The Engineer, with which is incorporated Steam engineering.

Subtitle varies.

Creep crack growth in cast steam turbine casing steels

The creep rupture properties of cast ½Cr½Mo¼V and 1Cr1Mo¼V alloy steel used in the manufacture of power station steam generating plant. have been investigated. The effects of constraint and geometry on the creep rupture properties are also considered. The validity of various criteria controlling macroscopic creep crack growth in cast CrMoV alloys has been examined. It is found that neither the stress intensity factor nor reference stress correlate satisfactorily the creep crack growth rates at the test temperature of 550°C. Certain minimum displacements must be achieved for crack initiation and propagation. It is found that this displacement as measured by crack opening displacement or crack aspect ratio, is the same in both compact tension and centre-cracked panel geometries, is invariant with crack length and decreases with increasing constraint. The effect of constraint on creep crack growth rate in the two geometries is less conclusive. A new model describing creep crack growth in cast CrMoV alloy steels has been developed. The model is based on the results from a numerical finite element creep analysis of the relaxation and redistribution of stress ahead of an incubating creep crack . It is found that macroscopic creep crack growth in a material undergoing either plane stress or plane strain deformation can be described by a fracture stress which is based on the Von Mises equivalent stress. It has been shown that this model is capable of rationalising all of the experimental crack velocity data from the cast CrMoV alloys. The resultant degree of data correlation is far superior to that obtained when using the stress intensity factor or reference stress. A cumulative damage creep fracture model based upon the results from the numerical analysis has been developed. It is found that the model is capable of predicting the behaviour of propagating creep cracks in cast CrMoV alloys from smooth bar creep rupture data.

Waste to power

ABSTRACT: There has been a growing trend towards the use of biomass as a primary energy source, which now contributes over 54% of the European pulp and paper industry energy needs [1]. The remaining part comes from natural gas, which to a large extent serves as the major source of energy for numerous recovered fiber paper mills located in regions with limited available forest resources. The cost of producing electricity to drive paper machinery and generate heat for steam is increasing as world demand for fossil fuels increases. Additionally, recovered fiber paper mills are also significant producers of fibrous sludge and reject waste material that can contain high amounts of useful energy. Currently, a majority of these waste fractions is disposed of by landspreading, incineration, or landfill. Paper mills must also pay a gate fee to process their waste streams in this way and the result of this is a further increase in operating costs. This work has developed methods to utilize the waste fractions produced at recovered fiber paper mills for the onsite production of combined heat and power (CHP) using advanced thermal conversion methods (pyrolysis and gasification) that are well suited to relatively small scales of throughput. The electrical power created would either be used onsite to power the paper making process or alternatively exported to the national grid, and the surplus heat created could also be used onsite or exported to a local customer. The focus of this paper is to give a general overview of the project progress so far and will present the experimental results of the most successful thermal conversion trials carried out by this work to date. Application: The research provides both paper mills and energy providers with methodologies to condition their waste materials for conversion into useful energy. The research also opens up new markets for gasifier and pyrolysis equipment manufacturers and suppliers.

Computationsl modelling of dimethyl ether separation and steam reforming in fluidized bed reactors

