State of the art of industrial wood protection in Portugal

This work intended to give a perspective of industrial wood protection in Portugal. A survey was made of the companies treating wood mainly for use classes 3 and 4 such as autoclave treatments with biocides and wood modification procedures. Currently there are 23 companies with 33 production plants with an autoclave installed for wood preservation by impregnation. There are also two companies producing modified wood by thermal treatment. Most of the plants are located in the central and northern regions of Portugal. The leading preservation chemicals used in Portugal are Tanalith E and Celcure brands. The main wood species used in all companies is Pinus pinaster from local producers. The products commercialized by the treating companies are diverse: pre-fabricated houses, garden furniture and playgrounds, decks, poles, stakes, and sawn wood. Modified wood producers sell mostly decks and cladding. Considerable changes are expected in the next few years due to the requirements of European Directives and the typical constraints of the Portuguese market.

Predicting the concentration of residual methanol in industrial formalin using machine learning

In this thesis, a machine learning approach was used to develop a predictive model for residual methanol concentration in industrial formalin produced at the Akzo Nobel factory in Kristinehamn, Sweden. The MATLABTM computational environment supplemented with the Statistics and Machine LearningTM toolbox from the MathWorks were used to test various machine learning algorithms on the formalin production data from Akzo Nobel. As a result, the Gaussian Process Regression algorithm was found to provide the best results and was used to create the predictive model. The model was compiled to a stand-alone application with a graphical user interface using the MATLAB CompilerTM.

Production de biodiesel à partir de microalgues par catalyses homogène et hétérogène

Résumé : Au Canada, près de 80% des émissions totales, soit 692 Mt eq. CO[indice inférieur 2], des gaz à effet de serre (GES) sont produits par les émissions de dioxyde de carbone (CO[indice inférieur 2]) provenant de l’utilisation de matières fossiles non renouvelables. Après la Conférence des Nations Unies sur les changements climatiques, COP21 (Paris, France), plusieurs pays ont pour objectif de réduire leurs émissions de GES. Dans cette optique, les microalgues pourraient être utilisées pour capter le CO[indice inférieur 2] industriel et le transformer en biomasse composée principalement de lipides, de glucides et de protéines. De plus, la culture des microalgues n’utilise pas de terre arable contrairement à plusieurs plantes oléagineuses destinées à la production de biocarburants. Bien que les microalgues puissent être transformées en plusieurs biocarburants tels le bioéthanol (notamment par fermentation des glucides) ou le biométhane (par digestion anaérobie), la transformation des lipides en biodiesel pourrait permettre de réduire la consommation de diesel produit à partir de pétrole. Cependant, les coûts reliés à la production de biodiesel à partir de microalgues demeurent élevés pour une commercialisation à court terme en partie parce que les microalgues sont cultivées en phase aqueuse contrairement à plusieurs plantes oléagineuses, ce qui augmente le coût de récolte de la biomasse et de l’extraction des lipides. Malgré le fait que plusieurs techniques de récupération des lipides des microalgues n’utilisant pas de solvant organique sont mentionnées dans la littérature scientifique, la plupart des méthodes testées en laboratoire utilisent généralement des solvants organiques. Les lipides extraits peuvent être transestérifiés en biodiesel en présence d’un alcool tel que le méthanol et d’un catalyseur (catalyses homogène ou hétérogène). Pour la commercialisation du biodiesel à partir de microalgues, le respect des normes ASTM en vigueur est un point essentiel. Lors des essais en laboratoire, il a été démontré que l’extraction des lipides en phase aqueuse était possible afin d’obtenir un rendement maximal en lipides de 36% (m/m, base sèche) en utilisant un prétraitement consistant en une ébullition de la phase aqueuse contenant les microalgues et une extraction par des solvants organiques. Pour l’estérification, en utilisant une résine échangeuse de cations (Amberlyst-15), une conversion des acides gras libres de 84% a été obtenue à partir des lipides de la microalgue Chlorella protothecoïdes dans les conditions suivantes : température : 120°C, pression autogène, temps de réaction : 60 min, ratio méthanol/lipides: 0.57 mL/g et 2.5% (m/m) Amberlyst-15 par rapport aux lipides. En utilisant ces conditions avec une catalyse homogène (acide sulfurique) et une seconde étape alcaline avec de l’hydroxyde de potassium (température : 60°C ; temps de réaction : 22.2 min; ratio catalyseur microalgue : 2.48% (m/m); ratio méthanol par rapport aux lipides des microalgues : 31.4%), un rendement en esters méthyliques d’acides gras (EMAG) de 33% (g EMAG/g lipides) a été obtenu à partir des lipides de la microalgue Scenedesmus Obliquus. Les résultats démontrent que du biodiesel peut être produit à partir de microalgues. Cependant, basé sur les présents résultats, il sera necessaire de mener d’autre recherche pour prouver que les microalgues sont une matière première d’avenir pour la production de biodiesel.

