Search results for: tangentially fired boiler

Authors: Kiurski S. Jelena, Ranogajec G. Jonjaua, Kecić S. Vesna, Oros B. Ivana

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The present study investigates the effectiveness of newly designed clayey pellets (fired clay pellets diameter sizes of 5 and 8 mm, and unfired clay pellets with the diameter size of 15 mm) as the beds in the column adsorption process. The adsorption experiments in the batch mode were performed before the column experiment with the purpose to determine the order of adsorbent package in the column which was to be designed in the investigation. The column experiment was performed by using a known mass of the clayey beds and the volume of the waste printing developer, which was purified. The column was filled in the following order: fired clay pellets of the diameter size of 5 mm, fired clay pellets of the diameter size of 8 mm, and unfired clay pellets of the diameter size of 15 mm. The selected order of the adsorbents showed a high removal efficiency for zinc (97.8%) and copper (81.5%) ions. These efficiencies were better than those in the case of the already existing mode adsorption. The obtained experimental data present a good basis for the selection of an appropriate column fill, but further testing is necessary in order to obtain more accurate results.

Keywords: clay materials, fix bed adsorption column, metal ions, printing developer

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Authors: Chanchal Biswas, Anrin Bhattacharyya, Gopes Chandra Das, Mahua Ghosh Chaudhuri, Rajib Dey

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Boiler coals with low fixed carbon and higher ash content have always challenged the metallurgists to develop a suitable method for their utilization. In the present study, an attempt is made to establish an energy effective method for the reduction of iron ore fines in the form of nuggets by using ‘Syngas’. By devolatisation (expulsion of volatile matter by applying heat) of boiler coal, gaseous product (enriched with reducing agents like CO, CO2, H2, and CH4 gases) is generated. Iron ore nuggets are reduced by this syngas. For that reason, there is no direct contact between iron ore nuggets and coal ash. It helps to control the minimization of the sulphur intake of the reduced nuggets. A laboratory scale devolatisation furnace designed with reduction facility is evaluated after in-depth studies and exhaustive experimentations including thermo-gravimetric (TG-DTA) analysis to find out the volatile fraction present in boiler grade coal, gas chromatography (GC) to find out syngas composition in different temperature and furnace temperature gradient measurements to minimize the furnace cost by applying one heating coil. The nuggets are reduced in the devolatisation furnace at three different temperatures and three different times. The pre-reduced nuggets are subjected to analytical weight loss calculations to evaluate the extent of reduction. The phase and surface morphology analysis of pre-reduced samples are characterized using X-ray diffractometry (XRD), energy dispersive x-ray spectrometry (EDX), scanning electron microscopy (SEM), carbon sulphur analyzer and chemical analysis method. Degree of metallization of the reduced nuggets is 78.9% by using boiler grade coal. The pre-reduced nuggets with lesser sulphur content could be used in the blast furnace as raw materials or coolant which would reduce the high quality of coke rate of the furnace due to its pre-reduced character. These can be used in Basic Oxygen Furnace (BOF) as coolant also.

Keywords: alternative ironmaking, coal gasification, extent of reduction, nugget making, syngas based DRI, solid state reduction

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Authors: Ebuwa Osagie, Chet Biliyok, Yeung Hoi

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Regeneration energy requirement and ways to reduce it is the main aim of most CO2 capture researches currently being performed and thus, post-combustion carbon capture (PCC) option is identified to be the most suitable for the natural gas-fired power plants. From current research and development (R&D) activities worldwide, two main areas are being examined in order to reduce the regeneration energy requirement of amine-based PCC, namely: (a) development of new solvents with better overall performance than 30wt% monoethanolamine (MEA) aqueous solution, which is considered as the base-line solvent for solvent-based PCC, (b) Integration of the PCC Plant to the power plant. In scaling-up a PCC pilot plant to the size required for a commercial-scale natural gas-fired power plant, process modelling and simulation is very essential. In this work, an integrated process made up of a 482MWe natural gas-fired power plant, an MEA-based PCC plant which is developed and validated has been modelled and simulated. The PCC plant has four absorber columns and a single stripper column, the modelling and simulation was performed with Aspen Plus® V8.4. The gas turbine, the heat recovery steam generator and the steam cycle were modelled based on a 2010 US DOE report, while the MEA-based PCC plant was modelled as a rate-based process. The scaling of the amine plant was performed using a rate based calculation in preference to the equilibrium based approach for 90% CO2 capture. The power plant was integrated to the PCC plant in three ways: (i) flue gas stream from the power plant which is divided equally into four stream and each stream is fed into one of the four absorbers in the PCC plant. (ii) Steam draw-off from the IP/LP cross-over pipe in the steam cycle of the power plant used to regenerate solvent in the reboiler. (iii) Condensate returns from the reboiler to the power plant. The integration of a PCC plant to the NGCC plant resulted in a reduction of the power plant output by 73.56 MWe and the net efficiency of the integrated system is reduced by 7.3 % point efficiency. A secondary aim of this study is the parametric studies which have been performed to assess the impacts of natural gas on the overall performance of the integrated process and this is achieved through investigation of the capture efficiencies.

Keywords: natural gas-fired, power plant, MEA, CO2 capture, modelling, simulation

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Authors: Laurent Debailleux

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Although past research has focused on parameters influencing the vulnerability of brick and its decay, in practice ancient fired clay bricks are usually replaced without any particular assessment of their characteristics. This paper presents results of non-destructive Schmidt hammer tests performed on ancient fired clay bricks sampled from historic masonry. Samples under study were manufactured between the 18th and 20th century and came from facades and interior walls. Tests were performed on three distinct brick surfaces, depending on their position within the masonry unit. Schmidt hammer tests were carried out in order to measure the mean rebound value (Rn), which refers to the resistance of the surface to successive impacts of the hammer plunger tip. Results indicate that rebound values increased with successive impacts at the same point. Therefore, mean Schmidt hammer rebound values (Rn), limited to the first impact on a surface minimises the estimation of compressive strength. In addition, the results illustrate that this technique is sensitive enough to measure weathering differences, even for different surfaces of a particular sample. Finally, the paper also highlights the relevance of considering the position of the brick within the masonry when conducting particular assessments of the material’s strength.

