Roal Oy:n käyttöhyödykejärjestelmän arviointi, optimointi ja raportointi

Prosessiteollisuudessa tarvitaan usein erilaisia apujärjestelmiä pääprosessin tueksi. Tyypillisiä tällaisia järjestelmiä ovat jäähdytys-, höyry- ja ilmajärjestelmät. Hyödykejärjestelmien kehitys jää helposti pääprosessin varjoon, joka usein johtaa tarpeettoman suuriin hyödykekustannuksiin ja järjestelmien teknisen tilan laskuun. Työn kirjallisuusosassa käsitellään Roal Oy:n fermentointiprosessin kannalta olennaisimpia hyödykevaatimuksia, niiden laskennallista ilmaisua ja vuorovaikutuksia sekä PINCH-menetelmää lämpöenergian hyötykäyttöön. Jäähdytysjärjestelmän osalta käydään läpi merkittävimmät laitetekniset ratkaisut, jäähdytystorni ja lämpöpumppu, toimintaperiaatteineen sekä luonnonvesien käyttö jäähdytykseen. Työn soveltavassa osassa seurattiin Aspergillus, Trichoderma ja Bacillus fermentointeja, joiden pohjalta luotiin kasvatuskohtainen empiirinen malli jäähdytystarpeen arviointiin perustuen sekoitustehoon, kasvatuksen hiilidioksidituottoon ja haihtumisen vaikutukseen. Kasvatuksien aikana seurattiin myös tilavuusperusteista lämmönsiirtokerrointa. Mitattujen lämmönsiirtokertoimien perustella laskettiin ominaislämmöntuottoon perustuva maksimilämpötila käytettävälle jäähdytysvedelle ja fermentorien maksimitilavuudet tunnetuilla kasvatusparametreilla eri lämpöisille jäähdytysvesille. Soveltavassa osassa käydään myös läpi Roalin höyry- ja kuumavesikulutukset ja tärkeimmät käyttökohteet. Mittaustulosten ja mallien perusteella on tehtiin kehitysehdotukset hyödykejärjestelmän optimoimiseksi.

Climate variations in greenhouse cultivated with gerbera and relationship with external conditions

Black meshes used in greenhouses provide shade to plants, affecting photosynthesis and presenting certain properties that change the microclimatic conditions in these environments. The objective of this study was to evaluate the variation in climate elements in greenhouse cultivated with gerbera (Gerbera jamesonii, Vr. Rambo) in relation to external conditions and the reference evapotranspiration (ETo) at Teresina, State of Piauí, Brazil. The measurements were obtained from July to October 2007 by an automatic data acquisition system installed inside and outside the greenhouse. The global solar radiation, evapotranspiration, precipitation, temperature, relative humidity, and wind speed were estimated. The results showed that major effect of the shading occurred on the mean air temperature during the 120 days, making it higher than the external environment. Inside the greenhouse, mean values of relative air humidity, reference evapotranspiração, global solar radiation and wind speed were lower compared to those outside the greenhouse.

Modeling and simulation of forced-air cooling of strawberries using variable convective coefficient

In the forced-air cooling process of fruits occurs, besides the convective heat transfer, the mass transfer by evaporation. The energy need in the evaporation is taken from fruit that has its temperature lowered. In this study it has been proposed the use of empirical correlations for calculating the convective heat transfer coefficient as a function of surface temperature of the strawberry during the cooling process. The aim of this variation of the convective coefficient is to compensate the effect of evaporation in the heat transfer process. Linear and exponential correlations are tested, both with two adjustable parameters. The simulations are performed using experimental conditions reported in the literature for the cooling of strawberries. The results confirm the suitability of the proposed methodology.

