, refuerzo de hipótesis, etc., vamos adquiriendo y refinando el conocimiento, y elaborando un modelo mental. Podemos diseñar un método análogo, que pueda ser implementado en un sistema informático, mediante el empleo de técnicas de Inteligencia Artificial.Así, en un proceso complejo muchas veces disponemos de un conjunto de datos del proceso que a priori no nos dan información suficientemente estructurada para que nos sea útil. Para la adquisición de conocimiento pasamos por una serie de etapas: - Hacemos una primera selección de cuales son las variables que nos interesa conocer. - Estado del sistema. En primer lugar podemos empezar por aplicar técnicas de clasificación (aprendizaje no supervisado) para agrupar los datos y obtener una representación del estado de la planta. Es posible establecer una clasificación, pero normalmente casi todos los datos están en una sola clase, que corresponde a la operación normal. Hecho esto y para refinar el conocimiento utilizamos métodos estadísticos clásicos para buscar correlaciones entre variables (análisis de componentes principales) y así poder simplificar y reducir la lista de variables. - Análisis de las señales. Para analizar y clasificar las señales (por ejemplo la temperatura del horno) es posible utilizar métodos capaces de describir mejor el comportamiento no lineal del sistema, como las redes neuronales. Otro paso más consiste en establecer relaciones causales entre las variables. Para ello nos sirven de ayuda los modelos analíticos - Como resultado final del proceso se pasa al diseño del sistema basado en el conocimiento. El objetivo principal es aplicar el método al caso concreto del control de una planta de tratamiento de residuos sólidos urbanos por valorización energética. En primer lugar, en el capítulo 2 Los residuos sólidos urbanos, se trata el problema global de la gestión de los residuos, dando una visión general de las diferentes alternativas existentes, y de la situación nacional e internacional en la actualidad. Se analiza con mayor detalle la problemática de la incineración de los residuos, poniendo especial interés en aquellas características de los residuos que tienen mayor importancia de cara al proceso de combustión.En el capítulo 3, Descripción del proceso, se hace una descripción general del proceso de incineración y de los distintos elementos de una planta incineradora: desde la recepción y almacenamiento de los residuos, pasando por los distintos tipos de hornos y las exigencias de los códigos de buena práctica de combustión, el sistema de aire de combustión y el sistema de humos. Se presentan también los distintos sistemas de depuración de los gases de combustión, y finalmente el sistema de evacuación de cenizas y escorias.El capítulo 4, La planta de tratamiento de residuos sólidos urbanos de Girona, describe los principales sistemas de la planta incineradora de Girona: la alimentación de residuos, el tipo de horno, el sistema de recuperación de energía, y el sistema de depuración de los gases de combustión Se describe también el sistema de control, la operación, los datos de funcionamiento de la planta, la instrumentación y las variables que son de interés para el control del proceso de combustión.En el capítulo 5, Técnicas utilizadas, se proporciona una visión global de los sistemas basados en el conocimiento y de los sistemas expertos. Se explican las diferentes técnicas utilizadas: redes neuronales, sistemas de clasificación, modelos cualitativos, y sistemas expertos, ilustradas con algunos ejemplos de aplicación.Con respecto a los sistemas basados en el conocimiento se analizan en primer lugar las condiciones para su aplicabilidad, y las formas de representación del conocimiento. A continuación se describen las distintas formas de razonamiento: redes neuronales, sistemas expertos y lógica difusa, y se realiza una comparación entre ellas. Se presenta una aplicación de las redes neuronales al análisis de series temporales de temperatura.Se trata también la problemática del análisis de los datos de operación mediante técnicas estadísticas y el empleo de técnicas de clasificación. Otro apartado está dedicado a los distintos tipos de modelos, incluyendo una discusión de los modelos cualitativos.Se describe el sistema de diseño asistido por ordenador para el diseño de sistemas de supervisión CASSD que se utiliza en esta tesis, y las herramientas de análisis para obtener información cualitativa del comportamiento del proceso: Abstractores y ALCMEN. Se incluye un ejemplo de aplicación de estas técnicas para hallar las relaciones entre la temperatura y las acciones del operador. Finalmente se analizan las principales características de los sistemas expertos en general, y del sistema experto CEES 2.0 que también forma parte del sistema CASSD que se ha utilizado.El capítulo 6, Resultados, muestra los resultados obtenidos mediante la aplicación de las diferentes técnicas, redes neuronales, clasificación, el desarrollo de la modelización del proceso de combustión, y la generación de reglas. Dentro del apartado de análisis de datos se emplea una red neuronal para la clasificación de una señal de temperatura. También se describe la utilización del método LINNEO+ para la clasificación de los estados de operación de la planta.En el apartado dedicado a la modelización se desarrolla un modelo de combustión que sirve de base para analizar el comportamiento del horno en régimen estacionario y dinámico. Se define un parámetro, la superficie de llama, relacionado con la extensión del fuego en la parrilla. Mediante un modelo linealizado se analiza la respuesta dinámica del proceso de incineración. Luego se pasa a la definición de relaciones cualitativas entre las variables que se utilizan en la elaboración de un modelo cualitativo. A continuación se desarrolla un nuevo modelo cualitativo, tomando como base el modelo dinámico analítico.Finalmente se aborda el desarrollo de la base de conocimiento del sistema experto, mediante la generación de reglas En el capítulo 7, Sistema de control de una planta incineradora, se analizan los objetivos de un sistema de control de una planta incineradora, su diseño e implementación. Se describen los objetivos básicos del sistema de control de la combustión, su configuración y la implementación en Matlab/Simulink utilizando las distintas herramientas que se han desarrollado en el capítulo anterior.Por último para mostrar como pueden aplicarse los distintos métodos desarrollados en esta tesis se construye un sistema experto para mantener constante la temperatura del horno actuando sobre la alimentación de residuos.Finalmente en el capítulo Conclusiones, se presentan las conclusiones y resultados de esta tesis.

