Optimization of energy in a pulp mill

This study presents examination of ways to increase power generation in pulp mills. The main purpose was to identify and verify the best ways of power generation growth. The literature part of this study presented operation of energy pulp mill departments, energy consumption and generation by the recovery and power boilers. The second chapter of this part described the main directions for increase of electricity generation rise of black liquor dry solid content, increase of main steam parameters, flue gas heat recovery technologies, feed water and combustion air preheating. The third chapter of the literature part presented possible technical, environment and corrosion risks appeared from described alternatives. In the experimental part of this study, calculations and results of possible models with alternatives was presented. The possible combinations of alternatives were generated in 44 `models of energy pulp mill. The target of this part was define extra electricity generation after alternatives using and estimate profitability of generated models. The calculations were made by computer programme PROSIM. In the conclusions, the results were estimated on the basis of extra electricity generation and equipment design data of models. The profitability of cases was verified by their payback periods and additional incomes.

Chelating Adsorbents in Purification of Hydrometallurgical Solutions

In this thesis, equilibrium and dynamic sorption properties of weakly basic chelating adsorbents were studied to explain removal of copper, nickel from a concentrated zinc sulfate solution in a hydrometallurgical process. Silica-supported chelating composites containing either branched poly(ethyleneimine) (BPEI) or 2-(aminomethyl)pyridine (AMP) as a functional group were used. The adsorbents are commercially available from Purity Systems Inc, USA as WP-1® and CuWRAM®, respectively. The fundamental interactions between the adsorbents, sulfuric acid and metal sulfates were studied in detail and the results were used to find the best conditions for removal of copper and nickel from an authentic ZnSO4 process solution. In particular, the effect of acid concentration and temperature on the separation efficiency was considered. Both experimental and modeling aspectswere covered in all cases. Metal sorption is considerably affected by the chemical properties of the studied adsorbents and by the separation conditions. In the case of WP-1, acid affinity is so high that column separation of copper, nickel and zinc has to be done using the adsorbent in base-form. On the other hand, the basicity of CuWRAM is significantly lower and protonated adsorbent can be used. Increasing temperature decreases the basicity and the metals affinity of both adsorbents, but the uptake capacities remain practically unchanged. Moreover, increasing temperature substantially enhances intra-particle mass transport and decreases viscosities thus allowing significantly higher feed flow rates in the fixed-bed separation. The copper selectivity of both adsorbents is very high even in the presence of a 250-fold excess of zinc. However, because of the basicity of WP-1, metal precipitation is a serious problem and therefore only CuWRAM is suitable for the practical industrial application. The optimum temperature for copper removal appears to be around 60 oC and an alternative solution purification method is proposed. The Ni/Zn selectivity of both WP-1 and CuWRAM is insufficient for removal of the very small amounts of nickel present in the concentrated ZnSO4 solution.

Application of cholesterol determination method to indirectly detect meat and bone meals in ruminant feeds

The aim of this study was to verify the presence of meat and bone meal (MBM) in ruminant feed, by identifying the cholesterol using gas chromatography with a flame ionization detector. The proposed method demonstrated precision, trueness, and capability to detect MBM in the ruminant feed.

Separation of Gas Bubbles from Circulation Waters and Pulp Suspensions in Open Channel Flow

The objective of this thesis was to study the removal of gases from paper mill circulation waters experimentally and to provide data for CFD modeling. Flow and bubble size measurements were carried out in a laboratory scale open gas separation channel. Particle Image Velocimetry (PIV) technique was used to measure the gas and liquid flow fields, while bubble size measurements were conducted using digital imaging technique with back light illumination. Samples of paper machine waters as well as a model solution were used for the experiments. The PIV results show that the gas bubbles near the feed position have the tendency to escape from the circulation channel at a faster rate than those bubbles which are further away from the feed position. This was due to an increased rate of bubble coalescence as a result of the relatively larger bubbles near the feed position. Moreover, a close similarity between the measured slip velocities of the paper mill waters and that of literature values was obtained. It was found that due to dilution of paper mill waters, the observed average bubble size was considerably large as compared to the average bubble sizes in real industrial pulp suspension and circulation waters. Among the studied solutions, the model solution has the highest average drag coefficient value due to its relatively high viscosity. The results were compared to a 2D steady sate CFD simulation model. A standard Euler-Euler k-ε turbulence model was used in the simulations. The channel free surface was modeled as a degassing boundary. From the drag models used in the simulations, the Grace drag model gave velocity fields closest to the experimental values. In general, the results obtained from experiments and CFD simulations are in good qualitative agreement.