Evaluation of empirical methods to estimate reference evapotranspiration in Uberaba, State of Minas Gerais, Brazil

Evapotranspiration is the process of water loss of vegetated soil due to evaporation and transpiration, and it may be estimated by various empirical methods. This study had the objective to carry out the evaluation of the performance of the following methods: Blaney-Criddle, Jensen-Haise, Linacre, Solar Radiation, Hargreaves-Samani, Makkink, Thornthwaite, Camargo, Priestley-Taylor and Original Penman in the estimation of the potential evapotranspiration when compared to the Penman-Monteith standard method (FAO56) to the climatic conditions of Uberaba, state of Minas Gerais, Brazil. A set of 21 years monthly data (1990 to 2010) was used, working with the climatic elements: temperature, relative humidity, wind speed and insolation. The empirical methods to estimate reference evapotranspiration were compared with the standard method using linear regression, simple statistical analysis, Willmott agreement index (d) and performance index (c). The methods Makkink and Camargo showed the best performance, with "c" values ​​of 0.75 and 0.66, respectively. The Hargreaves-Samani method presented a better linear relation with the standard method, with a correlation coefficient (r) of 0.88.

Jatropha seed oil content and yield under different irrigation and potassium fertilization levels

The aim of this research was to evaluate the effects of different irrigation depths and potassium dosages, of Jatropha seed oil content and yield. The experimental design used was randomized blocks, in split-plots, with four replicates. The treatments were four water depths (plots) and four potassium dosages (subplots) applied through irrigation water. The water depths were applied based on the percentage of accumulated evaporation of a Class A (ECA) tank and of rainfall, as following: L0 = without irrigation, L40, L80 and L120, representing 40, 80 and 120% of the balance, respectively. The potassium dosages were K30, K60, K90 and K120 (30, 60, 90 and 120kg ha-1 of potassium, respectively). The oil extraction of samples was done through chemical extraction by organic solvent. The seeds used in this test were from the sampling of two seed productions from 2009, second year of crop production. It was possible to observe that irrigation use increased oil yield and decreased the oil content of Jatropha seed. Potassium fertilization did not influence oil content and yield. There was a relative increase of efficiency in water use producing oil until certain water depth, and after that there was a decrease.

Irrigation management in pruned coffee tree crop

It was evaluated the effect of irrigation management on the production characteristics of coffee cultivar Acaiá MG-1474, planted in spacing of 3.00 m x 0.60 m, pruned in 2004, and irrigated by drip since the planting, in 1997. The experimental designed used was of randomized blocks with five treatments and four replications. The treatments consisted of irrigation management strategies, applying or not applying controlled moisture deficit in layer of 0 to 0.4m, in dry seasons of the year: A = no irrigation (control), B = irrigation during all year considering the factor of water availability in the soil (f) equal to 0.75, C = irrigation during all year considering f = 0.25, D = irrigation during all year, but in January /February /March /July /October /November /December with f = 0.25 and April /May /June /August /September with f = 0.75, E = irrigation only during April /May /June /August /September with f = 0.25. From July /2005 to June /2007 the applied water depth was defined based on Class A pan evaporation (ECA) and the period from July/2007 to June/2008 based on readings of matric potential of soil obtained from Watermark® sensors. Each plot consisted of three rows with ten plants per row, considering as useful plot five plants of center line. The results indicated that the E irrigation management was the most suitable for technical reasons.

Potential of utilization of rain water excess for irrigation of green roofs in Mato Grosso, Brasil

The aim of this study was to identify the relation between the evapotranspirometer demand and the supply of water from local rainfall, evaluating the possibility of using water excess for irrigation of Green Roofs in the State of Mato Grosso, in Brazil. The study was done using a series of historical data provided by the National Institute of Meteorology (INMET - Instituto Nacional de Meteorologia) which has official climatological stations in 12 cities and regions of the State. The evapotranspiration values were obtained by the Penman-Monteith method and by the Climatic Water Balance (CWB) by the Thornthwaite and Mather method using Available Water Capacity (AWC) of 12mm. With the CWB the excess and deficit were calculated, which were used for the estimative of the volume and area of a reservoir as a function of a collector area of a roof of 100m² and the volume of supplementary water for irrigation. With the obtained results, it was found that in most investigated regions of the State the use of green roofs is not compromised by the water deficiency. On the other hand, the use of a reservoir to accumulate the rain water excess may be impractical, because it requires a considerable area for installation and also because of the high cost of the land.

