M.Phil. / The aim of this research is to study the underhood airflow thermal behaviour of the extra low profile (XLP) dozer due to the excessive heat dissipated and observed during testing sessions executed at ground level, using computational fluid dynamics (CFD). The motivation of this project is to identify the reasons of poor cooling performance of this equipment, to develop and to demonstrate the capabilities of CFD in thermal research by validating the CFD result with experiments using a scaled model, prior to analyzing the full-scale dozer ...

Resumo: Em alguns tipos de indústria, como por exemplo a de laticínios, bebidas e frigoríficos, o sistema de refrigeração é responsável por uma parcela significativa no consumo de energia elétrica. Tendo como objetivo a redução deste consumo, foi realizado um estudo de caso em uma indústria produtora de bebidas, sendo analisados todos os componentes do sistema de refrigeração. O sistema de refrigeração analisado utiliza amônia anidra (NH3) como fluido refrigerante no circuito principal e solução de etanol no circuito secundário, sendo composto por compressores do tipo parafuso, condensadores evaporativos, evaporadores de placas, conjunto de bombas e válvulas expansoras com controle eletrônico. Usualmente, os sistemas de refrigeração atendem diversos processos e etapas de produção, que diferem nos requisitos de temperatura de produto. Além disso, por serem projetados para atender a maior demanda esperada, constituem uma grande oportunidade de otimização nos períodos fora de pico de consumo. Foram descritos e detalhados os componentes do sistema de refrigeração, bem como todas as ações e requisitos necessários para melhoria na eficiência energética da instalação. A implementação destas ações de melhoria de eficiência na planta industrial estudada contou com um investimento total de R$ 302.000,00, e foram responsáveis por um ganho anual de R$ 241.000,00, correspondentes a uma redução no consumo elétrico de 1,7 GWh/ano. O payback simples, portanto, é de 1,25 anos / Abstract: In some types of industry where cooling systems are required, for example, dairy products, beverages and frozen foods, the cooling system is responsible for a significant portion of electricity consumption. Aiming to reduce this consumption, a case study was performed in a beverage industry, and all the refrigeration systems components were analyzed. The cooling system operates using anhydrous ammonia (NH3) as the refrigerant in the main circuit and ethanol solution in the secondary circuit, it consists of screw compressors, evaporative condensers, plate and frame coolers, pumps and expansion valves with electronic control. Usually, refrigeration systems have several processes and production stages to meet for different products, depending on the products temperature requirements. Moreover, they are designed to attain the highest demand expected, which gives a great opportunity to optimize the off-peak periods of consumption. We have described and itemized whole refrigeration systems components, as well as all actions and requirements to improve the energy efficiency of the installation. The energy efficiency improvements actions that were implemented in this industrial plant study had a total investment of R$ 302,000.00. These improvementes resulted in an annual saving of R$ 241,000.00, as well a relative a reduction in electricity consumption of 1,7 GWh/year. Therefore, the simple payback is 1.25 years / Orientador: Pedro Magalhães Sobrinho / Coorientador: José Luz Silveira / Banca: José Alexandre Matelli / Banca: Christian Jeremi Coronado Rodriguez / Mestre