Synthetic polymers blend used in the production of high activated carbon for pesticides removals from liquid phase

For the activated carbon (AC) production, we used the most common industrial and consumer solid waste, namely polyethyleneterephthalate (PET), alone or blended with other synthetic polymer such polyacrylonitrile (PAN). By mixing PET, with PAN, an improvement in the yield of the AC production was found and the basic character and some textural and chemical properties were enhanced. The PET–PAN mixture was subjected to carbonisation, with a pyrolysis yield of 31.9%, between that obtained with PET (16.9%) or PAN (42.6%) separately. The AC revealed a high surface area (1400, 1230 and 1117 m2 g−1) and pore volume (0.46, 0.56 and 0.50 cm3 g−1), respectively, for PET, PAN and PET–PAN precursors. Selected ACs were successfully tested for 4- chloro-2-methylphenoxyacetic acid (MCPA) and diuron removal from the liquid phase, showing a higher adsorption capacity (1.7 and 1.2 mmol g−1, respectively, for MCPA and diuron) and good fits with the Langmuir (PET) and Freundlich equation (PAN and PET–PAN blend). With MCPA, the controlling factor to the adsorption capacity was the porous volume and the average pore size. Concerning diuron, the adsorption was controlled essentially by the external diffusion. A remarkable result is the use of different synthetic polymers wastes, as precursors for the production of carbon materials, with high potential application on the pesticides removals from the liquid phase.

MDF and PB composites wastes used in the production of activated carbons by physical activation

O desenvolvimento de materiais de carbono continua a ser, na atualidade, uma das áreas de grande interesse junto das comunidades científica e industrial [1]. Especial atenção é dada à valorização de resíduos da indústria, de baixo valor económico, tentando desta forma resolver problemas de gestão de grandes quantidades de desperdícios [2]. De especial relevo destacamos os resíduos potencialmente perigosos, segundo os dados da FAO – Food and Agriculture Organization das Nações Unidas [3]. O desenvolvimento de novos materiais para a indústria do mobiliário, substitutos da madeira, tem gerado uma enorme diversidade de produtos mas também de resíduos. Os mais comuns no mercado são os materiais compósitos, entre eles o PB – ParticleBoard e o MDF – Medium Density Fibreboard, os quais registam um aumento de consumo na Europa de 1,3% e 4,3%, respetivamente, mesmo em período de crise económica como a que estamos a atravessar [3]. O presente trabalho tem como objetivo o estudo do potencial destes resíduos para a produção de carvões ativados (CA) em formas monolíticas, gerando um produto com um elevado valor acrescentado e com características inovadoras para a posterior aplicação em processos de adsorção.

Design and Technology: A Historical Perspective on the Mediating Role of Technology Between Industrial Design and Engineering

The interdisciplinary relationship between industrial design and mechanical engineering is sensitive. This research focuses on understanding how one can positively mediate this relation, in order to foster innovation. In this paper, technology is considered for this role since it has, in some historical moments, served as an integrator of these two disciplines, in processes that led to innovation. By means of an extensive literature review, covering three different periods of technological development, both disciplines’ positioning in society and their link with technology are analyzed and compared. The three case studies selected help to illustrate, precisely, the technology positioning between both disciplines and society. Literature assumes that industrial design is rooted in the rise of criticism against both the machine and the mechanized production. This is an opposing approach to the current paradigm, in which design plays a fundamental role in adapting technology to society. Also, the social problems caused by the mechanized and massive production triggered the mechanical engineering emergence, as a professionalized discipline. Technology was intrinsically connected with both industrial design and mechanical engineering emergence and subsequent evolution. In the technology conflict with society lays the reform and regulation for design practice, in its broadest sense.