Irrigation with domestic treated sewage and nitrogen fertilizing in sunflower cultivation

The objective of this study was to evaluate the productive performance of sunflower plants irrigated with different levels of domestic treated sewage and groundwater well with different doses of nitrogen. It was used randomized blocks design in split-split plots with four replications. In the plots, we evaluated the effect of two types of irrigation water, in the subplots we evaluated the five irrigation levels expressed as 25, 50, 75, 100 and 125% of the Class A pan Evaporation (CAE), and in the sub subplots, we evaluated the effect of four different doses of nitrogen (25, 50, 75 and 100 kg ha-1). The irrigation of sunflower with domestic sewage produced greater yield potential of grain and oil. The use of water from treated wastewater can replace up to 50 kg N ha-1 without affecting productivity. It is recommended for the commercial production of sunflower the use of treated sewage water with irrigation depth relative to 100% of CAE (296.64 mm) and nitrogen of 25 kg ha-1.

Estimation methods of reference evapotranspiration (ETo) for Uberlândia -MG

One approach to verify the adequacy of estimation methods of reference evapotranspiration is the comparison with the Penman-Monteith method, recommended by the United Nations of Food and Agriculture Organization - FAO, as the standard method for estimating ET0. This study aimed to compare methods for estimating ET0, Makkink (MK), Hargreaves (HG) and Solar Radiation (RS), with Penman-Monteith (PM). For this purpose, we used daily data of global solar radiation, air temperature, relative humidity and wind speed for the year 2010, obtained through the automatic meteorological station, with latitude 18° 91' 66" S, longitude 48° 25' 05" W and altitude of 869m, at the National Institute of Meteorology situated in the Campus of Federal University of Uberlandia - MG, Brazil. Analysis of results for the period were carried out in daily basis, using regression analysis and considering the linear model y = ax, where the dependent variable was the method of Penman-Monteith and the independent, the estimation of ET0 by evaluated methods. Methodology was used to check the influence of standard deviation of daily ET0 in comparison of methods. The evaluation indicated that methods of Solar Radiation and Penman-Monteith cannot be compared, yet the method of Hargreaves indicates the most efficient adjustment to estimate ETo.

Technology for sugarcane agroindustry waste reuse as granulated organomineral fertilizer

Aiming to evaluate the use of sugarcane industry waste such as byproducts from vinasse concentration process, it was assessed the organomineral fertilizer BIOFOM (concentrated vinasse, filter cake, boiler ash, soot from chimneys and supplemented with mineral fertilizers). The study included characterization and agronomic potential analysis of a test plant (corn), by noting the differences between mineral fertilizers and BIOFOM fertilization until 45 days after sowing. The technology traditionally used to produce BIOFOM was based on vinasse evaporation with high heat transfer coefficients. It was observed that the technology, which can be formulated according to the needs of any crop, could be used in many cases as mineral fertilizer. Therefore, the use of this organomineral fertilizer reduces waste generation of sugarcane industry.

Corrosion behaviour of boiler tube materials during combustion of fuels containing Zn and Pb

Många förbränningsanläggningar som bränner utmanande bränslen såsom restfraktioner och avfall råkar ut för problem med ökad korrosion på överhettare och/eller vattenväggar pga. komponenter i bränslena som är korrosiva. För att minimera problemen i avfallseldade pannor hålls ångparametrarna på en relativt låg nivå, vilket drastiskt minskar energiproduktionen. Beläggningarna i avfallseldade pannor består till största delen av element som är förknippade med högtemperaturkorrosion: Cl, S, alkalimetaller, främst K och Na, och tungmetaller som Pb och Zn, och det finns också indikationer av Br-förekomst. Det låga ångtrycket i avfallseldade pannor påverkar också stålrörens temperatur i pannväggarna i eldstaden. I dagens läge hålls temperaturen normalt vid 300-400 °C. Alkalikloridorsakad (KCl, NaCl) högtemperaturkorrosion har inte rapporterats vara relevant vid såpass låga temperaturer, men närvaro av Zn- och Pb-komponenter i beläggningarna har påvisats förorsaka ökad korrosion redan vid 300-400 °C. Vid förbränning kan Zn och Pb reagera med S och Cl och bilda klorider och sulfater i rökgaserna. Dessa tungmetallföreningar är speciellt problematiska pga. de bildar lågsmältande saltblandningar. Dessa lågsmältande gasformiga eller fasta föreningar följer rökgasen och kan sedan fastna eller kondensera på kallare ytor på pannväggar eller överhettare för att sedan bilda aggressiva beläggningar. Tungmetallrika (Pb, Zn) klorider och sulfater ökar risken för korrosion, och effekten förstärks ytterligare vid närvaro av smälta. Motivet med den här studien var att få en bättre insikt i högtemperaturkorrosion förorsakad av Zn och Pb, samt att undersöka och prediktera beteendet och motståndskraften hos några stålkvaliteter som används i överhettare och pannväggar i tungmetallrika förhållanden och höga materialtemperaturer. Omfattande laboratorie-, småskale- och fullskaletest utfördes. Resultaten kan direkt utnyttjas i praktiska applikationer, t.ex. vid materialval, eller vid utveckling av korrosionsmotverkande verktyg för att hitta initierande faktorer och förstå deras effekt på högtemperaturkorrosion.