Keywords: brick, non-destructive tests, rebound number, Schmidt hammer, weathering grade

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Authors: A. S. Grewal, Sh. Dharambir, R. S. Sangwan, Vikas Dhanda

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Every Scene of Crime is of different kind in nature. Sometimes we see such type of circumstances that we become confused to judge whether the case is of homicide or suicide. In such circumstances a doyen is asked for the option. On the basis of his esoteric knowledge he finds such clues which force the sleuth to change the under sections of Indian penal Code. Here we have examined a case by visiting Scene of Crime and found that a person was found lying dead in a room. There was only one passage which was found opened, the pistol along with the fired cartridge case, misfired cartridge were lying on the spot. Observation method, mathematical calculations, chemical examination and other aspects were considered.

Keywords: country-made pistol, misfired cartridge, fired cartridge case, blackening, nitrite

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Authors: Yoftahe Nigussie Worku

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This study focused on designing a Fire tube boiler to generate saturated steam with a 2000kg/h capacity at a 12bar design pressure. The primary project goal is to achieve efficient steam production while minimizing costs. This involves selecting suitable materials for component parts, employing cost-effective construction methods, and optimizing various parameters. The analysis phase employs iterative processes and relevant formulas to determine key design parameters. This includes optimizing the diameter of tubes for overall heat transfer coefficient, considering a two-pass configuration due to tube and shell size, and using heavy oil fuel no.6 with specific heating values. The designed boiler consumes 140.37kg/hr of fuel, producing 1610kw of heat at an efficiency of 85.25%. The fluid flow is configured as cross flow, leveraging its inherent advantages. The tube arrangement involves welding the tubes inside the shell, which is connected to the tube sheet using a combination of gaskets and welding. The design of the shell adheres to the European Standard code for pressure vessels, accounting for weight and supplementary accessories and providing detailed drawings for components like lifting lugs, openings, ends, manholes, and supports.

Keywords: efficiency, coefficient, saturated steam, fire tube

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Authors: Yoftahe Nigussie

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This report presents a final year project pertaining to the design of Fire tube boiler for the purpose of producing saturated steam. The objective of the project is to produce saturated steam for different purpose with a capacity of 2000kg/h at 12bar design pressure by performing a design of a higher performance fire tube boiler that considered the requirements of cost minimization and parameters improvement. This is mostly done in selection of appropriate material for component parts, construction materials and production methods in different steps of analysis. In the analysis process, most of the design parameters are obtained by iterating with related formulas like selection of diameter of tubes with overall heat transfer coefficient optimization, and the other selections are also as like considered. The number of passes is two because of the size and area of the tubes and shell. As the analysis express by using heavy oil fuel no6 with a higher heating value of 44000kJ/kg and lower heating value of 41300kJ/kg and the amount of fuel consumed 140.37kg/hr. and produce 1610kw of heat with efficiency of 85.25%. The flow of the fluid is a cross flow because of its own advantage and the arrangement of the tube in-side the shell is welded with the tube sheet, and the tube sheet is attached with the shell and the end by using a gasket and weld. The design of the shell, using European Standard code section, is as like pressure vessel by considering the weight, including content and the supplementary accessories such as lifting lugs, openings, ends, man hole and supports with detail and assembly drawing.

Keywords: steam generation, external treatment, internal treatment, steam velocity

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Authors: Rebecca Hafner, David Elmes, Daniel Read

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The current research applies decision-making theory to the problem of increasing uptake of energy efficient technologies in the market place, where uptake is currently slower than one might predict following rational choice models. We apply the alignable/non-alignable features effect and explore the impact of varying information structure on the consumers’ preference for standard versus energy efficient technologies. In two studies we present participants with a choice between similar (boiler vs. boiler) vs. dissimilar (boiler vs. heat pump) technologies, described by a list of alignable and non-alignable attributes. In study One there is a preference for alignability when options are similar; an effect mediated by an increased tendency to infer missing information is the same. No effects of alignability on preference are found when options differ. One explanation for this split-shift in attentional focus is a change in construal levels potentially induced by the added consideration of environmental concern. Study two was designed to explore the interplay between alignability and construal level in greater detail. We manipulated construal level via a thought prime task prior to taking part in the same heating systems choice task, and find that there is a general preference for non-alignability, regardless of option type. We draw theoretical and applied implications for the type of information structure best suited for the promotion of energy efficient technologies.