Doctor of Philosophy / This research aimed to develop new cooling methods to replace, or at least minimise, the use of currently used grinding coolants which are known to be harmful to the environment. The methods used involved the application of a cold air and vegetable oil mist mixture (CAOM), and the use of liquid nitrogen as cooling media. Allied research focused on the development of a segmented grinding wheel equipped with a coolant chamber. The feasibility of a grinding system using CAOM was assessed on the surface grinding of plain carbon steel 1045. It was found that at low material removal rates, ground surfaces were obtained with a quality comparable to that from grinding with a conventional coolant in association with a reduction of grinding forces. There was no significant difference in the subsurface hardness of the components using CAOM, although the latter method showed a stronger dependence of surface residual stresses on the depth of cut due to the limit in cooling capacity of CAOM. The effects of using liquid nitrogen as a cooling medium on the microstructure of quenchable steel were explored. It was found that a martensite layer was induced on the ground surface. The microstructure featured a dispersion of very fine carbides within the martensite lattice, resulting in a remarkable increase in hardness and high compressive residual stresses within the layer. The topography of the ground surfaces indicated that the material was predominantly removed by brittle fracture. Furthermore surface oxidisation was suppressed. In the interest of coolant minimisation, a segmented wheel equipped with a pressurized coolant chamber was developed. A higher quality ground surface was obtained in conjunction with a coolant saving of up to 70%. In addition, the adhesion of ground chips on the wheel surface largely disappeared. Furthermore, surface tensile residual stresses caused by thermal deformation were minimised. The mechanism of coolant disintegration to form mists using this type of wheel system was studied. The Weber theory for Newtonian jet instability was applied to quantitatively determine the contribution of coolant flow rate to mist and ligament modes. A semi-analytical model was then developed to predict the mist flow rate by taking into account both grinding parameters and coolant properties. The model prediction was in agreement with experimental measurements. Based on the principles of fluid motion and the mechanisms of spin-off and splash, analytical models for both conventional and segmented wheels were established to provide a physical understanding of the mechanisms of coolant penetration into the grinding zone. Coolant minimisation was evident using the segmented wheel where the coolant pumping power into the grinding zone increased with wheel speed, but for the conventional wheel it decreased. A quantitative analysis was developed that accounted for the coolant properties and system design characteristics governing the penetration mechanism revealed by the theory established above. In conjunction with the mist formation analysis, the developed model offers a practical guideline for the optimal use of grinding coolants in achieving a balance between the demands of productivity and care for the environment.

This work addresses the problem of using seawater for cooling and the associated environmental problems caused by the usage and discharge of biocides. The discharged biocide and its byproducts are toxic to aquatic lives and must be decreased below certain discharge limits on load prior to discharge. The conventional approach has been to add biocide removal units as an end-of-pipe treatment. This work introduces an integrated approach to reducing biocide discharge throughout a set of coordinated strategies for inplant modifications and biocide removal. In particular, process integration tools are used to reduce heating and cooling requirements through the synthesis of a heat-exchange network. Heat integration among process of hot and cold streams is pursued to an economic extent by reconciling cost reduction in utilities versus any additional capital investment of the heat exchangers. Other strategies include maximization of the temperature range for seawater through the process and optimization of biocide dosage. This new approach has the advantage of providing cost savings while reducing the usage and discharge of biocides. A case study is used to illustrate the usefulness of this new approach and the accompanying design techniques.

Mine cooling system components are an integral part of a mine‟s ventilation system. A mine‟s reliance on these capital intensive components are set to increase as mines deepen. Mine cooling systems consume up to a quarter of the electricity used on mines. Component efficiency should be monitored to ensure optimum utilisation. Downtime should be minimised so that production is not negatively influenced. Replacing expensive components in an age of severe economic pressure should be avoided altogether. In this study, the performance of mine cooling system components was monitored. The effects of various operational and maintenance interventions on component performance have been quantified. Quantifying the effects of management decisions led to the refining of operational procedures, the optimisation of future maintenance, and the subsequent identification of electrical energy savings potential without the need for expensive modifications. Investigations show that a mine could realise a saving of up to nine hundred thousand rand annually by optimising the maintenance schedule of chillers. Extrapolated results estimate an electrical energy saving of 52 127 MWh per year if the strategy were implemented on twenty of South Africa‟s biggest mines. In addition, a monetary saving in excess of five hundred thousand rand could be saved through refining operational procedures. These strategies will be possible without the need for expensive installations or complicated modifications. Monitoring cooling system performance allows management to identify trends in performance, to understand component inter-dependence, and to allow for informed decision-making. In addition, performance monitoring allows for the identification of component and instrumentation faults. Statistical control charts and simulation modelling are some of the tools that have been employed in this study. These tools assist management formulate strategies and decisions with a higher degree of confidence. / MIng (Mechanical Engineering), North-West University, Potchefstroom Campus, 2014