Production of Mg(OH)2 from Mg-silicate rock for CO2 mineral sequestration

Sequestration of carbon dioxide in mineral rocks, also known as CO2 Capture and Mineralization (CCM), is considered to have a huge potential in stabilizing anthropogenic CO2 emissions. One of the CCM routes is the ex situ indirect gas/sold carbonation of reactive materials, such as Mg(OH)2, produced from abundantly available Mg-silicate rocks. The gas/solid carbonation method is intensively researched at Åbo Akademi University (ÅAU ), Finland because it is energetically attractive and utilizes the exothermic chemistry of Mg(OH)2 carbonation. In this thesis, a method for producing Mg(OH)2 from Mg-silicate rocks for CCM was investigated, and the process efficiency, energy and environmental impact assessed. The Mg(OH)2 process studied here was first proposed in 2008 in a Master’s Thesis by the author. At that time the process was applied to only one Mg-silicate rock (Finnish serpentinite from the Hitura nickel mine site of Finn Nickel) and the optimum process conversions, energy and environmental performance were not known. Producing Mg(OH)2 from Mg-silicate rocks involves a two-staged process of Mg extraction and Mg(OH)2 precipitation. The first stage extracts Mg and other cations by reacting pulverized serpentinite or olivine rocks with ammonium sulfate (AS) salt at 400 - 550 oC (preferably < 450 oC). In the second stage, ammonia solution reacts with the cations (extracted from the first stage after they are leached in water) to form mainly FeOOH, high purity Mg(OH)2 and aqueous (dissolved) AS. The Mg(OH)2 process described here is closed loop in nature; gaseous ammonia and water vapour are produced from the extraction stage, recovered and used as reagent for the precipitation stage. The AS reagent is thereafter recovered after the precipitation stage. The Mg extraction stage, being the conversion-determining and the most energy-intensive step of the entire CCM process chain, received a prominent attention in this study. The extraction behavior and reactivity of different rocks types (serpentinite and olivine rocks) from different locations worldwide (Australia, Finland, Lithuania, Norway and Portugal) was tested. Also, parametric evaluation was carried out to determine the optimal reaction temperature, time and chemical reagent (AS). Effects of reactor types and configuration, mixing and scale-up possibilities were also studied. The Mg(OH)2 produced can be used to convert CO2 to thermodynamically stable and environmentally benign magnesium carbonate. Therefore, the process energy and life cycle environmental performance of the ÅAU CCM technique that first produces Mg(OH)2 and the carbonates in a pressurized fluidized bed (FB) were assessed. The life cycle energy and environmental assessment approach applied in this thesis is motivated by the fact that the CCM technology should in itself offer a solution to what is both an energy and environmental problem. Results obtained in this study show that different Mg-silicate rocks react differently; olivine rocks being far less reactive than serpentinite rocks. In summary, the reactivity of Mg-silicate rocks is a function of both the chemical and physical properties of rocks. Reaction temperature and time remain important parameters to consider in process design and operation. Heat transfer properties of the reactor determine the temperature at which maximum Mg extraction is obtained. Also, an increase in reaction temperature leads to an increase in the extent of extraction, reaching a maximum yield at different temperatures depending on the reaction time. Process energy requirement for producing Mg(OH)2 from a hypothetical case of an iron-free serpentine rock is 3.62 GJ/t-CO2. This value can increase by 16 - 68% depending on the type of iron compound (FeO, Fe2O3 or Fe3O4) in the mineral. This suggests that the benefit from the potential use of FeOOH as an iron ore feedstock in iron and steelmaking should be determined by considering the energy, cost and emissions associated with the FeOOH by-product. AS recovery through crystallization is the second most energy intensive unit operation after the extraction reaction. However, the choice of mechanical vapor recompression (MVR) over the “simple evaporation” crystallization method has a potential energy savings of 15.2 GJ/t-CO2 (84 % savings). Integrating the Mg(OH)2 production method and the gas/solid carbonation process could provide up to an 25% energy offset to the CCM process energy requirements. Life cycle inventory assessment (LCIA) results show that for every ton of CO2 mineralized, the ÅAU CCM process avoids 430 - 480 kg CO2. The Mg(OH)2 process studied in this thesis has many promising features. Even at the current high energy and environmental burden, producing Mg(OH)2 from Mg-silicates can play a significant role in advancing CCM processes. However, dedicated future research and development (R&D) have potential to significantly improve the Mg(OH)2 process performance.