This study presents a computational fluid dynamic (CFD) study of Dimethyl Ether (DME) gas adsorptive separation and steam reforming (DME-SR) in a large scale Circulating Fluidized Bed (CFB) reactor. The CFD model is based on Eulerian-Eulerian dispersed flow and solved using commercial software (ANSYS FLUENT). Hydrogen is currently receiving increasing interest as an alternative source of clean energy and has high potential applications, including the transportation sector and power generation. Computational fluid dynamic (CFD) modelling has attracted considerable recognition in the engineering sector consequently leading to using it as a tool for process design and optimisation in many industrial processes. In most cases, these processes are difficult or expensive to conduct in lab scale experiments. The CFD provides a cost effective methodology to gain detailed information up to the microscopic level. The main objectives in this project are to: (i) develop a predictive model using ANSYS FLUENT (CFD) commercial code to simulate the flow hydrodynamics, mass transfer, reactions and heat transfer in a large scale dual fluidized bed system for combined gas separation and steam reforming processes (ii) implement a suitable adsorption models in the CFD code, through a user defined function, to predict selective separation of a gas from a mixture (iii) develop a model for dimethyl ether steam reforming (DME-SR) to predict hydrogen production (iv) carry out detailed parametric analysis in order to establish ideal operating conditions for future industrial application. The project has originated from a real industrial case problem in collaboration with the industrial partner Dow Corning (UK) and jointly funded by the Engineering and Physical Research Council (UK) and Dow Corning. The research examined gas separation by adsorption in a bubbling bed, as part of a dual fluidized bed system. The adsorption process was simulated based on the kinetics derived from the experimental data produced as part of a separate PhD project completed under the same fund. The kinetic model was incorporated in FLUENT CFD tool as a pseudo-first order rate equation; some of the parameters for the pseudo-first order kinetics were obtained using MATLAB. The modelling of the DME adsorption in the designed bubbling bed was performed for the first time in this project and highlights the novelty in the investigations. The simulation results were analysed to provide understanding of the flow hydrodynamic, reactor design and optimum operating condition for efficient separation. Bubbling bed validation by estimation of bed expansion and the solid and gas distribution from simulation agreed well with trends seen in the literatures. Parametric analysis on the adsorption process demonstrated that increasing fluidizing velocity reduced adsorption of DME. This is as a result of reduction in the gas residence time which appears to have much effect compared to the solid residence time. The removal efficiency of DME from the bed was found to be more than 88%. Simulation of the DME-SR in FLUENT CFD was conducted using selected kinetics from literature and implemented in the model using an in-house developed user defined function. The validation of the kinetics was achieved by simulating a case to replicate an experimental study of a laboratory scale bubbling bed by Vicente et al [1]. Good agreement was achieved for the validation of the models, which was then applied in the DME-SR in the large scale riser section of the dual fluidized bed system. This is the first study to use the selected DME-SR kinetics in a circulating fluidized bed (CFB) system and for the geometry size proposed for the project. As a result, the simulation produced the first detailed data on the spatial variation and final gas product in such an industrial scale fluidized bed system. The simulation results provided insight in the flow hydrodynamic, reactor design and optimum operating condition. The solid and gas distribution in the CFB was observed to show good agreement with literatures. The parametric analysis showed that the increase in temperature and steam to DME molar ratio increased the production of hydrogen due to the increased DME conversions, whereas the increase in the space velocity has been found to have an adverse effect. Increasing temperature between 200 oC to 350 oC increased DME conversion from 47% to 99% while hydrogen yield increased substantially from 11% to 100%. The CO2 selectivity decreased from 100% to 91% due to the water gas shift reaction favouring CO at higher temperatures. The higher conversions observed as the temperature increased was reflected on the quantity of unreacted DME and methanol concentrations in the product gas, where both decreased to very low values of 0.27 mol% and 0.46 mol% respectively at 350 °C. Increasing the steam to DME molar ratio from 4 to 7.68 increased the DME conversion from 69% to 87%, while the hydrogen yield increased from 40% to 59%. The CO2 selectivity decreased from 100% to 97%. The decrease in the space velocity from 37104 ml/g/h to 15394 ml/g/h increased the DME conversion from 87% to 100% while increasing the hydrogen yield from 59% to 87%. The parametric analysis suggests an operating condition for maximum hydrogen yield is in the region of 300 oC temperatures and Steam/DME molar ratio of 5. The analysis of the industrial sponsor’s case for the given flow and composition of the gas to be treated suggests that 88% of DME can be adsorbed from the bubbling and consequently producing 224.4t/y of hydrogen in the riser section of the dual fluidized bed system. The process also produces 1458.4t/y of CO2 and 127.9t/y of CO as part of the product gas. The developed models and parametric analysis carried out in this study provided essential guideline for future design of DME-SR at industrial level and in particular this work has been of tremendous importance for the industrial collaborator in order to draw conclusions and plan for future potential implementation of the process at an industrial scale.

