Eco-efficiency approaches towards a sustainable composite materials manufacturing industry’

In this study the potential eco-efficiency performance of a pultrusion manufacturing company was assessed. Indicators values and eco-efficiency ratios were estimated taking into account the implementation of new proceedings and procedures in the production process of glass fibre reinforced polymers (GFRP) pultrusion profiles. Two different approaches were foreseen: 1)Adoption of a new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; and 2) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

A case study on the improvement of eco-efficiency ratios: application to a composite processing industry

The World Business Council for Sustainable Development (WBCSD) defines Eco-Efficiency as follows: ‘Eco- Efficiency is achieved by the delivery of competitively priced-goods and services that satisfy human needs and bring quality of life, while progressively reducing ecological impacts and resource intensity throughout the life-cycle to a level at least in line with the earth’s estimated carrying capacity’. Eco-Efficiency is under this point of view a key concept for sustainable development, bringing together economic and ecological progress. Measuring the Eco-Efficiency of a company, factory or business, is a complex process that involves the measurement and control of several and relevant parameters or indicators, globally applied to all companies in general, or specific according to the nature and specificities of the business itself. In this study, an attempt was made in order to measure and evaluate the eco-efficiency of a pultruded composite processing company. For this purpose the recommendations of WBCSD [1] and the directives of ISO 14301 standard [2] were followed and applied. The analysis was restricted to the main business branch of the company: the production and sale of standard GFRP pultrusion profiles. The main general indicators of eco-efficiency, as well as the specific indicators, were defined and determined according to ISO 14031 recommendations. With basis on indicators’ figures, the value profile, the environmental profile, and the pertinent eco-efficiency’s ratios were established and analyzed. In order to evaluate potential improvements on company eco-performance, new indicators values and ecoefficiency ratios were estimated taking into account the implementation of new proceedings and procedures, both in upstream and downstream of the production process, namely: a) Adoption of new heating system for pultrusion die in the manufacturing process, more effective and with minor heat losses; b) Implementation of new software for stock management (raw materials and final products) that minimize production failures and delivery delays to final consumer; c) Recycling approach, with partial waste reuse of scrap material derived from manufacturing, cutting and assembly processes of GFRP profiles. In particular, the last approach seems to significantly improve the eco-efficient performance of the company. Currently, by-products and wastes generated in the manufacturing process of GFRP profiles are landfilled, with supplementary added costs to this company traduced by transport of scrap, landfill taxes and required test analysis to waste materials. However, mechanical recycling of GFRP waste materials, with reduction to powdered and fibrous particulates, constitutes a recycling process that can be easily attained on heavy-duty cutting mills. The posterior reuse of obtained recyclates, either into a close-looping process, as filler replacement of resin matrix of GFRP profiles, or as reinforcement of other composite materials produced by the company, will drive to both costs reduction in raw materials and landfill process, and minimization of waste landfill. These features lead to significant improvements on the sequent assessed eco-efficiency ratios of the present case study, yielding to a more sustainable product and manufacturing process of pultruded GFRP profiles.

How to reduce energy consumption on pultrusion

The global warming due to high CO2 emission in the last years has made energy saving a global problem nowadays. However, manufacturing processes such as pultrusion necessarily needs heat for curing the resin. Then, the only option available is to apply all efforts to make the process even more efficient. Different heating systems have been used on pultrusion, however, the most widely used are the planar resistances. The main objective of this study is to develop another heating system and compares it with the former one. Thermography was used in spite of define the temperature profile along the die. FEA (finite element analysis) allows to understand how many energy is spend with the initial heating system. After this first approach, changes were done on the die in order to test the new heating system and to check possible quality problems on the product. Thus, this work allows to conclude that with the new heating system a significant reduction in the setup time is now possible and an energy reduction of about 57% was achieved.

Optimization of the Pultrusion process

Manufacturing processes need permanently to innovate and optimize because any can be susceptible to continuous improvement. Innovation and commitment to the development of these new solutions resulting from existing expertise and the continuing need to increase productivity, flexibility and ensuring the necessary quality of the manufactured products. To increase flexibility, it is necessary to significantly reduce set-up times and lead time in order to ensure the delivery of products ever faster. This objective can be achieved through a normalization of the pultrusion line elements. Implicitly, there is an increase of productivity by this way. This work is intended to optimize the pultrusion process of structural profiles. We consider all elements of the system from the storehouse of the fibers (rack) to the pultrusion die. Particular attention was devoted to (a) the guidance system of the fibers and webs, (b) the resin container where the fibers are impregnated, (c) standard plates positioning of the fibers towards the entrance to the spinneret and also (d) reviewed the whole process of assembling and fixing the die as well as its the heating system. With the implementation of these new systems was achieved a significant saving of time set-up and were clearly reduced the unit costs of production. Quality assurance was also increased.