Pretreatment in membrane filtration of wood hydrolysate

Interest in recovery of valuable components from process streams has increased in recent years. Purpose of biorefinery is to utilize components that otherwise would go to waste. Hemicelluloses, for example, could be utilized in production of many valuable products. One possible way to separate and fractionate hemicelluloses is membrane filtration. In the literature part of this work membrane fouling in filtration processes of pulp and paper process- and wastewaters was investigated. Especially purpose was to find out the possible fouling compounds, after which facilities to remove or modify such components less harmful were studied. In the experimental part different pretreatment methods, mainly to remove or degrade lignin from wood hydrolysate, were studied. In addition, concentration of hemicelluloses and separation from lignin were examined with two ultrafiltration membranes; UFX5 and RC70PP. Changes in feed solution, filtration capacity and fouling of membranes were used to evaluate the effects of pretreatment methods. Changes in hydrolysate composition were observed with different analysis methods. Filtration of hydrolysate proved to be challenging, especially with the UFX5 membrane. The more hydrophilic RC70PP membrane did not seem to be fouled as severely as the UFX5 membrane, according to pure water flux measurements. The UFX5 membrane retained hemicelluloses rather well, but problems arose from rapid flux decline resulting from concentration polarization and fouling of membrane. Most effective pretreatment methods in the case with the UFX5 membrane proved to be prefiltration with the RC70PP membrane, activated carbon adsorption and photocatalytic oxidation using titanium dioxide and UV radiation. An additional experiment with PHW extract showed that pulsed corona discharge treatment degraded lignin quite efficiently and thus improved filtration capacity remarkably, even over six times compared to the filtration with untreated extract.

Biokaasun tuottaminen ja hyödyntäminen Lappeenrannassa

Lappeenrannassa kerätään ja hyödynnetään tällä hetkellä kaatopaikkakaasua 0,3 milj.m3 vuodessa. Biokaasua voitaisiin tuottaa Lappeenrannassa mädättämällä bioperäisiä jätteitä ja biokaasuntuotantoa varten kasvatettuja energiakasveja. Biokaasuntuotantoon soveltuvia jätteitä ovat erilliskerätty biojäte, jätevedenpuhdistamon jätevesiliete, puutarhajäte, lietelannat ja oljet. Kesannolla olevilla peltoaloilla voitaisiin kasvattaa ruokohelpeä. Biokaasun tuotantoon soveltuvia materiaaleja voitaisiin kerätä 143 000 t/a ja kasvattaa 68 000 t/a. Työssä tarkastellaan vaihtoehtoa, jossa mädätetään vain puhdistamoliete, sekä useita materiaaleja mädättävää yhteismädättämöä, johon liittyen tutkitaan kolmea eri vaihtoehtoa: kunnallisen jätteen mädätystä, kaiken jätteen mädätystä ja jätteen sekä energiakasvien mädätystä. Paras sijoituspaikka mädättämölle olisi jätevedenpuhdistamon läheisyydessä. Jätemateriaalista saataisiin kaasua enintään 12 milj. m3 ja energiakasveista enintään 16 milj. m3. Kaasusta voitaisiin tuottaa energiaa CHP-laitoksessa enintään 184 GWh. Mikäli biokaasun tuotannolla halutaan ensisijaisesti vähentää kasvi-huonekaasupäästöjä, kannattaa kaasu jalostaa ajoneuvopolttoaineeksi. Jalostettu kaasu on mahdollista myös syöttää maakaasuverkostoon. Suurimmat tulot on mahdollista saavuttaa yhdistetyssä sähkön- ja lämmöntuotannossa, mikäli biokaasulle suunniteltu syöttötariffi toteutuu. Muussa tapauksessa suurimmat tulot saadaan jalostamalla biokaasua ajoneuvojen polttoaineeksi.

A study of combustion phenomena in circulating fluidized beds by developing and applying experimental and modelling methods for laboratory-scale reactors