Production of activated carbons from single and mixtures of synthetic polymers

The production of activated carbons (ACs) involves two main steps: the carbonization of the carbonaceous of raw materials at temperatures below 1073 K in the absence of oxygen and the activation had realized at the temperature up to 1173 but the most useful temperature at 1073 K. In our study we used the most common industrial and consumer solid waste, namely PET, alone or blended with other synthetic polymer PAN. By mixing the two polymers in different ratios, an improvement of the yield of the AC production was found and some textural properties were enhanced by comparison with the AC prepared using each polymer separately. When all the samples were exposed through the carbonization process with a pyrolysis the mixture of PAN-PET (1:1w/w) yield around 31.9%, between that obtained with PET (16.9%) or PAN (42.6%) separately. The combine activation, with CO2 at 1073 K, allow ACs with a lower burn-off degree isothermally, when compared with those attained with PET or PAN alone, but with similarly chemicals or textural properties. The resultant ACs are microporous in their nature, as the activation time increase, the PET-PAN mixture AC are characterized by a better developed porous structure, when associated with the AC prepared from PAN. The AC prepared from PET-PAN mixture are characterized by basic surface characteristics, with a pHpzc around 10.5, which is an important characteristic for future applications on acidic pollutants removals from liquid or gaseous phase. In this study we had used the FTIR methods to determine the main functional groups in the surface of the activated carbons. The adsorbents prepared from PAN fibres presents an IR spectrum with similar characteristics to those obtained with PET wastes, but with fewer peaks and bands with less intensity, in particular for the PAN-8240 sample. This can be reflected by the stretching and deformation modes of NH bond in the range 3100 – 3300 cm-1 and 1520 – 1650 cm-1, respectively. Also, stretching mode associated to C–N, C=N, can contributed to the profile of IR spectrum around 1170 cm-1, 1585 – 1770 cm-1. And the TGA methods was used to study the loses of the precursors mass according to the excessive of the temperature. The results showed that, there were different decreasing of the mass of each precursors. PAN degradation started at almost 573 K and at 1073 K, PAN preserve more than 40% of the initial mass. PET degradation started at 650 K, but at 1073 K, it has lost 80% of the initial mass. However, the mixture of PET-PAN (1:1w/w) showed a thermogravimetric profile between the two polymers tested individually, with a final mass slightly less than 30%. From a chemical point of view, the carbonisation of PET mainly occurs in one step between 650 and 775 K.

Design, development, and analysis of hybrid metal-composite tube for industrial application

In the aerospace, automotive, printing, and sports industries, the development of hybrid Carbon Fiber Reinforced Polymer (CFRP)-metal components is becoming increasingly important. The coupling of metal with CFRP in axial symmetric components results in reduced production costs and increased mechanical properties such as bending, torsional stiffness, mass reduction, damping, and critical speed compared to the single material-built ones. In this thesis, thanks to a novel methodology involving a rubbery/viscoelastic interface layer, several hybrid aluminum-CFRP prototype tubes were produced. Besides, an innovative system for the cure of the CFRP part has been studied, analyzed, tested, and developed in the company that financed these research activities (Reglass SRL, Minerbio BO, Italy). The residual thermal stresses and strains have been investigated with numerical models based on the Finite Element Method (FEM) and compared with experimental tests. Thanks to numerical models, it was also possible to reduce residual thermal stresses by optimizing the lamination sequence of CFRP and determining the influence of the system parameters. A novel software and methodology for evaluating mechanical and damping properties of specimens and tubes made in CFRP were also developed. Moreover, to increase the component's damping properties, rubber nanofibers have been produced and interposed throughout the lamination of specimens. The promising results indicated that the nanofibrous mat could improve the material damping factor over 77% and be adopted in CFRP components with a negligible increment of weight or losing mechanical properties.

