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The Swedish industry uses large volumes of compressed air. The compressed air process isenergy intensive and creates large amounts of excess heat. It is therefore important to utilizethe excess heat, optimize the operation of the compressors and to have a regular maintenanceon the system. This thesis is a pre-study to make a compressed air system energy efficient andis done in collaboration with Ljunghäll AB. Ljunghäll AB is one of Northern Europe's leadingdie casting companies and are located in Södra Vi, Sweden. The purpose is to describe andmap the compressed air system in the old part of the facility in Södra Vi. The thesis will alsogive an explanation of how Ljunghäll AB can improve the compressed air system. Providethem suggestions for energy savings and lower the environmental impact of production. Theobjective of the thesis is to create an understanding of how improvements in the compressedair system can be done by studying the operation, compressor, pipe system and leak detecting.The economic aspects of the solutions together with the effect of noise and engine operationof the compressors have not been taken into consideration. To reach improvement measures avisit to the facility in Södra Vi was made, where measuring and mapping was executed andthen compared with earlier studies and literature. The conclusions of the thesis show thatLjunghäll AB has a good operation and control of the compressors, through the variable speeddrive and steering system. It also showed that the choice of the existing compressors are goodfor their compressed air usage. The study also resulted in the following suggestions for theenergy efficiency and lowering of the environmental impact of production at Ljunghäll AB’scompressed air system: Water heat recovery, replacement of old pipes, cover the leakage,regular maintenance of compressors and fittings, training in compressed air for workers,centralized compressor central and sectioning of the pipe system.

There is a constant struggle to increase the efficiency in gas turbines, where one method is to have a higher inlet temperature to the turbine. Often, this results in temperatures higher than the critical temperature of the materials, which makes cooling of the components an important part of the turbine. The cooling air is tapped from the compressor, and has hence required work while being compressed, but since it is removed from the thermodynamic cycle it will not provide any work in the turbine stages. Therefore, it is important to understand the losses in the cooling system to be able to use the smallest amount of cooling air possible, while still cool sufficiently to not decrease the turbine’s lifetime. The pressure losses in the cooling and secondary air systems are due to either friction or minor losses; contractions, expansions and bends. The losses can be described by a discharge coefficient, ; a rate of how close the actual mass flow is to the ideal mass flow, or a pressure loss coefficient, ; a rate of the pressure drop. In the cooling and secondary air systems there are orifices and cooling geometries. These can have different geometrical properties depending on application, and thereby have different heat transfer performances and causing a higher or lower pressure drop. At Siemens Industrial Turbomachinery AB, SIT AB, a one-dimensional in-house program named C3D is used for thermal calculations and calculations of flow properties of internal cooling flow networks. The program uses hydraulic networks consisting of nodes and branches to simulate the flow inside the components. Correlations used for describing pressure losses have been collected and divided depending on their valid ranges, with the aim to make pressure loss calculations easier. A MATLAB code have been developed, which, depending on input parameters, separates the correlations and returns a plot with the correlations that can be used. In order to make the code as useful as possible, a few assumptions were made; curve fitting of correlations which were only available as plots and interpolation to get larger valid ranges for some cases. These assumptions will influence the results, but the code will still be able to give an indication of which correlation to use, and hence, the objective is fulfilled. Simulations in one dimension are commonly used, since it is less time consuming than three-dimensional modelling. Therefore, with focus on the pressure losses, a one-dimensional model of a blade in the in-house program C3D has been evaluated using a three-dimensional model in the CFD program Ansys CFX. Also, two new models were created in C3D; both with geometrical properties and pressure loss coefficients adjusted to the CFX model, but the first model is using the same hydraulic network as in the evaluated, reference, model while the second is using a new network, built according to the streamlines in CFX. The resulting mass flows in the C3D models were compared to the mass flows in the CFX model, which ended in the conclusion that it is hard for the one-dimensional models to understand the complex, three-dimensional flow situations, even when adjusting them to the CFX model. Anyhow, the adjustments made the model somewhat closer to the three-dimensional case, and hence CFX should be used in an earlier stage when developing C3D models.