Keywords: alignability effects, decision making, energy-efficient technologies, sustainable behaviour change

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Authors: Mouna Ettoumi, Jouini Marouen, Carmen Mihaela Neculita, Salah Bouhlel, Lucie Coudert, Mostafa Benzaazoua, Y. Taha

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In the context of sustainable development and circular economy, waste valorization is considered a promising alternative to overcome issues related to their disposal or elimination. The aim of this study is to evaluate the potential use of phosphate sludges (tailings) from the Kef Shfeir mine site (Gafsa, Tunisia) as an alternative material in the production of fired bricks. To do so, representative samples of raw phosphate treatment sludges were collected and characterized for their physical, chemical, mineralogical and environmental characteristics. Then, the raw materials were baked at different temperatures (900°C, 1000°C, and 1100°C) for bricks making. Afterward, fired bricks were characterized for their physical (particle size distribution, density, and plasticity), chemical (XRF and digestion), mineralogical (XRD) and mechanical (flexural strength) properties as well as for their environmental behavior (TCLP, SPLP, and CTEU-9) to ensure whether they meet the required construction standards. Results showed that the raw materials had low density (2.47g/cm 3), were non-plastic and were mainly composed of fluoroapatite (15.6%), calcite (23.1%) and clays (22.2% - mainly as heulandite, vermiculite and palygorskite). With respect to the environmental behavior, all metals (e.g., Pb, Zn, As, Cr, Ba, Cd) complied with the requirements set by the USEPA. In addition, fired bricks had varying porosity (9-13%), firing shrinking (5.2-7.5%), water absorption (12.5-17.2%) and flexural strength (3.86-13.4 MPa). Noteworthy, an improvement in the properties (porosity, firing shrinking, water absorption, and flexural strength) of manufactured fired bricks was observed with the increase of firing temperature from 900 to 1100°C. All the measured properties complied with the construction norms and requirements. Moreover, regardless of the firing temperature, the environmental behavior of metals obeyed the requirements of the USEPA standards. Finally, fired bricks could be produced at high temperatures (1000°C) based on 100% of phosphate sludge without any substitution or addition of either chemical agents or binders. This sustainable brick-making process could be a promising approach for the Phosphate Company to partially manage these wastes, which are considered “non-profitable” for the moment and preserve soils that are exploited presently.

Keywords: phosphate treatment sludge, mine waste, backed bricks, waste valorization

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Authors: Muhammad Ghaffar Doggar, Farah

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The primary objective of this feasibility study is to conduct a techno-financial assessment for installation of biomass based power plant in Faisalabad division. The study involves identification of best site for power plant followed by an assessment of biomass resource potential in the area and propose power plant of suitable size. The study also entailed comprehensive supply chain analysis to determine biomass fuel pricing, transportation and storage. Further technical and financial analyses have been done for selection of appropriate technology for the power plant and its financial viability, respectively. The assessment of biomass resources and the subsequent technical analysis revealed that 20 MW biomass power plant could be implemented at one of the locations near Faisalabad city i.e. AARI Site, Near Chak Jhumra district Faisalabad, Punjab province. Three options for steam pressure; namely, 70 bar, 90 bar and 100 bar boilers have been considered. Using international experience and prices on power plant technology and local prices on locally available equipment, the study concludes biomass fuel price of around 50 US dollars (USD) per ton when delivered to power plant site. The electricity prices used for feasibility calculations were 0.13 USD per KWh for electricity from a locally financed project and 0.11 USD per KWh for internationally financed power plant. For local financing the most viable choice is the 70 bar solution and with international financing, the most feasible solution is using a 90 bar boiler. Between the two options, the internationally financed 90 bar boiler setup gives better financial results than the locally financed 70 bar boiler project. It has been concluded that 20 MW with 90 bar power plant and internationally financed would have an equity IRR of 23% and a payback period of 7 years. This will be a cheap option for installation of power plants.

Keywords: AARI, Ayub agriculture research institute, biomass - crops residue, KWh - electricity Units, MG - Muhammad Ghaffar

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Authors: Ambreen Aslam, Tahira Aziz Mughal, Skye R. Thomas-Hall, Peer M. Schenk

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Biodiesel is an alternative to petroleum-derived fuel mainly composed of fatty acid from oleaginous microalgae feedstock. Microalgae produced fatty acid methyl esters (FAMEs) as they can store high levels of lipids without competing for food productivity. After lipid extraction and esterification, fatty acid profile from algae feedstock possessed the abundance of fatty acids with carbon chain length specifically C16 and C18. The qualitative analysis of FAME was done by cultivating mix microalgae consortia under three different CO₂ concentrations (1%, 3%, and 5.5%) from a coal fired flue gas. FAME content (280.3 µg/mL) and productivity (18.69 µg/mL/D) was higher under 1% CO₂ (flue gas) as compare to other treatments. Whereas, Mixed C. (F) supplemented with 5.5% CO₂ (50% flue gas) had higher SFA (36.28%) and UFA (63.72%) which improve the oxidative stability of biodiesel. Subsequently, low Iodine value (136.3 gI₂/100g) and higher Cetane number (52) of Mixed C.+P (F) were found to be in accordance with European (EN 14214) standard under 5.5% CO₂ along with 50mM phosphate buffer. Experimental results revealed that sufficient phosphate reduced FAME productivity but significantly enhance biodiesel quality. This research aimed to develop an integrated approach of utilizing flue gas (as CO₂ source) for significant improvement in biodiesel quality under surplus phosphorus. CO₂ sequestration from industrial flue gas not only reduce greenhouse gases (GHG) emissions but also ensure sustainability and eco-friendliness of the biodiesel production process through microalgae.

Keywords: biodiesel analysis, carbon dioxide, coal fired flue gas, FAME productivity, fatty acid profile, fuel properties, lipid content, mixed culture microalgae

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Authors: Cigdem Safak Saglam

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Most thermal power plants use steam as working fluid in their power cycle. Therefore, in addition to fuel, water is the other main input for thermal plants. Water and steam must be highly pure in order to protect the systems from corrosion, scaling and biofouling. Pure process water is produced in water treatment plants having many several treatment methods. Treatment plant design is selected depending on raw water source and required water quality. Although working principle of fossil-fuel fired thermal power plants are same, there is no standard design and equipment arrangement valid for all thermal power plant utility systems. Besides that, there are many other technology evaluation and selection criteria for designing the most optimal water systems meeting the requirements such as local conditions, environmental restrictions, electricity and other consumables availability and transport, process water sources and scarcity, land use constraints etc. Aim of this study is explaining the adopted methodology for technology selection for process water preparation and industrial waste water treatment plant in a thermal power plant project located in Tufanbeyli, Adana Province in Turkey. Thermal power plant is fired with indigenous lignite coal extracted from adjacent lignite reserves. This paper addresses all above-mentioned factors affecting the thermal power plant water treatment facilities (demineralization + waste water treatment) design and describes the ultimate design of Tufanbeyli Thermal Power Plant Water Treatment Plant.