A techno-economic comparison of power production by biomass fast pyrolysis with gasification and combustion

This paper presents an assessment of the technical and economic performance of thermal processes to generate electricity from a wood chip feedstock by combustion, gasification and fast pyrolysis. The scope of the work begins with the delivery of a wood chip feedstock at a conversion plant and ends with the supply of electricity to the grid, incorporating wood chip preparation, thermal conversion, and electricity generation in dual fuel diesel engines. Net generating capacities of 1–20 MWe are evaluated. The techno-economic assessment is achieved through the development of a suite of models that are combined to give cost and performance data for the integrated system. The models include feed pretreatment, combustion, atmospheric and pressure gasification, fast pyrolysis with pyrolysis liquid storage and transport (an optional step in de-coupled systems) and diesel engine or turbine power generation. The models calculate system efficiencies, capital costs and production costs. An identical methodology is applied in the development of all the models so that all of the results are directly comparable. The electricity production costs have been calculated for 10th plant systems, indicating the costs that are achievable in the medium term after the high initial costs associated with novel technologies have reduced. The costs converge at the larger scale with the mean electricity price paid in the EU by a large consumer, and there is therefore potential for fast pyrolysis and diesel engine systems to sell electricity directly to large consumers or for on-site generation. However, competition will be fierce at all capacities since electricity production costs vary only slightly between the four biomass to electricity systems that are evaluated. Systems de-coupling is one way that the fast pyrolysis and diesel engine system can distinguish itself from the other conversion technologies. Evaluations in this work show that situations requiring several remote generators are much better served by a large fast pyrolysis plant that supplies fuel to de-coupled diesel engines than by constructing an entire close-coupled system at each generating site. Another advantage of de-coupling is that the fast pyrolysis conversion step and the diesel engine generation step can operate independently, with intermediate storage of the fast pyrolysis liquid fuel, increasing overall reliability. Peak load or seasonal power requirements would also benefit from de-coupling since a small fast pyrolysis plant could operate continuously to produce fuel that is stored for use in the engine on demand. Current electricity production costs for a fast pyrolysis and diesel engine system are 0.091/kWh at 1 MWe when learning effects are included. These systems are handicapped by the typical characteristics of a novel technology: high capital cost, high labour, and low reliability. As such the more established combustion and steam cycle produces lower cost electricity under current conditions. The fast pyrolysis and diesel engine system is a low capital cost option but it also suffers from relatively low system efficiency particularly at high capacities. This low efficiency is the result of a low conversion efficiency of feed energy into the pyrolysis liquid, because of the energy in the char by-product. A sensitivity analysis has highlighted the high impact on electricity production costs of the fast pyrolysis liquids yield. The liquids yield should be set realistically during design, and it should be maintained in practice by careful attention to plant operation and feed quality. Another problem is the high power consumption during feedstock grinding. Efficiencies may be enhanced in ablative fast pyrolysis which can tolerate a chipped feedstock. This has yet to be demonstrated at commercial scale. In summary, the fast pyrolysis and diesel engine system has great potential to generate electricity at a profit in the long term, and at a lower cost than any other biomass to electricity system at small scale. This future viability can only be achieved through the construction of early plant that could, in the short term, be more expensive than the combustion alternative. Profitability in the short term can best be achieved by exploiting niches in the market place and specific features of fast pyrolysis. These include: •countries or regions with fiscal incentives for renewable energy such as premium electricity prices or capital grants; •locations with high electricity prices so that electricity can be sold direct to large consumers or generated on-site by companies who wish to reduce their consumption from the grid; •waste disposal opportunities where feedstocks can attract a gate fee rather than incur a cost; •the ability to store fast pyrolysis liquids as a buffer against shutdowns or as a fuel for peak-load generating plant; •de-coupling opportunities where a large, single pyrolysis plant supplies fuel to several small and remote generators; •small-scale combined heat and power opportunities; •sales of the excess char, although a market has yet to be established for this by-product; and •potential co-production of speciality chemicals and fuel for power generation in fast pyrolysis systems.