Design and development of a low NOx Coanda ejector burner

Small gaseous combustion systems are being targeted by strict pollution legislation which will provide challenges to reduce the NOx being emitted. A novel type of gas burner has been successfully designed and developed which incorporates a Coanda ejector to promote recirculation of flue gas from the burner exit. This provides a combustion system which gives very low emissions of NOx and CO, whilst maintaining a high degree of flame stability over a range of air/fuel ratios and fuel flow rates. Recirculation of flue gas was obtained by manipulating the aerodynamics of the system, without the aid of external duct work or moving parts. The design of the burner allowed very low pollutant emissions near stoichiometric conditions, resulting in high temperatures of the exit gas. Potential applications of this type of burner are in small and intermediate furnaces where low NOx emissions are required. Moreover, very high-temperature applications, such as glass furnaces could benefit in both cost and pollutant emissions from such a burner.

Improving the Fluorescence Detectability of Polycyclic Aromatic Hydrocarbons for Evaluation of Workplace Environments of Cement Industries Processing Organic Residues

The burning of organic residues and wastes in furnaces of cement industries has been an attractive and lucrative approach to eliminate stocks of these pollutants. There is a potential risk for producing PAH in the workplace of industries burning organic wastes, so that highly sensitive analytical methods are needed for monitoring the air quality of these environments. An official method for determination of PAH is based on liquid chromatography with fluorescence detection at fixed excitation and emission wavelengths. We demonstrate that a suitable choice of these wavelengths, which are changed during the chromatographic run, significantly improves the detectability of PAH in atmosphere and particulate matter collected in cement industries.

Cr(N,C) diffusion coating formation on pre-nitrocarburised H13 tool steel

The microstructural processes of Cr(N,C) coating formation by thermoreactive deposition and diffusion (TRD) on pre-nitrocarburised H13 tool steel were studied. Both nitrocarburising and TRD were performed in fluidized bed furnaces at 570 °C. During TRD, chromium was transferred from chromium powder in the fluidized bed, to the nitrocarburised substrates by gas-phase reactions initiated by reaction of HCl gas with the chromium. Addition of 30% H2 to the input inert gas was found to increase the rate of coating formation, although hydrogen reduction resulted in rapid loss of nitrogen to the surface. The reason for the increased rate of coating formation could not be established without further investigation, although several possible explanations have been proposed. It was found that porosity and the formation of an iron nitride ‘cover layer’ during nitrocarburising were the biggest influences on the microstructure of the Cr(N,C) coating. Microstructural characterization of the coatings was performed by scanning electron microscopy (SEM), X-ray diffraction (XRD) and glow discharge optical emission spectroscopy (GDOES).

Reduction of fuel consumption in an industrial glass melting furnace

Reduction of fuel consumption in glass melting furnaces can cut the cost of production, and tackle the global warming. This paper presents three independent solutions to reduce the fuel consumption in industrial glass melting furnaces. The solutions include air preheating, raw material preheating, and improving the insulation of combustion space refractory. Energy balance equations are derived and used to identify the effects of each solution. The results indicate that the three solutions reduce the fuel consumption by 9.5%, 17%, and 34%, respectively.

A life cycle inventory of aluminium die casting

As part of an ongoing project, a life cycle inventory (LCI) of aluminium high pressure die casting (HPDC) has been collected. This has been conducted from the view of an individual product and also the entire process. The objective of the study was to analyse the process and suggest changes to reduce environmental impacts. One modem aluminium high pressure die casting plant located in Victoria, Australia was evaluated and modelled. Site specific data on energy and materials was gathered and the process was modelled using a typical automotive component. The paper also presents our experience and methodology used in this inventory data collection process from the real industry for LCA purposes. The inventory data collected itself reveals that the HPDC process is energy intensive and as such the major emissions were from the use of natural gas fired furnaces and from the brown coal derived electricity. It is also found the large environmental benefits of using secondary aluminium over primary aluminium in the HPDC process. A detailed LCA is being cal1ied out based on the inventory obtained.

Fluidised bed nitrocarburising of tool steels

The work examines how ferritic nitrocarburising, a common heat treatment process for steels, can be adapted to the fluidised bed furnace. The effect of fluidising powder contamination on repeatability, composition of the reactive gas mixture, the development of nitrocarburised tool steel microstructure and resulting wear properties were investigated.

Study of calcium and silicon migration in refractory magnesia

Studied the effect calcium and silicon impurities have on magnesia refractories, a material frequently used to line high-temperature furnaces. Advanced analytical techniques identified and mapped these impurities in both raw materials and finished magnesia refractories. This research considerably enhanced understanding of factors influencing refractory properties and quality.