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Doctor of Philosophy / This research aimed to develop new cooling methods to replace, or at least minimise, the use of currently used grinding coolants which are known to be harmful to the environment. The methods used involved the application of a cold air and vegetable oil mist mixture (CAOM), and the use of liquid nitrogen as cooling media. Allied research focused on the development of a segmented grinding wheel equipped with a coolant chamber. The feasibility of a grinding system using CAOM was assessed on the surface grinding of plain carbon steel 1045. It was found that at low material removal rates, ground surfaces were obtained with a quality comparable to that from grinding with a conventional coolant in association with a reduction of grinding forces. There was no significant difference in the subsurface hardness of the components using CAOM, although the latter method showed a stronger dependence of surface residual stresses on the depth of cut due to the limit in cooling capacity of CAOM. The effects of using liquid nitrogen as a cooling medium on the microstructure of quenchable steel were explored. It was found that a martensite layer was induced on the ground surface. The microstructure featured a dispersion of very fine carbides within the martensite lattice, resulting in a remarkable increase in hardness and high compressive residual stresses within the layer. The topography of the ground surfaces indicated that the material was predominantly removed by brittle fracture. Furthermore surface oxidisation was suppressed. In the interest of coolant minimisation, a segmented wheel equipped with a pressurized coolant chamber was developed. A higher quality ground surface was obtained in conjunction with a coolant saving of up to 70%. In addition, the adhesion of ground chips on the wheel surface largely disappeared. Furthermore, surface tensile residual stresses caused by thermal deformation were minimised. The mechanism of coolant disintegration to form mists using this type of wheel system was studied. The Weber theory for Newtonian jet instability was applied to quantitatively determine the contribution of coolant flow rate to mist and ligament modes. A semi-analytical model was then developed to predict the mist flow rate by taking into account both grinding parameters and coolant properties. The model prediction was in agreement with experimental measurements. Based on the principles of fluid motion and the mechanisms of spin-off and splash, analytical models for both conventional and segmented wheels were established to provide a physical understanding of the mechanisms of coolant penetration into the grinding zone. Coolant minimisation was evident using the segmented wheel where the coolant pumping power into the grinding zone increased with wheel speed, but for the conventional wheel it decreased. A quantitative analysis was developed that accounted for the coolant properties and system design characteristics governing the penetration mechanism revealed by the theory established above. In conjunction with the mist formation analysis, the developed model offers a practical guideline for the optimal use of grinding coolants in achieving a balance between the demands of productivity and care for the environment.

Master of Science / Department of Architectural Engineering and Construction Science / Charles L. Burton / Ground source heat pump systems have been around for nearly 50 years. The efficiencies that can be achieved today are difficult to match with any other type of heating and air conditioning system. With the familiarity of the system, installed costs have become very reasonable, and in some cases have been the same or less expensive than other comparable systems. Given all this, the question remains – why aren't more of these systems being proposed and installed? This report will investigate some of the reasons why and what can be done to remedy them. Major issues include professional education, availability of research and design material, industry or governmental incentives, and education in our K-12 schools and universities. Certainly all participants in the design process, from the designer to the owner, play a part in this dilemma. Recommendations will be made that address key hurdles this industry faces regarding making ground source heat pumps the system of choice.

The modelling and control method of a vehicle climatronic system, based on MATLAB/SIMULINK, is presented. In order to achieve high modelling accuracy, a developed simulation model library is introduced. The modelling approach is described and the developed models are validated with some of experimental data obtained. The models are nonlinear, independent of fluid type and based on thermo-dynamic principles. Analysis of the cooling circuit modelling and empirical real-time control models are created by using Fuzzy logic controller and Stateflow. Both of control input and output are implemented essentially at original vehicle CAN-Bus system. Feasible digital automatic control strategy basic to fuzzy theory, hardware and software solution are given. The simulation experiment is achieved with the Hardware-in-Loop technology. This control methodology is easily operated and worth applying for any further studies or methods.

Climatic conditions inside the dairy barn do not concern dairy farmers until those conditions begin to affect productivity and, consequently, profits. As heat and humidity increase beyond the cow's comfort levels, milk production declines, as does fertility and the welfare of the cow in general. To reinforce the cooling mechanisms currently used, this work proposes an alternative system for reducing the risk of heat stress. This innovative conductive cooling system does not depend on current weather conditions, and it does not require significant modifications when it is installed or during its operation. Also, the system circulates water that can be reused. Given that a review of the literature found very few related studies, it is suggested that each freestall be equipped with a viable prototype in the form of a waterbed able to exchange heat. Such a prototype has been simulated using Computational Fluid Dynamics (CFD) and later verified by a set of experiments designed to confirm its cooling capacity. Furthermore, this investigation sets the foundation for modeling temperature in a water supply system linked to the waterbeds. EPANET, a software program developed by the Environmental Protection Agency, simulates the hydraulic model. Its Water Quality Solver has been modified according to an analogy in the governing equation that compares mass to heat transfer and serves to simulate water temperature as the water is transported from its source to the point of delivery and then as it returns to the same source.