Keywords: thermal power plant, lignite coal, pretreatment, demineralization, electrodialysis, recycling, ash dampening

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Authors: Andi Fallahi, Bona Ryan Situmeang

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The Construction Industry is notoriously risky. Much of the preparatory paperwork that precedes construction project can be viewed as the formulation of risk allocation between the owner and the Contractor. The Owner is taking the risk that his project will not get built on the schedule that it will not get built for what he has budgeted and that it will not be of the quality he expected. The Contractor Face a multitude of risk. One of them is an unforeseen condition at the construction site. The Owner usually has the upper hand here if the unforeseen condition occurred. Site data contained in Ground Investigation report is often of significant contractual importance in disputes related to the unforeseen ground condition. A ground investigation can never fully disclose all the details of the underground condition (Risk of an unknown ground condition can never be 100% eliminated). Adipala Coal Fired Steam Power Plant (CSFPP) 1 x 660 project is one of the large CSFPP project in Indonesia based on Engineering, Procurement, and Construction (EPC) Contract. Unforeseen Ground Condition it’s responsible by the Contractor has stipulated in the clausal of Contract. In the implementation, there’s indicated unforeseen ground condition at Circulating Water Pump House (CWPH) area which caused the Contractor should be changed the Method of Work that give big impact against Time of Completion and Cost Project. This paper tries to analyze the best way for allocating the risk between The Owner and The Contractor. All parties that allocating of sharing risk fairly can ultimately save time and money for all parties, and get the job done on schedule for the least overall cost.

Keywords: unforeseen ground condition, coal fired steam power plant, circulating water pump house, Indonesia

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Authors: Ravi Inder Singh

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Due to high heat transfer rate, high carbon utilizing efficiency, fuel flexibilities and other advantages numerous circulating fluidized bed boilers have grown up in India in last decade. Many companies like BHEL, ISGEC, Thermax, Cethar Limited, Enmas GB Power Systems Projects Limited are making CFBC and installing the units throughout the India. Due to complexity many problems exists in CFBC units and only few have been reported. Agglomeration i.e clinker formation in riser, loop seal leg and stripper ash coolers is one of problem industry is facing. Proper documentation is rarely found in the literature. Circulating fluidized bed (CFB) boiler bottom ash contains large amounts of physical heat. While the boiler combusts the low-calorie fuel, the ash content is normally more than 40% and the physical heat loss is approximately 3% if the bottom ash is discharged without cooling. In addition, the red-hot bottom ash is bad for mechanized handling and transportation, as the upper limit temperature of the ash handling machinery is 200 °C. Therefore, a bottom ash cooler (BAC) is often used to treat the high temperature bottom ash to reclaim heat, and to have the ash easily handled and transported. As a key auxiliary device of CFB boilers, the BAC has a direct influence on the secure and economic operation of the boiler. There are many kinds of BACs equipped for large-scale CFB boilers with the continuous development and improvement of the CFB boiler. These ash coolers are water cooled ash cooling screw, rolling-cylinder ash cooler (RAC), fluidized bed ash cooler (FBAC).In this study prototype of a novel stripper ash cooler is studied. The Circulating Fluidized bed Ash Coolers (CFBAC) combined the major technical features of spouted bed and bubbling bed, and could achieve the selective discharge on the bottom ash. The novel stripper ash cooler is bubbling bed and it is visible cold test rig. The reason for choosing cold test is that high temperature is difficult to maintain and create in laboratory level. The aim of study to know the flow pattern inside the stripper ash cooler. The cold rig prototype is similar to stripper ash cooler used industry and it was made after scaling down to some parameter. The performance of a fluidized bed ash cooler is studied using a cold experiment bench. The air flow rate, particle size of the solids and air distributor type are considered to be the key parameters of the operation of a fluidized bed ash cooler (FBAC) are studied in this.

Keywords: CFD, Eulerian-Eulerian, Eulerian-Lagraingian model, parallel simulations

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Authors: Mir Shahnawaz Jagirani, Aziza Aftab, Noorullah Soomro, Syed Farman Ali Shah, Kambiz Vafai

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Utilization of indigenous adsorbent bed of power plant waste ash briquettes, a porous medium was used first time in Pakistan for low cost treatment facility for the toxic effluent of a dyes manufacturing plant effectively and economically. This could replace costly treatment facilities, such as reverse osmosis (RO) and the beds, containing imported and commercial grade expensive Granulated Activated Carbon (GAC).This bed was coupled with coagulants (Ferrous Sulphate and Lime) and found more effective. The coal fired ash (CFA) was collected from coal fired boilers of Lakhra Power Generation Company, Jamshoro, Pakistan. The use of this bed resolved the disposal and environmental issues and treated waste water of chemicals, dyes and pigment manufacturing plant. The bed reduced COD, color, turbidity and TSS remarkably. An adsorptive capacity and chemical behavior of fly ash bed was also studied. In coagulation treatment alone, elimination of COD by 32%, color by 48%, and turbidity by 50% and TSS by 51% respectively. When the bed was coupled with coagulants, it resulted an excessive removal of Color 88%, TSS 92%, COD 67% and Turbidity 89%. Its regeneration was also inexpensive and simple.

