Diploma thesis focuses on the topic of cleaning boilers in heating and power generation industry and automation of boiler cleaning process. There are summarized facts about cleaning devices, from which these systems consist of and as well as about support and control devices. Based on this facts, is developed control system and visualization interfaces with an emphasis on functionality into the system.

Neste trabalho, o comportamento do escoamento de ar nos dutos de suprimento para os queimadores de uma caldeira multicombustível de alta potência (categoria A- NR-13) de queima frontal é investigado experimentalmente. Sondas de Pitot foram instaladas em diversas regiões ao longo do escoamento nos dutos de ar, para medição das pressões estática e de estagnação, de forma a caracterizar o campo de velocidade na caixa de ar. Medições do campo de pressão foram realizadas para várias condições operacionais e configuração de abertura das entradas de ar dos queimadores. Através da análise dos dados verificou-se que a velocidade do ar na alimentação dos queimadores é influenciada pela condição de queimador aceso ou apagado e também pelas configurações de combustíveis e pela vazão total, que é ditada pela carga da caldeira. Também foram feitas medidas das pressão estática nas câmaras de ar primário e secundário de cada queimador. Os resultados mostraram que estas pressões são menores nas linhas de queimadores inferiores aumentando na direção dos queimadores superiores. A comparação dos resultados experimentais obtidos com a caldeira apagada (sem geração de vapor) e com os dados dos experimentos realizados com caldeira acesa, não apresentaram discrepância qualitativa e nem quantitativa relevante, possibilitando estudar o comportamento do escoamento a frio. Os resultados experimentais também indicaram a existência de uma região em que o escoamento ascendente tem maior velocidade, pelo lado direito do plano médio vertical da caixa de ar. Como parte do objetivo desenvolve-se uma aplicação com as técnicas de planejamento fatorial 23 e análise da variança nas principais variáveis de controle do ar de alimentação para os queimadores da caldeira. Os resultados calculados através do modelo obtido pelo planejamento fatorial a partir dos testes com caldeira desligada apresentam boa concordância com os resultados experimentais tanto para operação com caldeira desligada quanto ligada quando todos os queimadores estão abertos. Os experimentos revelaram que os modelos obtidos a partir da análise fatorial podem ser utilizados para estimar o campo de velocidades na seção vertical da caixa de ar. / Combustion air flow in the windbox of an industrial multifuel front wall boiler was experimentally investigated. The velocity field was mapped by measuring the static and stagnation pressure fields along the flow by means of Pitot tubes. Experimental tests were conducted for a range of operating conditions and a set of configurations involving dumped and open burner passages. It was observed that combustion air flow is affected by the arrangement of open and closed burners, by the arrangement of fuel being burned in the burners array, and by the total air flow rate, which is dictated by the boiler. Measurements of the static pressure in the primary and secondary air chambers of each burner were also conducted. It was verified that pressure in these chambers increases as the air flow ascends towards the line of burners in the top of the vertical section of the windbox did not present relevant differences. Comparison of results obtained for the boiler operating with and without steam generation did not present significant qualitative nor quantitative discrepancies, allowing for the conclusion that measurements taken in “cold flow” operation mode are representative of the air flow in the windbox. The experimental results also indicated the occurrence of a preferencial ascending path, characterized by higher air flow velocity, inside the windbox. In order to identify the main control variables in the process, design of experiments techniques were additionally used to define experiments. Factorial 23 planning and variance analysis of the main control variables affecting the flow of combustion air to the burners yielded models to predict the pressure field in the vertical section of the windbox as function of the total air flow rate and the opening position of the primary and secondary air dampers at the burners inlet. Predicted results presented good agreement with experimental results for the boiler operating without steam production in operating conditions different of those for which the models were generated and for the boiler operating with steam generation and all burners operating with primary and secondary air dampers fully open.