Indiana University-Purdue University Indianapolis (IUPUI) / Compressed air is a powerful source of stored energy and is used in a variety of applications varying from painting to pressing, making it a versatile tool for manufacturers. Due to the high cost and energy consumption associated with producing compressed air and it’s use within industrial manufacturing, it is often referred to as a fourth utility behind electricity, natural gas, and water. This is the reason why air compressors and associated equipment are often the focus for improvements in the eyes of manufacturing plant managers. As compressed air can be used in multiple ways, the methods used to extract and transfer the energy from this source vary as well. Compressed air can flow through different types of piping, such as aluminum, Polyvinyl Chloride (PVC), rubber, etc. with varying hydraulic diameters, and through different fittings such as 90-degree elbows, T-junctions, valves, etc. which can cause one of the major concerns related to managing the energy consumption of an air compressor, and that is the waste of air through leaks. Air leaks make up a considerable portion of the energy that is wasted in a compressed air system, as they cause a multitude of problems that the compressor will have to make up for to maintain the steady operation of the pneumatic devices on the manufacturing floor that rely on compressed air for their application. When air leaks are formed within the compressed air piping network, they act as continuous consumers and cause not only the siphoning off of said compressed air, put also reduce the pressure that is needed within the pipes. The air compressors will have to work harder to compensate for the losses in the pressure and the amount of air itself, causing an overconsumption of energy and power. Overworking the air compressor also causes the internal equipment to be stretched beyond its capabilities, especially if they are already running at full loads, reducing their total lifespans considerably. In addition, if there are multiple leaks close to the pneumatic devices on the manufacturing floor, the immediate loss in pressure and air can cause the devices to operate inefficiently and thus cause a reduction in production. This will all cumulatively impact the manufacturer considerably when it comes to energy consumption and profits. There are multiple methods of air leak detection and accounting that currently exist so as to understand their impact on the compressed air systems. The methods are usually conducted when the air compressors are running but during the time when there is no, or minimal, active consumption of the air by the pneumatic devices on the manufacturing floor. This time period is usually called non-production hours and generally occur during breaks or between employee shift changes. This time is specifically chosen so that the only air consumption within the piping is that of the leaks and thus, the majority of the energy and power consumed during this time is noted to be used to feed the air leaks. The collected data is then used to extrapolate and calculate the energy and power consumed by these leaks for the rest of the year. There are, however, a few problems that arise when using such a method to understand the effects of the leaks in the system throughout the year. One of the issues is that it is assumed that the air and pressure lost through the found leaks are constant even during the production hours i.e. the hours that there is active air consumption by the pneumatic devices on the floor, which may not be the case due to the increased air flow rates and varying pressure within the line which can cause an increase in the amount of air lost through the same orifices that was initially detected. Another challenge that arises with using only the data collected during a single non-production time period is that there may be additional air leaks that may be created later on, and the energy and power lost due to the newer air leaks would remain unaccounted for. As the initial estimates will not include the additional losses, the effects of the air leaks may be underestimated by the plant managers. To combat said issues, a continuous method of air leak analyses will be required so as to monitor the air compressors’ efficiency in relation to the air leaks in real time. By studying a model that includes both the production, and non-production hours when accounting for the leaks, it was observed that there was a 50.33% increase in the energy losses, and a 82.90% increase in the demand losses that were estimated when the effects of the air leaks were observed continuously and in real time. A real time monitoring system can provide an in-depth understanding of the compressed air system and its efficiency. Managing leaks within a compressed air system can be challenging especially when the amount of energy wasted through these leaks are unaccounted for. The main goal of this research was to find a nonintrusive way to calculate the amount of air as well as energy lost due to these leaks using time series pressure measurements. Previous studies have shown a strong relationship between the pressure difference, and the use of air within pneumatic lines, this correlation along with other factors has been exploited in this research to find a novel and viable method of leak accounting to develop a Continuous Air Leak Monitoring (CALM) system.