Additive Manufacturing by LPBF and WAAM of metals: correlation between production process, microstructure and mechanical properties

In the most recent years, Additive Manufacturing (AM) has drawn the attention of both academic research and industry, as it might deeply change and improve several industrial sectors. From the material point of view, AM results in a peculiar microstructure that strictly depends on the conditions of the additive process and directly affects mechanical properties. The present PhD research project aimed at investigating the process-microstructure-properties relationship of additively manufactured metal components. Two technologies belonging to the AM family were considered: Laser-based Powder Bed Fusion (LPBF) and Wire-and-Arc Additive Manufacturing (WAAM). The experimental activity was carried out on different metals of industrial interest: a CoCrMo biomedical alloy and an AlSi7Mg0.6 alloy processed by LPBF, an AlMg4.5Mn alloy and an AISI 304L austenitic stainless steel processed by WAAM. In case of LPBF, great attention was paid to the influence that feedstock material and process parameters exert on hardness, morphological and microstructural features of the produced samples. The analyses, targeted at minimizing microstructural defects, lead to process optimization. For heat-treatable LPBF alloys, innovative post-process heat treatments, tailored on the peculiar hierarchical microstructure induced by LPBF, were developed and deeply investigated. Main mechanical properties of as-built and heat-treated alloys were assessed and they were well-correlated to the specific LPBF microstructure. Results showed that, if properly optimized, samples exhibit a good trade-off between strength and ductility yet in the as-built condition. However, tailored heat treatments succeeded in improving the overall performance of the LPBF alloys. Characterization of WAAM alloys, instead, evidenced the microstructural and mechanical anisotropy typical of AM metals. Experiments revealed also an outstanding anisotropy in the elastic modulus of the austenitic stainless-steel that, along with other mechanical properties, was explained on the basis of microstructural analyses.

A distributed middleware for IT/OT convergence in modern industrial environments

The modern industrial environment is populated by a myriad of intelligent devices that collaborate for the accomplishment of the numerous business processes in place at the production sites. The close collaboration between humans and work machines poses new interesting challenges that industry must overcome in order to implement the new digital policies demanded by the industrial transition. The Industry 5.0 movement is a companion revolution of the previous Industry 4.0, and it relies on three characteristics that any industrial sector should have and pursue: human centrality, resilience, and sustainability. The application of the fifth industrial revolution cannot be completed without moving from the implementation of Industry 4.0-enabled platforms. The common feature found in the development of this kind of platform is the need to integrate the Information and Operational layers. Our thesis work focuses on the implementation of a platform addressing all the digitization features foreseen by the fourth industrial revolution, making the IT/OT convergence inside production plants an improvement and not a risk. Furthermore, we added modular features to our platform enabling the Industry 5.0 vision. We favored the human centrality using the mobile crowdsensing techniques and the reliability and sustainability using pluggable cloud computing services, combined with data coming from the crowd support. We achieved important and encouraging results in all the domains in which we conducted our experiments. Our IT/OT convergence-enabled platform exhibits the right performance needed to satisfy the strict requirements of production sites. The multi-layer capability of the framework enables the exploitation of data not strictly coming from work machines, allowing a more strict interaction between the company, its employees, and customers.

Integrating Machine Learning Paradigms for Predictive Maintenance in the Fourth Industrial Revolution era

In the last decade, manufacturing companies have been facing two significant challenges. First, digitalization imposes adopting Industry 4.0 technologies and allows creating smart, connected, self-aware, and self-predictive factories. Second, the attention on sustainability imposes to evaluate and reduce the impact of the implemented solutions from economic and social points of view. In manufacturing companies, the maintenance of physical assets assumes a critical role. Increasing the reliability and the availability of production systems leads to the minimization of systems’ downtimes; In addition, the proper system functioning avoids production wastes and potentially catastrophic accidents. Digitalization and new ICT technologies have assumed a relevant role in maintenance strategies. They allow assessing the health condition of machinery at any point in time. Moreover, they allow predicting the future behavior of machinery so that maintenance interventions can be planned, and the useful life of components can be exploited until the time instant before their fault. This dissertation provides insights on Predictive Maintenance goals and tools in Industry 4.0 and proposes a novel data acquisition, processing, sharing, and storage framework that addresses typical issues machine producers and users encounter. The research elaborates on two research questions that narrow down the potential approaches to data acquisition, processing, and analysis for fault diagnostics in evolving environments. The research activity is developed according to a research framework, where the research questions are addressed by research levers that are explored according to research topics. Each topic requires a specific set of methods and approaches; however, the overarching methodological approach presented in this dissertation includes three fundamental aspects: the maximization of the quality level of input data, the use of Machine Learning methods for data analysis, and the use of case studies deriving from both controlled environments (laboratory) and real-world instances.