Apresenta-se uma avaliação técnico-econômica para o préaquecimento solar da água de reposição em caldeiras de sistemas de vapor abertos. São empregados, para compor um estudo de caso, os dados de uma indústria de laticínios de médio porte situada próximo da cidade do Rio de Janeiro. Quarenta e oito simulações computacionais do sistema de aquecimento solar (SAS) foram realizadas em TRNSYS, correspondendo aos 5% melhores resultados econômicos de uma série de 2.700 simulações mais simples (método φ-f-chart), programados em MATLAB. Foram empregados dados horários de ano típico meteorológico (TMY) para a cidade do Rio de Janeiro. O ganho econômico foi baseado no consumo evitado dos três combustíveis mais comuns na indústria de laticínios, enquanto o custo de investimento foi composto a partir de valores comerciais e da literatura. Os resultados da avaliação econômica mostraram-se desfavoráveis para a substituição de óleo combustível, favoráveis no caso de caldeiras a gás natural, condicionado a existência de subsídios, e bem competitivos para a substituição de GLP. A eficiência térmica do sistema mostrou ser o parâmetro técnico chave para o desempenho econômico, consequentemente, uma vez que a eficiência se mostrou inversamente proporcional tanto ao volume do reservatório quanto à área de coletores, não há uma configuração ótima para o sistema. Não obstante, os resultados permitiram a proposição de políticas públicas para incentivar o uso da energia solar na indústria leiteira e, consequentemente, contribuir para a preservação ambiental. / It is presented a technical and economical feasibility assessment of solar preheating of steam boiler feed water for opened vapor systems. Data from a medium sized dairy industry near Rio de Janeiro city, in Brazil, is used to compose a case study. Forty eight solar heating system (SAS) computer simulations were carried out in TRNSYS, for a range of design parameters corresponding to the 5% best economical results of a series of 2700 simpler simulations (φ,f-chart method), programmed on MATLAB. Rio de Janeiro typical meteorological year (TMY) hourly weather data was used. Revenue was based on the avoided consumption of the three most used fuels on dairy industries, while investment cost was composed from both commercial and literature values. Economical assessment results showed unfavorable for the displacement of fuel oil, favorable for substituting natural gas, provided subsidizing, and well competitive against LPG. Systems thermal efficiency showed to be the key technical factor for economical performance, thus, as efficiency was found to be inversely proportional for both storage volume and collector area, there isnt an optimal system configuration. The results, though, made it possible to address environmentally sound public policies to encourage solar energy use on dairy industries.

Submitted by Vasti Diniz (vastijpa@hotmail.com) on 2017-07-26T14:36:11Z No. of bitstreams: 1 arquivototal.pdf: 3278618 bytes, checksum: 67f9a43a24037a5a7c532f8f0d2805f8 (MD5) / Made available in DSpace on 2017-07-26T14:36:11Z (GMT). No. of bitstreams: 1 arquivototal.pdf: 3278618 bytes, checksum: 67f9a43a24037a5a7c532f8f0d2805f8 (MD5) Previous issue date: 2016-12-12 / The water can be considered as a limiting factor for the industrial development. In Brazil, for example, there was the culture of we are the country in the world with more availability of potable water and we not learn how to manage our water properly. This mismanagement can compromise their quality, spending much more with treatments such as flocculation, softening, demineralization and active filtering. Rainwater can be considered a great alternative source, because their capture and storage provides good quality water for industry and also prevents flooding. One of the equipaments that consume more water in industry is the boilers, in addition, the quality of the water to the boiler’s feed requires special care and this make the rain water a good solution. The parameters that were evaluated for the water quality in this work were: Turbidity, Total Hardness, Dissolved Oxygen, Hardness Calcium, Electrical Conductivity, Hardness Magnesium, Total Dissolved Solids, Total Acidity, pH, alkalinity, chlorides and Total iron. The potentiometric methods, volumetrics of neutralization titration by complexation, and instruments were used. The economic viability was done with data collected in a big food industry, present in the state of Sergipe and was used the models of discounted cash flow, Net Present Value (NPV), Internal Rate of Return (IRR) and Payback Period Discounted. The results obtained in general, show in the rainwater an alternative source of high quality and that can reduce the costs with treatments for industrial water. They also show that the water captured by the direct method presents greater purity than that captured by the indirect method and in general both have parameters below the recommended limit for use in boilers, needing only some preliminary treatments. Economic analysis shows that it is a viable method over an estimated 20-year period. This study aims to contribute to the reduction of consumption of fluvial waters, which are of high drinking potential, and to increase the use of rainwater that has excellent quality for industry and low potential for human consumption. / A água pode ser considerada como um fator de limitação para o desenvolvimento