A cost-effective steam-driven RO plant for brackish groundwater

Desalination is a costly means of providing freshwater. Most desalination plants use either reverse osmosis (RO) or thermal distillation. Both processes have drawbacks: RO is efficient but uses expensive electrical energy; thermal distillation is inefficient but uses less expensive thermal energy. This work aims to provide an efficient RO plant that uses thermal energy. A steam-Rankine cycle has been designed to drive mechanically a batch-RO system that achieves high recovery, without the high energy penalty typically incurred in a continuous-RO system. The steam may be generated by solar panels, biomass boilers, or as an industrial by-product. A novel mechanical arrangement has been designed for low cost, and a steam-jacketed arrangement has been designed for isothermal expansion and improved thermodynamic efficiency. Based on detailed heat transfer and cost calculations, a gain output ratio of 69-162 is predicted, enabling water to be treated at a cost of 71 Indian Rupees/m3 at small scale. Costs will reduce with scale-up. Plants may be designed for a wide range of outputs, from 5 m3/day, up to commercial versions producing 300 m3/day of clean water from brackish groundwater.

A probabilistic approach to the estimation of regional photovoltaic power generation using meteorological data

In Germany the upscaling algorithm is currently the standard approach for evaluating the PV power produced in a region. This method involves spatially interpolating the normalized power of a set of reference PV plants to estimate the power production by another set of unknown plants. As little information on the performances of this method could be found in the literature, the first goal of this thesis is to conduct an analysis of the uncertainty associated to this method. It was found that this method can lead to large errors when the set of reference plants has different characteristics or weather conditions than the set of unknown plants and when the set of reference plants is small. Based on these preliminary findings, an alternative method is proposed for calculating the aggregate power production of a set of PV plants. A probabilistic approach has been chosen by which a power production is calculated at each PV plant from corresponding weather data. The probabilistic approach consists of evaluating the power for each frequently occurring value of the parameters and estimating the most probable value by averaging these power values weighted by their frequency of occurrence. Most frequent parameter sets (e.g. module azimuth and tilt angle) and their frequency of occurrence have been assessed on the basis of a statistical analysis of parameters of approx. 35 000 PV plants. It has been found that the plant parameters are statistically dependent on the size and location of the PV plants. Accordingly, separate statistical values have been assessed for 14 classes of nominal capacity and 95 regions in Germany (two-digit zip-code areas). The performances of the upscaling and probabilistic approaches have been compared on the basis of 15 min power measurements from 715 PV plants provided by the German distribution system operator LEW Verteilnetz. It was found that the error of the probabilistic method is smaller than that of the upscaling method when the number of reference plants is sufficiently large (>100 reference plants in the case study considered in this chapter). When the number of reference plants is limited (<50 reference plants for the considered case study), it was found that the proposed approach provides a noticeable gain in accuracy with respect to the upscaling method.

Computational modelling of non-equilibrium condensing steam flows in low-pressure steam turbines