The commercial buildings sector in the United States used 18 percent (17.93 Quads) of the U.S. primary energy in 2006. Office buildings are the largest single energy consumption category in the commercial buildings sector of the United States with annual energy consumption around 1.1 Quads. Traditional approaches used in commercial building designs are not adequate to save energy in both depth and scale. One of the most effective ways to reduce energy consumption is to improve energy performance of HVAC systems. High-performance HVAC systems and components, as well as application of renewable energy sources, were surveyed for buildings in hot and humid climates. An analysis of performance and energy saving potential estimation for selected HVAC systems in hot and humid climates was developed based on energy consumption simulation models in DOE-2.1E. A calibrated energy consumption model of an existing office building located in the hot and humid climate conditions of Texas was developed. Based on this model, the energy saving potential of the building was estimated. In addition, energy consumption simulation models were developed for a new office building, including simulation of energy saving measures that could be achieved with further improvements of HVAC system above the energy conservation codes requirements. The theoretical minimum energy consumption level for the same office building was estimated for the purpose of evaluating the whole building energy efficiency level. The theoretical minimum energy consumption model of the office building was designed to provide the same level of comfort and services to the building occupants as provided in the actual building simulation model. Finally, the energy efficiency of the building that satisfies valid energy conservation codes and the building with an improved HVAC system was estimated based on theoretically minimum energy consumption level. The analysis provided herein can be used for new building practitioners and existing building owners to evaluate energy reduction potential and the performance of innovative technologies such as dedicated outdoor air system, displacement ventilation, improved cooling system efficiency, air source heat pumps and natural gas heat pumps.

Advanced rotating shaft seals have the potential to significantly increase the efficiency and performance of steam and gas turbines. Two such seals, brush and leaf seals, rely on the use of thousands of flexible filaments to close clearances between rotating components and their static casings. The current life of the components is poor compared to the rest of the gas turbine, limiting the seals' deployment, particularly in the jet engine at high temperature and pressure. Poor understanding of the seal installation response to frictional heat generated at the point of filament-rotor contact during operation has limited the ability to predict engine closures and hence seal behaviour and life. The resulting temperature rises may compromise the mechanical integrity of the engine rotor in extremis leading to a shaft failure. This thesis considers the heat transfer mechanisms that govern frictional heating, of both the fluid and solid components in the vicinity of such seals, characterising the process both experimentally and using numerical models. Through the identification of key features of the heat transfer a simple numerical methodology is shown to predict the thermal behaviour of the seal installation sufficiently accurately for engine design purposes. A low order heat transfer model, using a simple electrical analogy for heat transfer is used to investigate frictional heat generation. When contact occurs between the rotor surface and the seal filaments, mechanical energy is dissipated as heat at the interface. This is conducted into the rotor and the seal filaments in proportions that depend on the heat transfer characteristics of both contacting bodies (thermal resistances). To calculate the heat partition ratio and the resulting contact temperature, the thermal resistances of both rotor and seal need to be known. To that end, a new test facility, the Seal Static Thermal Test Facility (SSTTF), is developed. This is first used to study the convective heat transfer occurring in the vicinity of the seal; heat transfer coefficients based on appropriate, scalable, gas reference temperatures are reported. Importantly the results show a larger area on the rotor surface affected by the presence of the seal than was assumed by previous workers. The test rig is further modified to generate heating in a static test rig equivalent to the frictional heating at the filament tips. The test rig allows the contact temperature between rotor and seal, a critical previously unknown parameter to be measured in a well-conditioned environment. The presence of many thousands of vanishingly small flow passages in filament seals makes their explicit modelling unfeasible for engine design purposes. Thus the results from the experimental campaign are used to develop a simple computational fluid dynamic model of the seal, including empirically derived frictional heating, and seal porosity models, to achieve similar leakage and surface heat transfer to the rotor as was seen in the static experiments. The low order CFD methodology presented in the thesis is finally employed to model the transient operation of a brush seal under engine representative rotor surface speeds and differential pressures. Experimental data were generated in the Oxford Engine Seal Test Facility for a typical brush seal rubbing against a high growth rotor. These experiments were modelled using CFD and finite element analysis using parameters derived from static tests for the porous modelling of the seal leakage. Comparison of results shows that, without further tuning, the thermal behaviour is captured well with a moderate conservative overestimation of rotor heating with increased differential pressure across the seal allowing the strategy to be used as an engine design tool.