Optimizing the embedded heaters position in the pultrusion process using finite element analysis

This study is based on a previous experimental work in which embedded cylindrical heaters were applied to a pultrusion machine die, and resultant energetic performance compared with that achieved with the former heating system based on planar resistances. The previous work allowed to conclude that the use of embedded resistances enhances significantly the energetic performance of pultrusion process, leading to 57% decrease of energy consumption. However, the aforementioned study was developed with basis on an existing pultrusion die, which only allowed a single relative position for the heaters. In the present work, new relative positions for the heaters were investigated in order to optimize heat distribution process and energy consumption. Finite Elements Analysis was applied as an efficient tool to identify the best relative position of the heaters into the die, taking into account the usual parameters involved in the process and the control system already tested in the previous study. The analysis was firstly developed with basis on eight cylindrical heaters located in four different location plans. In a second phase, in order to refine the results, a new approach was adopted using sixteen heaters with the same total power. Final results allow to conclude that the correct positioning of the heaters can contribute to about 10% of energy consumption reduction, decreasing the production costs and leading to a better eco-efficiency of pultrusion process.

Diagnóstico Energético e Modelação Energética de uma Piscina Municipal

Mestrado em Engenharia Mecânica – Ramo Energia

Breeding of Biomphalaria tenagophila in mass scale

An efficient method for breeding Biomphalaria tenagophila (Taim lineage/RS) was developed over a 5-year-period (2005-2010). Special facilities were provided which consisted of four cement tanks (9.4 x 0.6 x 0.22 m), with their bottom covered with a layer of sterilized red earth and calcium carbonate. Standard measures were adopted, as follows: each tank should contain an average of 3000 specimens, and would be provided with a daily ration of 35,000 mg complemented with lettuce. A green-house effect heating system was developed which constituted of movable dark canvas covers, which allowed the temperature to be controlled between 20 - 24 ºC. This system was essential, especially during the coldest months of the year. Approximately 27,000 specimens with a diameter of 12 mm or more were produced during a 14-month-period. The mortality rates of the newly-hatched and adult snails were 77% and 37%, respectively. The follow-up of the development system related to 310 specimens of B. tenagophila demonstrated that 70-day-old snails reached an average of 17.0 ± 0.9 mm diameter. The mortality rates and the development performance of B. tenagophila snails can be considered as highly satisfactory, when compared with other results in literature related to works carried out with different species of the genus Biomphalaria, under controlled laboratory conditions.

Influência das energias renováveis na certificação energética de uma habitação de acordo com o regulamento do desempenho energético dos edifícios de habitação

A presente dissertação tem como objetivo principal o estudo da importância que os sistemas de energias renováveis têm na obtenção da classe de eficiência energética em edifícios de habitação. Analisou-se assim, qual dos sistemas apresentados na legislação é mais vantajoso na relação entre a classe energética e o investimento necessário a efetuar. Como caso de estudo, utilizou-se um edifício de habitação em fase de projeto situada em ambiente urbano, a uma distância muito curta da costa marítima, no distrito do Porto. A primeira etapa da dissertação passou pela caracterização do edifício, determinando as suas necessidades nominais anuais de energia para aquecimento, para arrefecimento, para preparação de águas quentes sanitárias e por fim, as necessidades nominais de energia primária. Com isto, obteve-se a classe de eficiência energética da habitação sem a utilização de qualquer tipo de sistema de aproveitamento de energia renovável. Após esta obtenção, verificou-se que o edifício em análise já possuía uma classe muito eficiente, classe A, superior à classe mínima exigida pelo regulamento, B-. A desvantagem do edifício já possuir esta classe é que a implementação de sistemas de energia não iriam alterar drasticamente a classe, e por isso, não se iria conseguir retirar uma dedução correta de qual o melhor para promover a eficiência energética. De seguida, procedeu-se ao estudo dos sistemas de energia renovável, apresentando sistemas adequados para a habitação e calculando-se as novas classes de eficiência energética, com a utilização de cada sistema. Consecutivamente, começou-se a retirar ilações dos sistemas mais eficientes, ou seja, os sistemas que tem como função aquecer a moradia ou a função de preparar águas quentes sanitárias, pois, iriam mitigar necessidades nominais de energia, enquanto os sistemas de produção de energia elétrica apenas iriam contribuir para uma melhoria energética. Outra desvantagem verificada foi que, devido ao local onde a habitação se situa, não seria possível efetuar uma análise a todos os sistemas de aproveitamento de energia renovável. iv Por fim, efetuou-se uma análise dos investimentos necessários para a implementação dos sistemas de energias renováveis face às diminuições percentuais do rácio de eficiência energética. Posto isto, obteve-se os melhores sistemas a implementar na moradia, no ponto de vista de melhorar a classe de eficiência energética, seria uma caldeira a pellets com função de aquecimento e produção de águas quentes sanitárias, enquanto que, do ponto de vista financeiro obteve-se o sistema de aquecimento e produção de águas quentes sanitárias através de um recuperador de calor a lenha, que em ambos os casos a classe de eficiência energética passou de A para A+.