Liquid transportation and distribution during (re)wetting : impact on coated papers in printing

In many industrial applications, such as the printing and coatings industry, wetting of porous materials by liquids includes not only imbibition and permeation into the bulk but also surface spreading and evaporation. By understanding these phenomena, valuable information can be obtained for improved process control, runnability and printability, in which liquid penetration and subsequent drying play important quality and economic roles. Knowledge of the position of the wetting front and the distribution/degree of pore filling within the structure is crucial in describing the transport phenomena involved. Although exemplifying paper as a porous medium in this work, the generalisation to dynamic liquid transfer onto a surface, including permeation and imbibition into porous media, is of importance to many industrial and naturally occurring environmental processes. This thesis explains the phenomena in the field of heatset web offset printing but the content and the analyses are applicable in many other printing methods and also other technologies where water/moisture monitoring is crucial in order to have a stable process and achieve high quality end products. The use of near-infrared technology to study the water and moisture response of porous pigmented structures is presented. The use of sensitive surface chemical and structural analysis, as well as the internal structure investigation of a porous structure, to inspect liquid wetting and distribution, complements the information obtained by spectroscopic techniques. Strong emphasis has been put on the scale of measurement, to filter irrelevant information and to understand the relationship between interactions involved. The near-infrared spectroscopic technique, presented here, samples directly the changes in signal absorbance and its variation in the process at multiple locations in a print production line. The in-line non-contact measurements are facilitated by using several diffuse reflectance probes, giving the absolute water/moisture content from a defined position in the dynamic process in real-time. The nearinfrared measurement data illustrate the changes in moisture content as the paper is passing through the printing nips and dryer, respectively, and the analysis of the mechanisms involved highlight the roles of the contacting surfaces and the relative liquid carrier properties of both non-image and printed image areas. The thesis includes laboratory studies on wetting of porous media in the form of coated paper and compressed pigment tablets by mono-, dual-, and multi-component liquids, and paper water/moisture content analysis in both offline and online conditions, thus also enabling direct sampling of temporal water/moisture profiles from multiple locations. One main focus in this thesis was to establish a measurement system which is able to monitor rapid changes in moisture content of paper. The study suggests that near-infrared diffuse reflectance spectroscopy can be used as a moisture sensitive system and to provide accurate online qualitative indicators, but, also, when accurately calibrated, can provide quantification of water/moisture levels, its distribution and dynamic liquid transfer. Due to the high sensitivity, samples can be measured with excellent reproducibility and good signal to noise ratio. Another focus of this thesis was on the evolution of the moisture content, i.e. changes in moisture content referred to (re)wetting, and liquid distribution during printing of coated paper. The study confirmed different wetting phases together with the factors affecting each phase both for a single droplet and a liquid film applied on a porous substrate. For a single droplet, initial capillary driven imbibition is followed by equilibrium pore filling and liquid retreat by evaporation. In the case of a liquid film applied on paper, the controlling factors defining the transportation were concluded to be the applied liquid volume in relation to surface roughness, capillarity and permeability of the coating giving the liquid uptake capacity. The printing trials confirmed moisture gradients in the printed sheet depending on process parameters such as speed, fountain solution dosage and drying conditions as well as the printed layout itself. Uneven moisture distribution in the printed sheet was identified to be one of the sources for waving appearance and the magnitude of waving was influenced by the drying conditions.