The aim of this diploma thesis is to elaborate alternative designs of the Dětkovice sewer network. The first part deals with reasons of this work and the area of interest. In the next part the thesis deals with describe of current condition and proposed alternative designs. Furthermore, the economic assessment of alternative designs is elaborate.

För att tillgodose framtidens växande behov av energi och samtidigt bidra till en långsiktigt hållbar energitillförsel krävs resurs- och energieffektivisering inom flera sektorer. Inte minst inom industrin som år 2016 stod för mer än 50 procent av det globala energibehovet. Tillvaratagandet av befintliga resurser såsom spillvärme från tryckluftsproduktion är en möjlig effektiviseringsåtgärd. Till grund för examensarbetet ligger ett önskemål från koncernen Sandvik AB att utreda besparingspotential och kostnader för reinvestering i en av industrins kompressorcentraler, Götvalsverket. Reinvesteringen avser två nya kompressorer vars spillvärme integreras i industrins befintliga närvärmesystem och möjliggör för minskade resurs- och energikostnader samt utsläpp av CO2. Arbetet syftar till att analysera olika kompressorlösningar utifrån ett ekonomiskt och miljömässig perspektiv. Detta görs med hjälp av insamlad data, känslighetsanalyser och lönsamhetskalkyler med tillhörande LCC. Målet är att kunna besvara olika frågeställningar rörande total investeringskostnad, energi- och resursbesparing samt utsläppsreducering. Två fall av produktion undersöks, dels vid drift enligt Götvalsverkets befintliga produktionstid och dels med en optimerad drifttid för kompressorenheterna. En litteraturstudie har också genomförts där flera studier visar att tryckluft är ett dyrt alternativ för energiproduktion och att implementering av effektiviseringsåtgärder, däribland återvinning av spillvärme, därför kan vara väl grundade investeringar. Även andra fördelar kan kopplas till energieffektivisering, exempelvis förbättrad produktion och arbetsmiljö för anställda. Resultatet av arbetet visade att särskilt ett kompressoralternativ stod ut från de övriga ur både en ekonomisk- och miljömässig synpunkt. Detta alternativ erbjöd inte den billigaste investeringen men däremot var mängden återvunnen värme så pass mycket större än för andra alternativ, att energibesparingen minskade återbetalningstiden drastiskt. Tillvaratagande av befintliga resurser som spillvärme, tillsammans med industrins minskade energianvändning, anses vara en nödvändighet för att kunna säkerställa välmående hos både människor, djur och natur i framtiden. / In order to meet the growing demand for energy in the future, while contributing to a long-term sustainable energy supply, resource and energy efficiency measures are required within several sectors. In 2016 the industry sector accounted for more than 50 percent of the global power demand. The use of existing resources, such as waste heat from compressed air production, is a possible efficiency measure.  Behind this thesis work is a request from the Sandvik AB Group to estimate savings potential and reinvestment costs in one of the industry's compressor centers, Götvalsverket. The reinvestment refers to two new compressors whose waste heat is integrated into the industry's existing district heating system and allows for reduced resource and energy costs as well as a reduction of CO2-emissions.  This work aims to investigate different compressor alternatives from an economic- and environmental perspective. This is done using collected data, a sensitivity analysis and profitability calculations with an attached LCC-analysis. The aim is to answer various questions regarding total investment cost, energy and resource saving as well as emission reduction. Two cases in production are investigated. The first according to the existing operation hours in Götvalsverket and the second case with an optimized operating time for the compressor units.  A literature review has also been conducted where several studies show that compressed air is an expensive alternative to energy production and that implementation of efficiency measures, including waste heat recovery, can be well-founded investments. Other benefits can also be linked to energy efficiency, such as improved production and an improved work environment for employees.  The result of the work showed that one alternative in particular stood out from the other compressor solutions, both from an economic and environmental point of view. This option did not offer the cheapest investment but the amount of recovered waste heat was much larger than for the other alternatives and therefore, energy savings reduced the payback period drastically.  The utilizing of existing resources such as waste heat, together with the industry sector’s reduced energy consumption, is considered a necessity in order to ensure the well-being of people, animals and nature in the future.