industrial. No Brasil, por exemplo, teve-se a cultura do país no mundo com mais disponibilidade de água doce e por isso não aprendemos como gerir nossa água adequadamente. Esse mau gerenciamento pode comprometer a sua qualidade, gastando-se ainda mais com tratamentos, como floculação, abrandamento, desmineralização e filtragem ativa. A água da chuva pode ser considerada como uma ótima fonte alternativa, uma vez que sua captação e armazenamento proporciona água de boa qualidade para a indústria e ainda previne cheias. Um dos equipamentos que mais consomem água na indústria são as caldeiras, além disso, a qualidade da água para caldeira exige cuidados bastantes especiais que fazem com que a água da chuva seja uma boa solução. Os parâmetros que foram avaliados para a qualidade da água nesse trabalho foram: Turbidez, Dureza Total, Oxigênio Dissolvido, Dureza de Cálcio, Condutividade Elétrica, Dureza de Magnésio, Sólidos Totais Dissolvidos, Acidez Total, pH, Alcalinidade, Cloretos e Ferro Total. Foram utilizados os métodos potenciométricos, volumetria de neutralização, titulação por complexação, e instrumentais. A viabilidade econômica foi feita com os dados coletados em uma indústria alimentícia de grande porte, presente no estado de Sergipe e utilizando os modelos de fluxo de caixa descontado, valor presente líquido (VPL), taxa interna de retorno (TIR) e período de payback descontado. Os resultados obtidos de forma geral, mostram nas águas pluviais uma fonte alternativa de alta qualidade e que reduz os custos com tratamentos para água industrial. Mostram também que a água captada pelo método direto apresenta maior pureza que a captada pelo método indireto e no geral ambas têm parâmetros abaixo do limite recomendado para uso em caldeiras precisando apenas de alguns tratamentos preliminares. A análise econômica mostra ser um método viável num período estimado em 20 anos. Este estudo visa contribuir com a redução do consumo de águas fluviais, que são de alto potencial potável, e aumentar o uso de água pluvial que tem ótima qualidade para indústria e baixo potencial para consumo humano.

Neste trabalho, o comportamento do escoamento de ar nos dutos de suprimento para os queimadores de uma caldeira multicombustível de alta potência (categoria A- NR-13) de queima frontal é investigado experimentalmente. Sondas de Pitot foram instaladas em diversas regiões ao longo do escoamento nos dutos de ar, para medição das pressões estática e de estagnação, de forma a caracterizar o campo de velocidade na caixa de ar. Medições do campo de pressão foram realizadas para várias condições operacionais e configuração de abertura das entradas de ar dos queimadores. Através da análise dos dados verificou-se que a velocidade do ar na alimentação dos queimadores é influenciada pela condição de queimador aceso ou apagado e também pelas configurações de combustíveis e pela vazão total, que é ditada pela carga da caldeira. Também foram feitas medidas das pressão estática nas câmaras de ar primário e secundário de cada queimador. Os resultados mostraram que estas pressões são menores nas linhas de queimadores inferiores aumentando na direção dos queimadores superiores. A comparação dos resultados experimentais obtidos com a caldeira apagada (sem geração de vapor) e com os dados dos experimentos realizados com caldeira acesa, não apresentaram discrepância qualitativa e nem quantitativa relevante, possibilitando estudar o comportamento do escoamento a frio. Os resultados experimentais também indicaram a existência de uma região em que o escoamento ascendente tem maior velocidade, pelo lado direito do plano médio vertical da caixa de ar. Como parte do objetivo desenvolve-se uma aplicação com as técnicas de planejamento fatorial 23 e análise da variança nas principais variáveis de controle do ar de alimentação para os queimadores da caldeira. Os resultados calculados através do modelo obtido pelo planejamento fatorial a partir dos testes com caldeira desligada apresentam boa concordância com os resultados experimentais tanto para operação com caldeira desligada quanto ligada quando todos os queimadores estão abertos. Os experimentos revelaram que os modelos obtidos a partir da análise fatorial podem ser utilizados para estimar o campo de velocidades na seção vertical da caixa de ar. / Combustion air flow in the windbox of an industrial multifuel front wall boiler was experimentally investigated. The velocity field was mapped by measuring the static and stagnation pressure fields along the flow by means of Pitot tubes. Experimental tests were conducted for a range of operating conditions and a set of configurations involving dumped and open burner passages. It was observed that combustion air flow is affected by the arrangement of open and closed burners, by the arrangement of fuel being burned in the burners array, and by the total air flow rate, which is dictated by the boiler. Measurements of the static pressure in the primary and secondary air chambers of each burner were also conducted. It was verified that pressure in these chambers increases as the air flow ascends towards the line of burners in the top of the vertical section of the windbox did not present relevant differences. Comparison of results obtained for the boiler operating with and without steam generation did not present significant qualitative nor quantitative discrepancies, allowing for the conclusion