Keywords: coal fly ash, spheres, dyes, wastewater

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Authors: Alexsandro Bayestorff da Cunha, Dpebora Caline de Mello, Camila Alves Corrêa

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In the production of fiberboards, an adhesive based on urea-formaldehyde resin is used, which has the advantages of low cost, homogeneity of distribution, solubility in water, high reactivity in an acid medium, and high adhesion to wood. On the other hand, as a disadvantage, there is low resistance to humidity and the release of formaldehyde. The objective of the study was to determine the viability of adding industrial boiler ash to the urea formaldehyde-based adhesive for the production of medium-density fiberboard. The raw material used was composed of Pinus spp fibers, urea-formaldehyde resin, paraffin emulsion, ammonium sulfate, and boiler ash. The experimental plan, consisting of 8 treatments, was completely randomized with a factorial arrangement, with 0%, 1%, 3%, and 5% ash added to the adhesive, with and without the application of a catalyst. In each treatment, 4 panels were produced with density of 750 kg.m⁻³, dimensions of 40 x 40 x 1,5 cm, 12% urea formaldehyde resin, 1% paraffin emulsion and hot pressing at a temperature of 180ºC, the pressure of 40 kgf/cm⁻² for a time of 10 minutes. The different compositions of the adhesive were characterized in terms of viscosity, pH, gel time and solids, and the panels by physical and mechanical properties, in addition to evaluation using the IMAL DPX300 X-ray densitometer and formaldehyde emission by the perforator method. The results showed a significant reduction of all adhesive properties with the use of the catalyst, regardless of the treatment; while the percentage increase of ashes provided an increase in the average values of viscosity, gel time, and solids and a reduction in pH for the panels with a catalyst; for panels without catalyst, the behavior was the opposite, with the exception of solids. For the physical properties, the results of the variables of density, compaction ratio, and thickness were equivalent and in accordance with the standard, while the moisture content was significantly reduced with the use of the catalyst but without the influence of the percentage of ash. The density profile for all treatments was characteristic of medium-density fiberboard, with more compacted and dense surfaces when compared to the central layer. For thickness, the swelling was not influenced by the catalyst and the use of ash, presenting average values within the normalized parameters. For mechanical properties, the influence of ashes on the adhesive was negatively observed in the modulus of rupture from 1% and in the traction test from 3%; however, only this last property, in the percentages of 3% and 5%, were below the minimum limit of the norm. The use of catalyst and ashes with percentages of 3% and 5% reduced the formaldehyde emission of the panels; however, only the panels that used adhesive with catalyst presented emissions below 8mg of formaldehyde / 100g of the panel. In this way, it can be said that boiler ash can be added to the adhesive with a catalyst without impairing the technological properties by up to 1%.

Keywords: reconstituted wood panels, formaldehyde emission, technological properties of panels, perforator

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Authors: Alexander Hedlund, Anna-Karin Stengard, Olof Björkqvist

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A step towards reducing greenhouse gases and energy consumption is to collaborate with the energy system between several industries. This work is based on a case study on integration of pulp and paper mills with a district heating system in Sundsvall, Sweden. Present research shows that it is possible to make a significant reduction in the electricity demand in the mechanical pulping process. However, the profitability of the efficiency measures could be an issue, as the excess steam recovered from the refiners decreases with the electricity consumption. A consequence will be that the fuel demand for steam production will increase. If the fuel price is similar to the electricity price it would reduce the profit of such a project. If the paper mill can be integrated with a district heating system, it is possible to upgrade excess heat from a nearby kraft pulp mill to process steam via the district heating system in order to avoid the additional fuel need. The concept is investigated by using a simulation model describing both the mass and energy balance as well as the operating margin. Three scenarios were analyzed: reference, electricity reduction and energy substitution. The simulation show that the total input to the system is lowest in the Energy substitution scenario. Additionally, in the Energy substitution scenario the steam from the incineration boiler covers not only the steam shortage but also a part of the steam produced using the biofuel boiler, the cooling tower connected to the incineration boiler is no longer needed and the excess heat can cover the whole district heating load during the whole year. The study shows a substantial economic advantage if all stakeholders act together as one system. However, costs and benefits are unequally shared between the actors. This means that there is a need for new business models in order to share the system costs and benefits.

Keywords: energy system, cooperation, simulation method, excess heat, district heating

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Authors: Fabienne Baraud, Lydia Leleyter, Sandra Poree, Melanie Lemoine, Fatiha Oudghiri

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Alternative solutions to immersion at sea are searched for the huge amounts of dredged sediments around the world that might contain various types of contaminants. Possible re-uses of such materials in civil engineering appear as sustainable solutions. The French SEDIBRIC project (valorisation de SEDIments en BRIQues et tuiles) aims to replace a part of natural clays with dredged sediments in the preparation of fired bricks. The potential environmental impact of this re-use is explored to complete the technical and economic feasibility of the study. As part of the project, we investigate the environmental availability of metallic elements (Al, Ca, Cd, Co, Cr, Cu, Fe, Ni, Mg, Mn, Pb, Ti, and Zn) initially present in the dredged sediments selected for the project. Leaching tests (with H₂O, HCl, or EDTA) are conducted in the sediments than in the final bricks in order to evaluate the possible influence of some steps of the bricks manufacturing (desalination pre-treatment, firing, etc.). The desalination pre-treatment using tap water has no or few impacts on the environmental availability of the studied elements. On the opposite, the firing process (900°C) affects the value of the total content of elements detected in the bricks but also the environmental availability for various elements. For instance, Cd, Cu, Pb, and Zn are stabilized in the bricks, whereas the availability of some other elements (i.e., Cr, Ni) increases, depending on the nature of the extracting solution.