Estudo de viabilidade técnico-económica da instalação de caldeiras a biomassa para o aquecimento central do ISEP

Neste projeto pretende-se utilizar uma fonte energética renovável (nomeadamente a biomassa), no âmbito da produção de água quente para aquecimento central das instalações do Instituto Superior de Engenharia do Porto (ISEP). O objetivo principal remete para a avaliação técnico-económica da substituição das quinze caldeiras existentes, alimentadas a gás natural, por seis caldeiras alimentadas a biomassa, nomeadamente a pellets. Desta forma, permite-se apostar na biomassa como uma alternativa para reduzir a dependência dos combustíveis fósseis. Neste trabalho apresenta-se uma comparação realista do sistema de aquecimento existente face ao novo a implementar, alimentado por um combustível renovável utilizando caldeiras a pellets de 85% de rendimento. Para realizar esta comparação, usou-se as faturas energéticas de gás natural do ISEP, o custo da quantidade equivalente necessária de pellets, os custos de manutenção dos dois tipos de caldeiras e, os custos do consumo de energia elétrica por parte de ambas as caldeiras. Com este estudo, estimou-se uma poupança anual de 84.100,76 €/ano. Determinaram-se experimentalmente, em laboratório, os parâmetros essenciais de uma amostra de pellets, que foram usados para calcular as necessidades energéticas em biomassa no ISEP, bem como a produção de cinzas gerada por parte das caldeiras. Foi proposto um destino ambientalmente adequado para os 788,5 kg/ano de cinzas obtidas – a utilização na compostagem, após tratamento e aprovação de ensaios ecotoxicológicos realizados pela empresa que fará a sua recolha. As caldeiras a pellets terão um consumo mínimo teórico de 16,47 kgpellets/h, consumindo previsivelmente 197,13 tpellets/ano. Para este efeito, serão usadas caldeiras Quioto de 150 kW da marca Zantia. Para comparar distintas possibilidades de investimento para o projeto, avaliaram-se dois cenários: um foi escolhido de forma a cobrir o somatório da potência instalada das caldeiras atuais e o outro de forma a responder aos consumos energéticos em aquecimento atuais. Além disso, avaliaram-se cenários de financiamento do investimento distintos: um dos cenários corresponde ao pagamento do investimento total do projeto no momento da aquisição das caldeiras, enquanto o outro cenário, mais provável de ser escolhido, refere-se ao pedido de um empréstimo ao banco, no valor de 75% do investimento total. Para o cenário mais provável de investimento, obteve-se um VAL de 291.364,93 €/ano, com taxa interna de rentabilidade (TIR) de 17 %, um índice de rentabilidade (IR) de 1,85 e um período de retorno (PBP) de 5 anos. Todos os cenários avaliados registam rentabilidade do projeto de investimento, sem risco para o projeto.

Compact ion-source based on superionic rubidium silver iodide (RbAg4I5) solid electrolyte

Dissertação para obtenção do Grau de Mestre em Engenharia Física

Cardiopulmonary support and extracorporeal membrane oxygenation for cardiac assist.