that measurements taken in “cold flow” operation mode are representative of the air flow in the windbox. The experimental results also indicated the occurrence of a preferencial ascending path, characterized by higher air flow velocity, inside the windbox. In order to identify the main control variables in the process, design of experiments techniques were additionally used to define experiments. Factorial 23 planning and variance analysis of the main control variables affecting the flow of combustion air to the burners yielded models to predict the pressure field in the vertical section of the windbox as function of the total air flow rate and the opening position of the primary and secondary air dampers at the burners inlet. Predicted results presented good agreement with experimental results for the boiler operating without steam production in operating conditions different of those for which the models were generated and for the boiler operating with steam generation and all burners operating with primary and secondary air dampers fully open.

Neste trabalho, o comportamento do escoamento de ar nos dutos de suprimento para os queimadores de uma caldeira multicombustível de alta potência (categoria A- NR-13) de queima frontal é investigado experimentalmente. Sondas de Pitot foram instaladas em diversas regiões ao longo do escoamento nos dutos de ar, para medição das pressões estática e de estagnação, de forma a caracterizar o campo de velocidade na caixa de ar. Medições do campo de pressão foram realizadas para várias condições operacionais e configuração de abertura das entradas de ar dos queimadores. Através da análise dos dados verificou-se que a velocidade do ar na alimentação dos queimadores é influenciada pela condição de queimador aceso ou apagado e também pelas configurações de combustíveis e pela vazão total, que é ditada pela carga da caldeira. Também foram feitas medidas das pressão estática nas câmaras de ar primário e secundário de cada queimador. Os resultados mostraram que estas pressões são menores nas linhas de queimadores inferiores aumentando na direção dos queimadores superiores. A comparação dos resultados experimentais obtidos com a caldeira apagada (sem geração de vapor) e com os dados dos experimentos realizados com caldeira acesa, não apresentaram discrepância qualitativa e nem quantitativa relevante, possibilitando estudar o comportamento do escoamento a frio. Os resultados experimentais também indicaram a existência de uma região em que o escoamento ascendente tem maior velocidade, pelo lado direito do plano médio vertical da caixa de ar. Como parte do objetivo desenvolve-se uma aplicação com as técnicas de planejamento fatorial 23 e análise da variança nas principais variáveis de controle do ar de alimentação para os queimadores da caldeira. Os resultados calculados através do modelo obtido pelo planejamento fatorial a partir dos testes com caldeira desligada apresentam boa concordância com os resultados experimentais tanto para operação com caldeira desligada quanto ligada quando todos os queimadores estão abertos. Os experimentos revelaram que os modelos obtidos a partir da análise fatorial podem ser utilizados para estimar o campo de velocidades na seção vertical da caixa de ar. / Combustion air flow in the windbox of an industrial multifuel front wall boiler was experimentally investigated. The velocity field was mapped by measuring the static and stagnation pressure fields along the flow by means of Pitot tubes. Experimental tests were conducted for a range of operating conditions and a set of configurations involving dumped and open burner passages. It was observed that combustion air flow is affected by the arrangement of open and closed burners, by the arrangement of fuel being burned in the burners array, and by the total air flow rate, which is dictated by the boiler. Measurements of the static pressure in the primary and secondary air chambers of each burner were also conducted. It was verified that pressure in these chambers increases as the air flow ascends towards the line of burners in the top of the vertical section of the windbox did not present relevant differences. Comparison of results obtained for the boiler operating with and without steam generation did not present significant qualitative nor quantitative discrepancies, allowing for the conclusion that measurements taken in “cold flow” operation mode are representative of the air flow in the windbox. The experimental results also indicated the occurrence of a preferencial ascending path, characterized by higher air flow velocity, inside the windbox. In order to identify the main control variables in the process, design of experiments techniques were additionally used to define experiments. Factorial 23 planning and variance analysis of the main control variables affecting the flow of combustion air to the burners yielded models to predict the pressure field in the vertical section of the windbox as function of the total air flow rate and the opening position of the primary and secondary air dampers at the burners inlet. Predicted results presented good agreement with experimental results for the boiler operating without steam production in operating conditions different of those for which the models were generated and for the boiler operating with steam generation and all burners operating with primary and secondary air dampers fully open.