Keywords: availability, bricks, dredged sediments, metals

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Authors: Subodh N. Patel, Abhijit Pusty, Manashi Adhikary, Sandip Bhattacharyya

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The steam superheater (SH) is a coil type heat exchanger which is used to produce superheated steam or to convert the wet steam to dry steam (69.6 kg/cm² and 495°C), generated by a boiler. There were two superheaters in the system, SH I and SH II. SH II is a set of tubes that faces the initial interaction with flue gas at high temperature followed by SH I tubes. After a service life of 2100 hours, a tube in the SH II found to be punctured. Dye penetrant test revealed that out of 50 such tubes, 14 more tubes had severe cracks at a similar location. The failure was investigated in detail. The materials and scale were characterized by optical microscope and advance characterization technique. Scale, observed on fracture surface, was characterized under scanning electron microscope and Raman spectroscopy. Stresses acting on the tubes in working condition were analyzed by finite element method software, ANSYS. Cyclic stresses were observed in the simulation at the same prone location due to restriction in expansion of tubes. Based on scale characterization and stress analysis, it was concluded that the tube failed in thermo-mechanical fatigue. Finally, prevention and control measures were taken to avoid such failure in the future.

Keywords: finite element analysis, oxide scale, superheater tube, thermomechanical fatigue

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Authors: Vikas Chawla, Buta Singh Sidhu, Amita Rani, Amit Handa

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The main objective of the present work is microstructural and mechanical characterization of the conventional and nanostructured TiAlN and AlCrN coatings deposited on T-11 boiler steel. In case of conventional coatings, Al-Cr and Ti-Al metallic powders were deposited using plasma spray process followed by gas nitriding of the surface which was done in the lab with optimized parameters after conducting several trials on plasma-sprayed coated specimens. The physical vapor deposition process (PAPVD) was employed for depositing nanostructured TiAlN and AlCrN coatings. The field emission scanning electron microscopy (FE-SEM) with energy dispersive X-ray analysis (EDAX) attachment, X-ray diffraction (XRD) analysis, atomic force microscopy (AFM) analysis and the X-Ray mapping analysis techniques have been used to study surface and cross-sectional morphology of the coatings. The surface roughness and micro-hardness were also measured. A good adhesion of the conventional thick TiAlN and AlCrN coatings was found. The coatings under study are recommended for the applications to super-heater and re-heater tubes of the boilers based upon the outcomes of the research work.

Keywords: nanostructure, physical vapour deposition, oxides, thin films, electron microscopy

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Authors: Narges Razmjoo, Hamid Sefidari, Michael Strand

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Biomass combustion is a growing technique for heat and power production due to the increasing stringent regulations with CO2 emissions. Grate-fired systems have been regarded as a common and popular combustion technology for burning woody biomass. However, some grate furnaces are not well optimized and may emit significant amount of unwanted compounds such as dust, NOx, CO, and unburned gaseous components. The combustion characteristics inside the fuel bed are of practical interest, as they are directly related to the release of volatiles and affect the stability and the efficiency of the fuel bed combustion. Although numerous studies have been presented on the grate firing of biomass, to the author’s knowledge, none of them have conducted a detailed experimental study within the fuel bed. It is difficult to conduct measurements of temperature and gas species inside the burning bed of the fuel in full-scale boilers. Results from such inside bed measurements can also be applied by the numerical experts for modeling the fuel bed combustion. The current work presents an experimental investigation into the combustion behavior of wet woody biomass (53 %) in a 4 MW reciprocating grate boiler, by focusing on the gas species distribution along the height of the fuel bed. The local concentrations of gases (CO, CO2, CH4, NO, and O2) inside the fuel bed were measured through a glass port situated on the side wall of the furnace. The measurements were carried out at five different heights of the fuel bed, by means of a bent stainless steel probe containing a type-k thermocouple. The sample gas extracted from the fuel bed, through the probe, was filtered and dried and then was analyzed using two infrared spectrometers. Temperatures of about 200-1100 °C were measured close to the grate, indicating that char combustion is occurring at the bottom of the fuel bed and propagates upward. The CO and CO2 concentration varied in the range of 15-35 vol % and 3-16 vol %, respectively, and NO concentration varied between 10-140 ppm. The profile of the gas concentrations distribution along the bed height provided a good overview of the combustion sub-processes in the fuel bed.

Keywords: experimental, fuel bed, grate firing, wood combustion

Procedia PDF Downloads 313

Authors: Fabienne Baraud, Lydia Leleyter, Sandra Poree, Melanie Lemoine

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SEDIBRIC (valorization de SEDIments en BRIQues et tuiles) is a French project that aims to replace a part of natural clays with dredged sediments in the preparation of fired bricks in order to propose an alternative solution for the management of harbor dredged sediments. The feasibility of such re-use is explored from a technical, economic, and environmental point of view. The present study focuses on the potential environmental impact of various chemical elements (Al, Ca, Cd, Co, Cr, Cu, Fe, Ni, Mg, Mn, Pb, Ti, and Zn) that are initially present in the dredged sediments. The total content (after acid digestion) and the environmental availability (estimated by single extractions with various extractants) of these elements are determined in the raw sediments and in the obtained fired bricks. The possible influence of some steps of the manufacturing process (sediment pre-treatment, firing) is also explored. The first results show that the pre-treatment step, which uses tap water to desalinate the raw sediment, does not influence the environmental availability of the studied elements. However, the firing process, performed at 900°C, can affect the amount of some elements detected in the bricks, as well as their environmental availability. We note that for Cr, or Ni, the HCl or EDTA availability was increased in the brick (compared to the availability in the raw sediment). For Cd, Cu, Pb, and Zn, the HCl and EDTA availability was reduced in the bricks, meaning that these elements were stabilized within the bricks.