BACKGROUND: Use of cardiopulmonary bypass for emergency resuscitation is not new. In fact, John Gibbon proposed this concept for the treatment of severe pulmonary embolism in 1937. Significant progress has been made since, and two main concepts for cardiac assist based on cardiopulmonary bypass have emerged: cardiopulmonary support (CPS) and extracorporeal membrane oxygenation (ECMO). The objective of this review is to summarize the state of the art in these two technologies. METHODS: Configuration of CPS is now fairly standard. A mobile cart with relatively large wheels allowing for easy transportation carries a centrifugal pump, a back-up battery with a charger, an oxygen cylinder, and a small heating system. Percutaneous cannulation, pump-driven venous return, rapid availability, and transportability are the main characteristics of a CPS system. Cardiocirculatory arrest is a major predictor of mortality despite the use of CPS. In contrast, CPS appears to be a powerful tool for patients in cardiogenic shock before cardiocirculatory arrest, requiring some type of therapeutic procedures, especially repair of anatomically correctable problems or bridging to other mechanical circulatory support systems such as ventricular assist devices. CPS is in general not suitable for long-term applications because of the small-bore cannulas, resulting in significant pressure gradients and eventually hemolysis. RESULTS: In contrast, ECMO can be designed for longer-term circulatory support. This requires large-bore cannulas and specifically designed oxygenators. The latter are either plasma leakage resistent (true membranes) or relatively thrombo-resistant (heparin coated). Both technologies require oxygenator changeovers although the main reason for this is different (clotting for the former, plasma leakage for the latter). Likewise, the tubing within a roller pump has to be displaced and centrifugal pump heads have to be replaced over time. ECMO is certainly the first choice for a circulatory support system in the neonatal and pediatric age groups, where the other assist systems are too bulky. ECMO is also indicated for patients improving on CPS. Septic conditions are, in general, considered as contraindications for ECMO. CONCLUSIONS: Ease of availability and moderate cost of cardiopulmonary bypass-based cardiac support technologies have to be balanced against the significant immobilization of human resources, which is required to make them successful.

Warm Front, Better Health: Health Impact Evaluation of the Warm Front Scheme

About 4 million households in the UK cannot adequately heat their homes in winter due to low income and poor quality housing, the two main causes of fuel poverty. The primary impact of fuel poverty is cold homes in winter which can lead to various health problems and even death among the vulnerable young and the elderly population. The government launched the Warm Front scheme in 2000 to tackle fuel poverty among the vulnerable households in England by providing energy efficiency measures in the forms insulation and modern heating system(??). By 2004, about 770,000 households had benefited from the Warm Front scheme and a total of 2 million households are still expected to benefit by 2010. Since 2001, the Bartlett has been investigating with London School of Hygiene & Tropical Medicine and Sheffield Hallam University, the health and the environmental impact of the Warm Front scheme. This investigative study is the most detailed to date on fuel poor dwellings based on detailed surveys of household and dwelling data, fuel consumption record and monitored temperature and relative humidity from 3,100 dwellings before and after the energy efficiency measures. The Warm Front investigation was expected to continue until the end of 2007. The findings from the investigation indicated that the Warm Front scheme was likely to have benefits in terms of improved thermal comfort and well-being as a result of mean temperature rise of 1.6C in the living room and 2.8C in the bedroom. Warm Front also lead to a decrease in indoor relative humidity mainly from the increased temperature since there appeared to be little impact on vapour pressure from changes in air tightness. Pressure test results indicated that the effects of air tightness measures such as draught stripping and cavity wall insulation were offset by the installation of a central heating system, particularly when the pipe work feeding radiators was installed below timber floors.

Energiansäästökohteiden kartoitus konepajateollisuuden yrityksessä

Tämän diplomityön tavoitteena on kartoittaa Vaahto Oy:n Hollolan tehtaan energiankulutus ja energiansäästökohteet. Ensin tutkittiin tehtaan energiankulutus ja energiankulutuksen jakautuminen. Tutkimuksessa käytettiin saatavilla olevia kulutustietoja, luettiin konekirjoja sekä haastateltiin tehtaan työntekijöitä. Lisäksi tehdashallien lämmityslaitteiden hyötysuhteet mitattiin. Tutkimuksen päätavoite oli selvittää, miksi tehtaan lämmitysenergiankulutus on kasvanut ja kannattaisiko rakennusten lämmittämiseen käyttää vaihtoehtoista lämmitysmuotoa öljylämmitykselle. Potentiaalisista energiansäästökohteista tehtiin investointilaskelmat ja toimenpide-ehdotukset. Kannattaviksi toimenpiteiksi tutkimuksessa todettiin: lämmityspolttoaineen vaihtaminen maakaasuun, nosto-ovien hankkiminen, paineilmaverkon huolto, paineilmakompressorin lämmöntalteenotto, tehdastilojen sisälämpötilan tarkastus ja työnjohtotilojen ilmanvaihdon käyntiaikojen muutos. Toimenpiteillä arvioidaan vuotuisten energiakustannusten pienenevän noin 34 000 euroa. Toimenpiteiden toteuttamisen arvioidaan maksavan 135 000 ¤, mistä lämmitysjärjestelmän vaihdon osuus on 100 000 ¤.