The results shown in this thesis are based on selected publications of the 2000s decade. The work was carried out in several national and EC funded public research projects and in close cooperation with industrial partners. The main objective of the thesis was to study and quantify the most important phenomena of circulating fluidized bed combustors by developing and applying proper experimental and modelling methods using laboratory scale equipments. An understanding of the phenomena plays an essential role in the development of combustion and emission performance, and the availability and controls of CFB boilers. Experimental procedures to study fuel combustion behaviour under CFB conditions are presented in the thesis. Steady state and dynamic measurements under well controlled conditions were carried out to produce the data needed for the development of high efficiency, utility scale CFB technology. The importance of combustion control and furnace dynamics is emphasized when CFB boilers are scaled up with a once through steam cycle. Qualitative information on fuel combustion characteristics was obtained directly by comparing flue gas oxygen responses during the impulse change experiments with fuel feed. A one-dimensional, time dependent model was developed to analyse the measurement data Emission formation was studied combined with fuel combustion behaviour. Correlations were developed for NO, N2O, CO and char loading, as a function of temperature and oxygen concentration in the bed area. An online method to characterize char loading under CFB conditions was developed and validated with the pilot scale CFB tests. Finally, a new method to control air and fuel feeds in CFB combustion was introduced. The method is based on models and an analysis of the fluctuation of the flue gas oxygen concentration. The effect of high oxygen concentrations on fuel combustion behaviour was also studied to evaluate the potential of CFB boilers to apply oxygenfiring technology to CCS. In future studies, it will be necessary to go through the whole scale up chain from laboratory phenomena devices through pilot scale test rigs to large scale, commercial boilers in order to validate the applicability and scalability of the, results. This thesis shows the chain between the laboratory scale phenomena test rig (bench scale) and the CFB process test rig (pilot). CFB technology has been scaled up successfully from an industrial scale to a utility scale during the last decade. The work shown in the thesis, for its part, has supported the development by producing new detailed information on combustion under CFB conditions.

Reproductive ecology of the exotic tree Muntingia calabura L. (Muntingiaceae) in southeastern Brazil

The exotic tree Muntingia calabura L. (Muntingiaceae), a species native to Central America, is used as fish feed and fiber and cellulose production in Brazil. This study was carried out in urban areas and verified the reproductive biology of this plant species. Flower and fruit morphology, compatibility system, reproductive phenology, pollination and frugivore animals, and germination of disseminated seeds were recorded by standard field and laboratory procedures. This tree is self-compatible and autonomously self-pollinated, with its flowers being mainly visited by bees and its fruits consumed by birds and bats. Germination of its dispersed seeds is fast and occurs at a high rate. The results of this work suggest that M. calabura is very adaptable to cultivated areas,thus being an excellent choice for urban reforestation. However, its reproductive characteristics place this plant as an invasive species with significant potential in southeastern Brazil.

Behavior, performance and physiological parameters of pigs reared in deep bedding

An experiment was conducted to evaluate the behavior, performance and physiological parameters of pigs in different production systems. Twenty four animals in the growth phase were distributed in a randomized block design in three treatments: T1 - concrete floor, T2 - deep bedding with wood shaving, and T3 - deep bedding with coffee husks. The behavioral study was carried out by observing the animal behavior for an uninterrupted period of eight hours throughout seven weeks. The proportions of time spent in each behavior were characterized using the frequency histogram composition. Environmental (IBGTH), physiological (rectal and skin temperature and respiratory rate) and performance (weight gain, feed intake and feed conversion) parameters were measured in animals during the period. The production systems of deep bedding showed higher values of IBGTH. There was no effect of production systems evaluated on the performance parameters. Rectal temperature was higher in animals reared on deep bedding with coffee husks in relation to the concrete floor. The use of deep bedding benefited the behavior of piglets in the growth phase and it reduced the agonistic behavior among individuals.

Several regulations in gravity table in quality of tobacco seeds

The use of gravity table can result in improved quality of seeds of several species, demonstrating the superiority of the quality attributes of seeds collected in the top positions in relation to the lower positions of the discharge zone of the gravity table. The availability of information on tobacco seeds, particularly on the action of gravity table, has not been addressed in the literature. The present study was to evaluate the influence of different regulations in the gravity table on the quality of tobacco seeds. The terminal edge of the machine of 50 cm width was divided into four parts plus the outlet for stones. The treatments were in the following fractions: original seed (obtained in the feed hopper), heavy seed (at the top), middle high, intermediate, and light seed (lower part), and the stones outlet of the gravity table. Each combination of regulation was in an independent adjustment with a total of seven adjusts. The gravity table, in the adjustments with high oscillation, was efficient in improving the physiological quality of seed lots of tobacco, by removing the fraction of light seeds discharged at the bottom of the terminal edge.

Evaluation of covering materials in individual shelters and its effects on physiological responses and performance of dairy calves

In Tropical regions, the animal performance is often affected by climate conditions. This study aimed to evaluate covering materials in individual shelters, normally used to house dairy calves, and its influence on the calves physiology and performance. The design used was completely randomized, with a 2x3 factorial arrangement to compare the averages of 5% through the Tukey's test, i.e., both genders- and three types of covering in the shelters (Z - zinc; AC - asbestos cement; and WPAC - white-painted asbestos cement). Parameters evaluated included daily weight gain (DWG), dry matter intake (DMI), feed conversion (FC), rectal temperature (RT), and respiratory frequency (RF). Results showed significant differences (P < 0.05) among males (1.04kg/day) and females (0.74kg/day) for DWG and interaction between gender and treatment (P < 0.05) for zinc covering (0.562kg/day for females and 1.120kg/day for males). Significant differences were also observed in FI of animals housed under shelters with the covering of zinc (48.35kgDM/day for females and 96.91 kgDM/day for males). There were no significant differences (P > 0.05) in the FC and the RT, and there were significant differences (P < 0.05) for RF in the Z treatments (56.9 mov.min-1), WPAC (62.2 mov.min-1) and FC (70.25 mov.min-1). It was concluded that different covering materials did not affect performance and dry matter intake of dairy calves. However, the animals' physiology of thermoregulation was altered by the different covering materials used in individual shelters.