Keywords: bricks, chemical extraction, metals, sediment

Procedia PDF Downloads 132

Authors: Mathias B. Michael, Esther T. Akinlabi, Tien-Chien Jen

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Thermal energy consumption in palm oil production plant comprises mainly of steam, hot water and hot air. In most efficient plants, hot water and air are generated from the steam supply system. Research has shown that thermal energy utilize in palm oil production plants is about 70 percent of the total energy consumption of the plant. In order to manage the plants’ energy efficiently, the energy systems are modelled and optimized. This paper aimed to present the model of steam supply systems of a typical palm oil production plant in Ghana. The models include exergy and energy models of steam boiler, steam turbine and the palm oil mill. The paper further simulates the virtual plant model to obtain the thermal energy performance of the plant under study. The simulation results show that, under normal operating condition, the boiler energy performance is considerably below the expected level as a result of several factors including intermittent biomass fuel supply, significant moisture content of the biomass fuel and significant heat losses. The total thermal energy performance of the virtual plant is set as a baseline. The study finally recommends number of energy efficiency measures to improve the plant’s energy performance.

Keywords: palm biomass, steam supply, exergy and energy models, energy performance benchmark

Procedia PDF Downloads 334

Authors: M. Ali Mandegari, S. Farzad, , J. F. Görgens

Abstract:

Sugar is one of the main agricultural industries in South Africa and approximately livelihoods of one million South Africans are indirectly dependent on sugar industry which is economically struggling with some problems and should re-invent in order to ensure a long-term sustainability. Second generation biorefinery is defined as a process to use waste fibrous for the production of biofuel, chemicals animal food, and electricity. Bioethanol is by far the most widely used biofuel for transportation worldwide and many challenges in front of bioethanol production were solved. Biorefinery annexed to the existing sugar mill for production of bioethanol and electricity is proposed to sugar industry and is addressed in this study. Since flowsheet development is the key element of the bioethanol process, in this work, a biorefinery (bioethanol and electricity production) annexed to a typical South African sugar mill considering 65ton/h dry sugarcane bagasse and tops/trash as feedstock was simulated. Aspen PlusTM V8.6 was applied as simulator and realistic simulation development approach was followed to reflect the practical behaviour of the plant. Latest results of other researches considering pretreatment, hydrolysis, fermentation, enzyme production, bioethanol production and other supplementary units such as evaporation, water treatment, boiler, and steam/electricity generation units were adopted to establish a comprehensive biorefinery simulation. Steam explosion with SO2 was selected for pretreatment due to minimum inhibitor production and simultaneous saccharification and fermentation (SSF) configuration was adopted for enzymatic hydrolysis and fermentation of cellulose and hydrolyze. Bioethanol purification was simulated by two distillation columns with side stream and fuel grade bioethanol (99.5%) was achieved using molecular sieve in order to minimize the capital and operating costs. Also boiler and steam/power generation were completed using industrial design data. Results indicates that the annexed biorefinery can be self-energy sufficient when 35% of feedstock (tops/trash) bypass the biorefinery process and directly be loaded to the boiler to produce sufficient steam and power for sugar mill and biorefinery plant.

Keywords: biorefinery, self-energy sufficiency, tops/trash, bioethanol, electricity

Procedia PDF Downloads 523

Authors: Md. R. Shattique, Md. T. Zaki, Md. G. Kibria

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Fly-ash bricks give a comprehensive solution towards recycling of fly-ash and since there is no requirement of firing to produce them, they are also eco-friendly bricks; little or no carbon-dioxide is emitted during their entire production cycle. As bricks are the most essential and widely utilized building materials in the construction industry, the significance of developing an alternate eco-friendly brick is substantial in modern times. In this paper, manufacturing and potential utilization of Fly-ash made building bricks have been studied and was found to be a prospective substitute for fired clay bricks that contribute greatly to polluting the environment. Also, a comparison between sand made and ceramic dust made Fly-ash bricks have been carried out experimentally. The ceramic dust made bricks seem to show higher compressive strength at lower unit volume weight compared to sand made Fly-ash bricks. Moreover, the water absorption capacity of ceramic dust Fly-ash bricks was lower than sand made bricks. Then finally a statistical comparison between fired clay bricks and fly-ash bricks were carried out. All the requirements for good quality building bricks are matched by the fly-ash bricks. All the facts from this study pointed out that these bricks give a new opportunity for being an alternate building material.

Keywords: coal fly-ash, ceramic dust, burnt clay bricks, sand, gypsum, absorption capacity, unit volume weight, compressive strength

Procedia PDF Downloads 401

Authors: Michal Urzynicok, Krzysztof Kwiecinski

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The development of materials used in the power generation industry for the production of boilers and their parts is characterized by high steam parameters, which present new challenges. Implementation of new combinations of alloying elements that lead to the best possible mechanical properties, including creep resistance, greatly affects new steels' weldability. All new grades have to undergo many different examinations, in regards to bending and welding, in order to enable the development of fabrication technologies, ensuring failure-free production and assembly of boiler components. 12% Cr martensitic steels like THOR™ 115 or VM-12 SHC are characterized by high oxidation resistance in high-temperature environments. At the moment, VM-12 SHC can be found in many boilers where both headers and superheater coils were produced. As this material is very difficult to obtain, a search for a proper replacement has begun. A new creep strength-enhanced ferritic steel for service in supercritical and ultra-supercritical boiler applications was developed by Tenaris in Italy and it is designated as Thor™115 (Tenaris High Oxidation Resistance). As high demand in power plants occurred to replace some parts of existing installations fabricated from VM12-SHC with other alternatives, a new development of welding procedures has begun to prepare fabricators for the challenges of joining old components with new THOR™ 115 material. This paper covers the first research of welding of dissimilar joints made out of VM12-SHC and THOR™ 115.