Orientador: Olivio Novaski / Dissertação (mestrado profissional) - Universidade Estadual de Campinas, Faculdade de Engenharia Mecanica / Made available in DSpace on 2018-08-07T00:42:00Z (GMT). No. of bitstreams: 1 Orsi_JoseAntonioDonizeti_M.pdf: 6142367 bytes, checksum: 1f5852217f37223e812bc80aacf3758f (MD5) Previous issue date: 2006 / Resumo: Neste trabalho procurou analisar o desenvolvimento de grupos semi-autônomos para as atividades de caldeiraria no ambiente produtivo de bens de capital sob encomenda, caracterizando o ambiente produtivo e as características do trabalhador desta atividade. A pesquisa foi desenvolvida com um estudo de simples caso motivado pela dificuldade de encontrar organizações que disponham desta forma de organização do trabalho e pela profundidade necessária ao estudo. Nove empresas foram pesquisadas as quais permitiram desenvolver os objetivos de caracterização do ambiente e do trabalhador. A análise dos resultados constatou a eficiência na aplicação da organização do trabalho em grupos semi-autônomos tendo como base de sucesso o aproveitamento da mão de obra com polivalência de funções e a manutenção de uma tensão positiva nos participantes proveniente das interações entre as características desta forma de autonomia e os fatores motivacionais que são desenvolvidos / Abstract: This research has tried to analyze the progress for semi-self work team on steel fabrication built by order activities, hereby pointing out the production environment and the worker's characteristics. Due the difficulties to find organizations which have such kind of work administration and also from the depth needed to consolidate this type of study a single case was applied. In order to achieve the objectives, nine companies have been studied and gave the basis to describe the worker' s characteristics and the production environment. The results allow us to understand how semi-self work team works and how it creates the interaction between the properties and the motivation factors. The success is based on the empowerment developed by taking advantages in not exchanging workers for different tasks, the resultant synergy that comes from the motivation created by application ofthe self-work / Mestrado / Planejamento e Gestão Estrategica da Manufatura / Mestre Profissional em Engenharia Mecanica

When speaking about energy it means speaking about life, activity, economy, growth and environmental issues. The issue of energy has been the main article all over the world in recent years, this is due to the importance of energy to life and its impact on the environment. For example, Paris climate change meeting in 2015 is one of the recent global meeting which directly related to the energy use by nations. The meeting was mainly focused up on the restriction of greenhouse gas emission which implies that industries should think about other alternative energy resources rather than fossil fuel for positive impact on climatic change. This is one of the cases that led industries into greater competition in the global market. Industries must consider energy alternatives which is safe for the environment and by using such energy a competitive product with better quality and quantity should be produced. This challenge has motivated industries to look and study the energy that they are using currently. Studies and researches show that one of the main and most abundant energy resources that most of these industries can get is by improving the energy efficiency or managing the energy that they currently use. The main aim of this thesis is to provide Arizona chemical plant (Kraton) at Sandarne on the potential energy saving by managing their energy use. The first wisdom in energy utilization is managing and using the energy they possess efficiently. In Arizona plant at Sandarne, the product named “Pitch” (a natural viscoelastic polymer or rosin) is a fuel used as the primary energy supply for the production of steam by boilers. The steam may be utilized well but the energy in the condensate (after steam loses its latent heat) is not addressed well enough. Hence this paper has studied on how significant is the energy lost by the steam condensate is and how its recovery can be used to save energy and cost. The plant produces about an average of 11.42 ton of steam each hour in a year. This steam can be returned or fully recovered (100%) as condensate from the law of conservation of mass since only energy is lost from the steam. But the plant returns a maximum of about 3ton of condensate each hour. This amount is relatively low compared to the amount of condensate recovery possibility. Recovery possibility of condensate return showed that the plant at Sandarne can return at least 8.5 ton of condensate  each hour. In comparison with the current