SammanfattningIntroduktion: Sedan år 2000 har antalet byggnader i Sverige ökat kraftigt. Enligt Statiska centralbyrån (SCB) fanns över 5 miljoner bostäder i Sverige i slutet av år 2021. Av dessa bostäder är cirka 42 % villor, 51 % flerbostadshus och resterande är lägenheter i specialbostäder. Energiförbrukningen i småhus har ökat med cirka 22% sedan 1970-talet, främst på grund av ökad användning av cirkulationspumpar, golvvärme och ventilation. Detta har resulterat i ökad miljöpåverkan från byggsektorn. Effektivisering av ventilationssystem har varit ett fokusområde under lång tid, eftersom användningsfasen av ventilationssystemen har visat sig ha hög energianvändning och stor miljöpåverkan. En studie visar att VVS-systemen påverkar miljön både vid tillverknings- och användningsfasen. Dessutom har nya lågenergihus en högre miljöpåverkan i byggfasen på grund av användningen av mer material för att minska driftanvändningen. Valet av ventilationssystem är avgörande för villor, eftersom ett effektivt ventilationssystem inte bara förbättrar inomhusluften utan också minskar risken för hälsoproblem som kan uppstå vid otillräcklig ventilation. Nyckelord: Livscykelkostnad, LCC, Ventilationssystem, Självdragssystem, FTX-system, VIP-Energy, Från- och tilluftssystem, Värmeåtervinning. Syfte: Syftet med examensarbetet är att visa att valet av ventilationssystem har betydelse för minskad klimatpåverkan vid tillverknings- och användningsfasen under 30 års tid. Mål: Målet är att ta fram vilket av självdragsventilation och från- och tilluftssystem med värmeåtervinning som är mest ekonomiskt och ger lägst klimatpåverkan baserat på ett livscykelperspektiv på ett småhus under en kalkylperiod på 30 år. Frågeställningar: Vilken av självdrag och FTX är mest effektivt med tanke på energiförbrukningen under tillverknings- och användningsfasen?Hur påverkar självdrag respektive FTX-systemet uppvärmningskostnaderna för ett småhus under förutsättning att uppvärmningen sker med fjärrvärme?Vilket av de två ventilationssystemen är mest ekonomisk lönsamt enligt en jämförande LCC, baserad på ett småhus med en kalkylperiod på 30 år?Vilket av ventilationssystemen orsakar störst klimatpåverkan? Metod: Metoden är en fallstudie där VIP-Energy används för att visa byggnadens energiförbrukning timme för timme under ett helt år. En LCC-beräkning utförs för att bestämma kostnaden för ventilationssystemet under dess livslängd, inklusive uppskattade underhållskostnader och nyinvesteringar. Slutsats: Baserat på energiförbrukningen under tillverknings- och användningsfasen är det mer effektivt att använda självdrag istället för ett FTX-system. Självdrag med vedeldning har ett lägre fjärrvärmebehov jämfört med FTX-systemet och ger därmed lägre årliga uppvärmningskostnader. Över en 30-årsperiod har självdragssystemet en lägre total livscykelkostnad än FTX-systemet. FTX-systemet har en högre elförbrukning och därmed en större påverkan på klimatet än självdragssystemet. / AbstractIntroduction: Since the year 2000, the number of buildings in Sweden has seen a significant increase. According to the Statistics Sweden (SCB), there were over 5 million dwellings in Sweden at the end of 2021. Out of these dwellings, approximately 42% are single-family houses, 51% are multi-family buildings, and the remaining is apartments in specialized housing. The energy consumption in single-family houses has increased by around 22% since the 1970’s, primarily due to the increased use of circulation pumps, underfloor heating, and ventilation. This has resulted in an increased environmental impact from the construction sector. Efficiency improvements in ventilation systems have been a longstanding focus due to the high energy consumption and significant environmental impact associated with their operational phase. A study reveals that HVAC systems impact the environment both during the manufacturing and the operational phases. Furthermore, new low-energy buildings have a higher environmental footprint during the construction phase due to the increased use of materials aimed at