Keywords: thor, vm12, dissimilar welding, weldability

Procedia PDF Downloads 137

Authors: Ichrak Hamrouni, Tariq Ouahbi, Natalija Lhuissier, Saïd Taibi, Mehrez Jemai, Olivier Crumeyrolle, Hatem Zenzri

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Raw earth is the oldest building technique used for over 11 centuries, thanks to its various benefits. The most known raw earth construction technics are compressed earth blocks, rammed earth, raw earth concrete, and daub. The raw earth can be stabilized with hydraulic binders, mixed by fibers, or hyper-compacted in order to improve its mechanical behaviour. Moreover, raw earth is characterized by a low thermal conductivity what make it a good thermal insulator, and it has a very important capacity to condense and evaporate relative humidity. In this context, many researches have been developed. They have shown that the mechanical characteristics of earth materials increase with the hyper-compaction and adding fibers or hydraulic binders. Besides, other researches have been determined the thermal and hygroscopic properties of raw earth. They have shown that this material able to contribute to moisture and heat control in constructions. Its hygrothermal properties are better than fired earth bricks and concrete. The aim of this study is to evaluate the thermal and hygrometric behavior of raw earth material using experimental tests allows to determine the main Hygrothermal properties such as the water Vapour permeability and thermal conductivity and compare the results with those of other building materials such as fired clay bricks and cement concrete is presented.

Keywords: raw earth material, hygro-thermal, thermal conductivity, water vapour permeability, building materials, building materials

Procedia PDF Downloads 156

Authors: Heba Al-Kelesh

Abstract:

Day after day, high-grade iron ores are consumed. Because of the strong global demand for iron and steel, it has necessitated the utilization of various low-grade iron ores, which are not suitable for direct exploitation in the iron industry. The low-grade ores cannot be dressed using traditional mineral processing methods because of complicated mineral compositions. The present work is aimed to investigate the reducibility of some Egyptian iron ores and concentrates by conditions emulate different blast furnace areas. Representative specimens are collected from El-Gedida–Baharia oasis, Eastern South Aswan, and Eastern desert-wadi Kareem (EDC). Some mineralogical and morphological characterizations are executed. The reactivity arrangement of green samples is Baharia>Aswan>EDC. The presence of magnetite decreased reactivity of EDC. The reducibility of the Aswan sample is lower than Baharia due to the presence of agglomerated metallic grain surrounded by semi-melted phases. Specimens are annealed at 1000ᵒC for 3 hours. After firing, the reducibility of Aswan becomes the lowest due to the formation of fayalite and calcium phosphate phases. The relative attitude for green and fired samples reduced at different conditions are studied. For thermal and top areas, the reactivity of fired samples is greater than green ones, which were confirmed by morphological examinations.

Keywords: reducibility, low grade, iron industry, blast furnace

Procedia PDF Downloads 108

Authors: Kun-Ping Cheng, Dong-Shang Chang, Rou-Wen Wang

Abstract:

Pre-treatment of automobile paint-shop procedures are the preparation of warm water rinsing tank, hot water rinsing tank, degreasing tank, phosphate tank. The conventional boiler steam fuel is natural gas, producing steam to supply the heat exchange of each tank sink. In this study, the high-frequency soldering economizer is developed for recovering waste heat in the automotive paint-shop (RTO, Regenerative Thermal Oxidation). The heat recovery rate of the new economizer is 20% to 30% higher than the conventional embedded heat pipe. The adaptive control system responded to both RTO furnace exhaust gas and heat demands. In order to maintain the temperature range of the tanks, pre-treatment tanks are directly heated by waste heat recovery device (gas-to-water heat exchanger) through the hot water cycle of heat transfer. The performance of developed waste heat recovery system shows the annual recovery achieved to 1,226,411,483 Kcal of heat (137.8 thousand cubic meters of natural gas). Boiler can reduce fuel consumption by 20 to 30 percent compared to without waste heat recovery. In order to alleviate environmental impacts, the temperature at the end of the flue is further reduced from 160 to 110°C. The innovative waste heat recovery is helpful to energy savings and sustainable environment.

Keywords: waste heat recovery system, sustainability, RTO (Regenerative Thermal Oxidation), economizer, automotive industry

Procedia PDF Downloads 243

Authors: Saeed Karimi, Ali Behbahaninia

Abstract:

In this study, the design and optimization of combined cooling, heating, and power system (CCHP) for a sustainable building are dealt with. Sustainable buildings are environmentally responsible and help us to save energy also reducing waste, pollution and environmental degradation. CCHP systems are widely used to save energy sources. In these systems, electricity, cooling, and heating are generating using just one primary energy source. The selection of the size of components based on the maximum demand of users will lead to an increase in the total cost of energy and equipment for the building complex. For this purpose, a system was designed in which the prime mover (gas turbine), heat recovery boiler, and absorption chiller are lower than the needed maximum. The difference in months with peak consumption is supplied with the help of electrical absorption chiller and auxiliary boiler (and the national electricity network). In this study, the optimum capacities of each of the equipment are determined based on Thermo economic method, in a way that the annual capital cost and energy consumption will be the lowest. The design was done for a gas turbine prime mover, and finally, the optimum designs were investigated using exergy analysis and were compared with a traditional energy supply system.

Keywords: sustainable building, CCHP, energy optimization, gas turbine, exergy, thermo-economic

Procedia PDF Downloads 74