return estimated 5.5 ton of condensate is being lost simply as waste each hour leading to about 400 SEK minimum cost loss. The calculation of cost is in minimum because the charge from water supply and condensate effluent disposal charge are not considered. In this paper only recovery from the easily recoverable steam condensate is being considered (25% of the system) which resulted in payback time of the proposed investment 1.88 years without considering the above explained charges. It is much motivating study considering the generalized approach and over simplified method. If a deeper investigation is made on the potential, it can be clearly shown that how significant the potential is in securing and sustaining energy and environmental issues. Ensuring the security and sustainability of energy which addresses the environmental issue precisely will help the plant to stay on the race of global market competition.   Keywords: Energy efficiency, Boiler efficiency, Energy management, Condensate recovery,

An existing furnace oil fired boiler is used to supply process steam to an instant tea manufacturing factory. The instant tea is manufactured the Broken Mixed Fannings (BMF) through extraction and other required processes. The average steam consumption of the plant is 6000 kg/h at 10 barg pressure. During the process, tea waste is generated at a nominal rate of 50,000 kg/day, about 2000 kg/h at around 70% MC content on wet basis. At the moment this waste tea is either dumped in the surrounding area by spending money or sent to landfilling purposes, which create environmental issues.   The tea waste coming out at 70% MC wet basis, is looked at to press through continuous belt press to reduce the moisture content to about 55% on wet basis. The water removed from this pressing process is sent to effluent treatment plant at the factory. The output from the belt press is sent to a steam operated  The average generation of tea waste from the instant tea manufacturing process process is about 2000 kg/h, after pressing in the belt press an output rate of about 1,400 kg/h at 55% MC. This amount of tea waste at 55% MC is sent to a rotary steam tube dryer and the MC is reduced from 55% to 30% and the output rate from the steam tube dryer is about 857 kg/h. The amount of steam consumed by the rotary steam tube dryer at 6 barg pressure is 760 kg/h. Then the tea waste from the rotary tube dryer is mixed with firewood of 30% MC and fed to the boiler to generate process steam, out of which 857 kg/h steam at 6 barg pressure is sent back to the rotary steam dryer. From tea waste alone, a steam amount of 2,472 kg/h can be supplied after giving steam to the rotary steam dryer. The balance steam amount of 3,528 kg/h for the process requirement is supplied by burning additional firewood at 30% MC content. The tea waste fuel and firewood in combination have an overall moisture content of 30% on wet basis. The boiler is rated at 10,000 kg/h F & A 100 deg C with an actual generating capacity of about 9000 kg/h at 10 barg operating pressure at 70 deg C feed water temperature. By implementing the combination of belt press, rotary steam tube dryer and firewood boiler in place of the existing furnace oil fired boiler, an annual monetary saving of 168 Mn SLR/year can be achieved with a simple payback period of 21 months which is a highly feasibly project.

The Organic Rankine Cycle (ORC) may be the superior cycle for power generation using low temperature and low power heat sources due to the utilization of high molecular mass fluids with low boiling points. They are flexible, simple, easy to operate and maintain, and offer many possible areas of applications including waste heat recovery and power generation from biomass, geothermal and even solar energy. Therefore, they may prove to be of significant importance in reducing global greenhouse gas emission and in the mitigation of climate change. In this thesis the technical feasibility and economic profitability of implementing an ORC in a district heating boiler station is investigated. A model of ORC connected to the hot water circuit of one of the biomass boilers of the boiler station is simulated. The achieved evaporation temperature is estimated to 135 degrees C and the condensation temperature is found to vary in the range of about 70-100 degrees C. The results show that it is both possible and profitable to implement an ORC in the studied boiler station. A maximum net present value of 2.3 MSEK is achieved for a 400 kW system and a maximum internal rate of return of 8.5%, equivalent to a payback period of 9.5 years, is achieved for a 300 kW system. Furthermore, the investment is found to be most sensitive to changes in the electricity price, net electric efficiency and capital expenditure cost.