The steam turbines play a significant role in global power generation. Especially, research on low pressure (LP) steam turbine stages is of special importance for steam turbine man- ufactures, vendors, power plant owners and the scientific community due to their lower efficiency than the high pressure steam turbine stages. Because of condensation, the last stages of LP turbine experience irreversible thermodynamic losses, aerodynamic losses and erosion in turbine blades. Additionally, an LP steam turbine requires maintenance due to moisture generation, and therefore, it is also affecting on the turbine reliability. Therefore, the design of energy efficient LP steam turbines requires a comprehensive analysis of condensation phenomena and corresponding losses occurring in the steam tur- bine either by experiments or with numerical simulations. The aim of the present work is to apply computational fluid dynamics (CFD) to enhance the existing knowledge and understanding of condensing steam flows and loss mechanisms that occur due to the irre- versible heat and mass transfer during the condensation process in an LP steam turbine. Throughout this work, two commercial CFD codes were used to model non-equilibrium condensing steam flows. The Eulerian-Eulerian approach was utilised in which the mix- ture of vapour and liquid phases was solved by Reynolds-averaged Navier-Stokes equa- tions. The nucleation process was modelled with the classical nucleation theory, and two different droplet growth models were used to predict the droplet growth rate. The flow turbulence was solved by employing the standard k-ε and the shear stress transport k-ω turbulence models. Further, both models were modified and implemented in the CFD codes. The thermodynamic properties of vapour and liquid phases were evaluated with real gas models. In this thesis, various topics, namely the influence of real gas properties, turbulence mod- elling, unsteadiness and the blade trailing edge shape on wet-steam flows, are studied with different convergent-divergent nozzles, turbine stator cascade and 3D turbine stator-rotor stage. The simulated results of this study were evaluated and discussed together with the available experimental data in the literature. The grid independence study revealed that an adequate grid size is required to capture correct trends of condensation phenomena in LP turbine flows. The study shows that accurate real gas properties are important for the precise modelling of non-equilibrium condensing steam flows. The turbulence modelling revealed that the flow expansion and subsequently the rate of formation of liquid droplet nuclei and its growth process were affected by the turbulence modelling. The losses were rather sensitive to turbulence modelling as well. Based on the presented results, it could be observed that the correct computational prediction of wet-steam flows in the LP turbine requires the turbulence to be modelled accurately. The trailing edge shape of the LP turbine blades influenced the liquid droplet formulation, distribution and sizes, and loss generation. The study shows that the semicircular trailing edge shape predicted the smallest droplet sizes. The square trailing edge shape estimated greater losses. The analysis of steady and unsteady calculations of wet-steam flow exhibited that in unsteady simulations, the interaction of wakes in the rotor blade row affected the flow field. The flow unsteadiness influenced the nucleation and droplet growth processes due to the fluctuation in the Wilson point.

Phenolic compounds and antioxidant capacity of three thymus species plants

Thymus plants comprise distinct species with claimed health properties [1], commonly associated to their essential oils and phenolic compounds. Albeit that, the phenolic composition and the biological activities of many Thymus species remain unclear. This work aimed to elucidate the phenolic composition and antioxidant properties of aqueous extracts from Thymus herba barona, Thymus caespetitus and Thymus fragrantissimus. The aqueous extracts of the three Thymus species were evaluated for their total phenolic compounds by an adaptation of the Folin-Ciocalteu method [2], and individual phenolic compounds were identified by high performance liquid chromatography associated with electrospray mass spectrometry (HPLC-DAD-ESI-MSn) in the negative mode. The antioxidant activity of each extract was carried out by DPPH● scavenging assay and ferric reducing antioxidant power assays [3]. Total phenolic compounds in the three extracts ranged from 236±27 (T. caespetitus) to 273±17 μg GAE/mg (T. fragrantissimus). Similarly to other Thymus species [1,4], these extracts were rich in caffeic acid derivatives (characteristic UV spectra maxima at 290 and 328 nm) and mainly composed of rosmarinic acid (MW 360). Other caffeic acid derivatives included salvianolic acid K (MW 556) and 3′-O-(8″-Z-caffeoyl)rosmarinic acid (MW 538). High amounts of the flavone luteolin-O-glucuronide ([M-H]− at m/z 461→285) were found in T. caespetitus while the others species contained moderate amounts of this compound. T. herba barona, T. caespetitus and T. fragrantissimus extracts showed high DPPH radical scavenge ability (EC50 values 11.6±0.9, 13.8±0.6 and 10.9±1.2 μg/mL respectively), as well as high reducing power (EC50 values of 35.1±4.5, 39.3±2.7 and 32.4±4.3 μg/mL, respectively), that were comparable to those of reference compounds. This work is an important contribution for the phytochemical characterization and the antioxidant capacity of these three Thymus species.