Lasirakenteiden aiheuttamien konvektiovirtausten hallinta lattialämmitysjärjestelmässä

Diplomityössä suoritettiin Lappeenrannassa uudessa asuntokerrostalossa asumisviihtyvyysmittauksia vuonna 2002. Kohteessa on koneellinen poistoilmanvaihto, jossa raitisilma johdetaan huonetilaan ikkunan yläpuolella sijaitsevien rakomaisten raitisilmaventtiilien kautta, sekä vesikiertoinen lattialämmitys. Diplomityössä kehitettiin Fluent-virtauslaskentaohjelmalla kaksiuloitteinen malli asuntokerrostalon huoneesta. Kehitettyä simulointimenetelmää käytettiin huoneen lämpöolosuhteiden hallinnan kehittämisessä mallintamalla tilan ilmavirtauskentälle yksityiskohtainen lämpötila- ja nopeusjakauma. Huoneen ilman nopeus- ja lämpötilajakaumaa tarkasteltiin eri lattia- ja ikkunapinnan lämpötiloilla, eri geometrioilla ja käyttäeneri virtauksia kuvaavia malleja. Huoneesta simuloitiin 12 eri tapausta, joista valittiin parhaiten mittaustuloksiin sopiva. Tähän tapaukseen tehtiin muutoksia lattia- ja ikkunapinnan lämpötiloihin. Työssä selvitettiin, kuinka nämä muutokset vaikuttavat huoneen nopeus- ja lämpötilajakaumiin.

Jyväskylän kaukolämpöverkon kehittäminen

Kaukolämmitys on yleisin Suomessa käytetty lämmitysmuoto ja sen osuus koko lämmitysmarkkinoista on noin 50 %. Kaukolämmön varsinainen tuotanto ja jakelu alkoivat Suomessa vuonna 1957 ja Jyväskylässä vuonna 1960. Jyväskylässä kaukolämmön piiriin kuuluivuoden 2006 loppuun mennessä noin 3200 asiakasta. Suurin tuntiteho laitoksilta oli noin 375 MW. Vuonna 2020 suurimman tuntitehon on ennustettu olevan noin 480 MW, mikä tarkoittaa asiakasmäärän ja verkon pituuden merkittävää kasvua. Jyväskylän kaukolämpöverkon nykytilanne on hyvä. Verkostolaskennan tulosten perusteella lämpö saadaan siirtymään nykyisillä laitoksilla ja verkon laitteilla jokaiselle asiakkaalle niin normaalitilanteessa kuin päälaitoksen häiriötilanteessa. Häiriötilanteessa paikallisia ongelmia voi esiintyä, mutta niihin voidaan vaikuttaa parantavasti esimerkiksi verkon staattisen paineen nostolla. Jyväskylän kaukolämpöverkon tulevaisuuden näkymät ovat erinomaiset. Laskennan perusteella verkkoa voidaan laajentaa kaikille laskennassa mukana olleille alueille ilman suurempia ongelmia. Uuden tuotantokapasiteetin, verkonlaajentumisen ja asiakasmäärän kasvun aiheuttamat kehitystarpeet saatiin selvitetyksi ja tulokset olivat aikaisempien tutkimusten suuntaisia. Tulevaisuutta ajatellen verkkoon joudutaan tekemään muutamia muutoksia suunniteltujen uusien yhteyksien lisäksi. Uuteen linjaan, joka yhdistää Palokan verkon toisen yhteyden kautta Jyväskylän pääverkkoon, rakennetaan mahdollisesti pumppaamo. Lisäkuristusventtiilejä tarvitaan viiteen eri paikkaan turvaamaan riittävän suuret kaukolämpöveden paluupaineet. Osa venttiileistä olisi suositeltavaa asentaa jo nykytilanteessa, sillä niiden hankinta parantaisi verkon nykytilaa.