reducing operational energy consumption. The choice of a ventilation system is crucial for homes, as an efficient ventilation system not only improves indoor air quality but also reduces the risk of health problems that can arise from inadequate ventilation. Keywords: Life Cycle Cost, LCC, Ventilation System, Self-Exhaust Ventilation, Supply and Exhaust Ventilation, VIP-Energy, Supply and Exhaust Air System, Heat Recovery. Purpose: The purpose of the thesis is to demonstrate that the choice of ventilation system has a significant impact on reducing environmental emissions during the manufacturing and operational phases over a 30-year period. Goal: The objective is to determine which of self-exhaust ventilation and supply and exhaust ventilation with heat recovery is the most cost-effective and has the lowest climate impact based on a life-cycle perspective for a single-family building over a calculation period of 30 years.Questions: Which of self-exhaust ventilation and supply and exhaust ventilation is the most efficient in terms of energy consumption during the manufacturing and usage phases?How do self-exhaust ventilation and supply and exhaust ventilation affect the heating costs for a single-family building assuming that heating is provided through district heating?Which of the two ventilation systems is most economically viable according to a comparative Life Cycle Cost (LCC) analysis, based on a single-family building with a calculation period of 30 years?Which of the two ventilation systems causes the greatest climate impact?

Une méthode non intrusive de construction d’un modèle de remplacement de l’écoulement dans une cavité de système d’air secondaire de turboréacteur est recherchée. Le modèle réduit doit pouvoir être intégré dans un modèle de l’ensemble du moteur et couplé à la thermique de la structure pour simuler son comportement thermique sur une mission complète sous aile. Pour cela, il doit prendre un grand nombre de paramètres en entrée, retourner autant de sorties et être utilisable sur des intervalles de variations étendus de ces paramètres. Plusieurs approches sont envisagées et implémentées, puis appliquées à la modélisation d’une cavité sous turbine fictive :— Création de surfaces de réponse des termes de la décomposition ANOVA des flux pariétaux.— Création de surfaces de réponse des flux pariétaux combinée avec une méthode de raffinement adaptative exploitant la trajectoire dans l’espace d’entrée issue du couplage modèle réduit - modèle de structure.— Réduction de dimension des champs d’interface échangés à partir de résultats des itérations du couplage des modèles thermiques de l’écoulement et de la structure, puis création de surfaces de réponse des coordonnées réduites.Cette dernière voie permets d'obtenir des résultats encourageants sur le cas test proposé d'abord dans le cas à conditions limites d'entrée de l'écoulement fixées, puis en incluant des variations de certaines d'entre-elles. / A non intrusive method to create surrogate models describing the flow in jet engines’ secondary air system is desired. The resulting model must be integrated in a thermal model describing the whole engine during a complete mission under the wing. This requires the model to use a high number of input and output parameters and to be valid on a broad domain of variation of its parameters. Several approches are explored in this thesis and applied to a simplified turbine cavity :— Surrogate modeling of terms of the ANOVA decomposition of wall fluxes.— Surrogate modeling of wall fluxes combined with an adaptive refinement method exploiting the trajectory followed by the input parameters during the coupling between the metamodel and the structural model.— Dimensionality reduction of the interface data exchanged during the coupling between flow and structure thermal model and surrogate modeling of the resulting reduced coordinate.This last approach leads to good results on the test case considered in this thesis with fixed inlet boundary conditions and then with variations of some of the inlet parameters.