Phenolic compounds and antioxidant capacity of three thymus species plants

Thymus plants comprise distinct species with claimed health properties [1], commonly associated to their essential oils and phenolic compounds. Albeit that, the phenolic composition and the biological activities of many Thymus species remain unclear. This work aimed to elucidate the phenolic composition and antioxidant properties of aqueous extracts from Thymus herba barona, Thymus caespetitus and Thymus fragrantissimus. The aqueous extracts of the three Thymus species were evaluated for their total phenolic compounds by an adaptation of the Folin-Ciocalteu method [2], and individual phenolic compounds were identified by high performance liquid chromatography associated with electrospray mass spectrometry (HPLC-DAD-ESI-MSn) in the negative mode. The antioxidant activity of each extract was carried out by DPPH● scavenging assay and ferric reducing antioxidant power assays [3]. Total phenolic compounds in the three extracts ranged from 236±27 (T. caespetitus) to 273±17 μg GAE/mg (T. fragrantissimus). Similarly to other Thymus species [1,4], these extracts were rich in caffeic acid derivatives (characteristic UV spectra maxima at 290 and 328 nm) and mainly composed of rosmarinic acid (MW 360). Other caffeic acid derivatives included salvianolic acid K (MW 556) and 3′-O-(8″-Z-caffeoyl)rosmarinic acid (MW 538). High amounts of the flavone luteolin-O-glucuronide ([M-H]− at m/z 461→285) were found in T. caespetitus while the others species contained moderate amounts of this compound. T. herba barona, T. caespetitus and T. fragrantissimus extracts showed high DPPH radical scavenge ability (EC50 values 11.6±0.9, 13.8±0.6 and 10.9±1.2 μg/mL respectively), as well as high reducing power (EC50 values of 35.1±4.5, 39.3±2.7 and 32.4±4.3 μg/mL, respectively), that were comparable to those of reference compounds. This work is an important contribution for the phytochemical characterization and the antioxidant capacity of these three Thymus species.

Added value from biomass by broader utilization of fuels and CHP plants

The present work, where additional value-creating processes in existing combined heat and power (CHP) structures have been examined, is motivated by a political- and consumer-driven strive towards a bioeconomy and a stagnation for the existing business models in large parts of the CHP sector. The research is based on cases where the integration of flash pyrolysis for co-production of bio-oil, co-gasification for production of fuel gas and synthetic biofuels as well as leaching of extractable fuel components in existing CHP plants have been simulated. In particular, this work has focused on the CHP plants that utilize boilers of fluidized bed (FB) type, where the concept of coupling a separate FB reactor to the FB of the boiler forms an important basis for the analyses. In such dual fluidized bed (DFB) technology, heat is transferred from the boiler to the new rector that is operating with other fluidization media than air, thereby enabling other thermochemical processes than combustion to take place. The result of this work shows that broader operations at existing CHP plants have the potential to enable production of significant volumes of chemicals and/or fuels with high efficiency, while maintaining heat supply to external customers. Based on the insight that the technical preconditions for a broader operation are favourable, the motivation and ability among the incumbents in the Swedish CHP sector to participate in a transition of their operation towards a biorefinery was examined. The result of this assessment showed that the incumbents believe that a broader operation can create significant values for their own operations, the society and the environment, but that they lack both a strong motivation as well as important abilities to move into the new technological fields. If the concepts of broader production are widely implemented in the Swedish FB based CHP sector, this can substantially contribute in the transition towards a bioeconomy.

Influence of host plant structure and microclimate on the abundance and behaviour of Tephritid fly

Microclimate and host plant architecture significantly influence the abundance and behavior of insects. However, most research in this field has focused at the invertebrate assemblage level, with few studies at the single-species level. Using wild Solanum mauritianum plants, we evaluated the influence of plant structure (number of leaves and branches and height of plant) and microclimate (temperature, relative humidity, and light intensity) on the abundance and behavior of a single insect species, the monophagous tephritid fly Bactrocera cacuminata (Hering). Abundance and oviposition behavior were signficantly influenced by the host structure (density of foliage) and associated microclimate. Resting behavior of both sexes was influenced positively by foliage density, while temperature positively influenced the numbers of resting females. The number of ovipositing females was positively influenced by temperature and negatively by relative humidity. Feeding behavior was rare on the host plant, as was mating. The relatively low explanatory power of the measured variables suggests that, in addition to host plant architecture and associated microclimate, other cues (e.g., olfactory or visual) could affect visitation and use of the larval host plant by adult fruit flies. For 12 plants observed at dusk (the time of fly mating), mating pairs were observed on only one tree. Principal component analyses of the plant and microclimate factors associated with these plants revealed that the plant on which mating was observed had specific characteristics (intermediate light intensity, greater height, and greater quantity of fruit) that may have influenced its selection as a mating site.