Recovery of carboxylic acids from aqueous streams by extraction and back extraction

Separation of carboxylic acids from aqueous streams is an important part of their manufacturing process. The aqueous solutions are usually dilute containing less than 10 % acids. Separation by distillation is difficult as the boiling points of acids are only marginally higher than that of water. Because of this distillation is not only difficult but also expensive due to the evaporation of large amounts of water. Carboxylic acids have traditionally been precipitated as calcium salts. The yields of these processes are usually relatively low and the chemical costs high. Especially the decomposition of calcium salts with sulfuric acid produces large amounts of calcium sulfate sludge. Solvent extraction has been studied as an alternative method for recovery of carboxylic acids. Solvent extraction is based on mixing of two immiscible liquids and the transfer of the wanted components form one liquid to another due to equilibrium difference. In the case of carboxylic acids, the acids are transferred from aqueous phase to organic solvent due to physical and chemical interactions. The acids and the extractant form complexes which are soluble in the organic phase. The extraction efficiency is affected by many factors, for instance initial acid concentration, type and concentration of the extractant, pH, temperature and extraction time. In this paper, the effects of initial acid concentration, type of extractant and temperature on extraction efficiency were studied. As carboxylic acids are usually the products of the processes, they are wanted to be recovered. Hence the acids have to be removed from the organic phase after the extraction. The removal of acids from the organic phase also regenerates the extractant which can be then recycled in the process. The regeneration of the extractant was studied by back-extracting i.e. stripping the acids form the organic solution into diluent sodium hydroxide solution. In the solvent regeneration, the regenerability of different extractants and the effect of initial acid concentration and temperature were studied.

Vesihöyrypiirin kiertolaskenta kuplapetikattilassa

Työssä selvitetään kiertolaskennan periaatteita kuplapetikattilassa, esitetään lyhyesti kattilan toimintaperiaate ja paneudutaan alan laskentaohjelmistoihin. Luonnonkierto kattilan vesihöyrypiirissä on seurausta hydrostaattisesta paineesta, joka aiheutuu tiheyserosta nousu- ja laskuputkien välillä. Kiertolaskennassa on huomioitava kaksifaasivirtauksen ominaispiirteet. Höyry ja neste virtaavat putkistossa eri nopeuksilla, jolloin esimerkiksi painehäviön määrityksessä käytetään erilaisia korrelaatioita ja käyrästöjä. Kaksifaasivirtauksen laskennassa tarvitaan kolmea eri taseyhtälöä: energiatasetta, massatasetta ja liikemäärätasetta. Luonnonkiertokattiloissa höyrykierron suunnittelussa on kaksi pääasiallista ehtoa. Ensimmäiseksi tulee varmistaa riittävä kiertoveden massavirta, jotta vältetään höyrystinputkien puhki palaminen. Toiseksi tulee välttää höyrystinputken pinnan lämpötilavaihteluita ja värähtelyitä. Alustavassa luonnonkierron mitoituksessa turvaudutaan kokemusperäiseen tietoon. Myöhemmässä tarkemmassa mitoituksessa käytettäviä ohjelmistoja ovat NOWA sekä kaupalliset PPSD ja Apros. Laskenta lähtee liikkeelle siitä, että lasketaan ensin vesihöyrykierron massavirrat erilaisilla lämpökuormilla ja höyryntuotanto määritellään painehäviöiden perusteella. NOWA- ja PPSD- ohjelmistoilla tehtyjen esimerkkilaskelmien perusteella voidaan sanoa, että tulokset riippuvat käytetystä laskentamallista.