Investment recovery period in electric motor of higher efficiency in pumping for irrigation

In this study, it was adjusted a mathematical model to measure the effect of electric motor efficiency on pumping system costs for irrigation on the tariff structure of conventional electricity and green horo-seasonal , and also to calculate the recovery period of the invested capital in higher efficiency equipment. Then, it was applied to a center pivot irrigation system in two options of electric motor efficiency, 92,6% (standard line) and 94,3% (high efficiency line), and the acquisition cost of the first corresponded to 70% the of the second. The power of the electric motor was 100hp. The results showed that the model allowed us to evaluate if a high efficiency motor was economically viable compared to the standard motor in each tariff structure. The high efficiency motor was not viable in the two tariff structures. In the green horo-seasonal tariff, would only be viable if its efficiency was 4.46% higher than the standard motor. In the conventional tariff, it would only be viable if the efficiency overcame 2.71%.

Light emitting diode (LED) use in artificial lighting for broiler chicken production

Light emitting diode (LED) has been used in commercial poultry industry by presenting superior energy savings and providing feasibility on production process. The objective of this research was to evaluate performance and carcass yield of broiler chickens exposed to different LED colors compared with fluorescent lamps. For that, two experiments (E1 and E2) were performed and 2,646 Cobb® chickens were used. In experiment E1, male birds were exposed to 20 lux artificial lighting with red, yellow, blue, and white LED bulbs; and fluorescent bulb. In experiment E2, male and female birds were exposed to 15 lux artificial lighting with red and blue LED bulbs; and fluorescent bulb. Cumulative weight gain (kg), feed intake (kg), feed conversion, hot carcass weight (kg), carcass yield (%), and breast and thigh + drumstick yield (%) were used as response variables. Results showed no difference (p > 0.05) among treatments for performance, carcass yield, and cut yield in experiment E1. In experiment E2 there was only difference between genders (p < 0.05) and males showed higher total weight gain, feed intake, hot carcass weight and thigh + drumstick yield. Different LED color use had same effect as fluorescent lights on broiler performance and carcass yield.

Heat loss in one day old pullets inside a hatchery

After hatching, pullets are transported to brooding area and vaccinated. One day old chicks have not already developed thermoregulation ability; thus, brooding temperature variations may affect pullet quality leading to broiler meat production losses. This research aimed to calculate sensible heat loss in one day old pullets in hatching area and vaccination room. Ten one day old pullets were randomly selected from hatching area of a commercial hatchery. Infrared images were used to calculate bird surface temperature. Exposure areas for the two conditions were quantified, and both air temperature and wind speed was recorded. Total sensible heat loss was calculated as heat loss by radiation plus heat loss by convection. It was found that heat transfer occurs in different ways at different bird body parts. Total heat loss found for hatching baskets was equivalent to 0.81 J s-1 while for vaccination room was 1.16 J s-1. Pullet nutrition is based on energy loss from brooding to farm, and the overall pullet heat loss from hatchery to farm accepted is 13.95 J s-1. Thus, "starter feed" has relevant excess of energy input. These findings indicate that less energy can be used in initial feed, once heat loss is lower than assumed nowadays. Improved knowledge on these conditions may enhance broiler farm feeding strategies and economics during first rearing week.

Energy balance in the poultry-shed system and its influence on broiler performance

ABSTRACTThe objective of this study was to determine the energy balance of the poultry-shed system and its effect on broiler performance during the production cycle. The experimental design was completely random with sub-divided blocks. The blocks were composed of five different types of sheds and the sub-blocks of the evaluation times (00:00 h to 23:00 h), allowing an analysis of variance and a comparison between means with the Tukey test. There were no significant differences between the mean values of the exchanges of sensible, latent and total heat between the poultry sheds but the differences for the evaluation times were significant (P<0.05). There was no significant difference between sheds 1 and 4 for broiler productive performance regarding weight gain, feed consumption and feed conversion. Bird performance was significant (P<0.05) for the remaining poultry sheds. The productive indexes remained below the ranges considered ideal for broilers and values in the final weeks were characterized by the poor installation efficiency in controlling temperature variations and, consequently, the energy balance in the system, which adversely affected bird productive performance.