Made available in DSpace on 2016-12-23T14:07:27Z (GMT). No. of bitstreams: 1 Dissertacao de Dirceu Soares Junior Parte 1.pdf: 2325132 bytes, checksum: 944653981d05fdcc1c69ff97b342de4f (MD5) Previous issue date: 2011-09-22 / Uma planta siderúrgica caracteriza-se pela existência em seu processo produtivo de cargas não lineares de elevada potência. Dentre estas cargas, as siderúrgicas do tipo mini-mill possuem normalmente Forno Elétrico a Arco (FEA) na sua fase inicial de produção do aço, que ocorre a partir da fusão de sucatas metálicas como principal matéria-prima utilizada. Os fornos elétricos absorvem uma corrente distorcida da rede elétrica, causando assim uma distorção de tensão no ponto de acoplamento comum (PAC) e inúmeros problemas de qualidade de energia elétrica. Uma solução muito utilizada para a mitigação harmônica neste tipo de carga elétrica é obtida através do uso de filtros passivos, com vários estágios de filtragem. Porém esta é uma solução que pode levar ao efeito da ressonância harmônica, elevando com isto a distorção harmônica no sistema elétrico e causando sobrecarga no sistema de filtragem. Neste trabalho é apresentado um estudo de caso em uma siderúrgica não integrada (siderúrgica que possui sucata metálica e ferro gusa como matérias-primas principais na fabricação do aço), localizada na região da Grande Vitória. Por meio de medições na subestação principal da usina, são apresentadas as principais formas de onda das correntes e tensões, em conjunto com seus espectros harmônicos, que comprovam a existência de distorções harmônicas, sobretudo provenientes da corrente do forno elétrico a arco. As medições consideradas no trabalho, para simulação dos modelos contendo os filtros híbridos, foram aquelas originadas da condição operacional mais crítica do processo, sob o ponto de vista de momento onde o comportamento da carga acarreta o maior desvio quanto à qualidade de energia nas variáveis elétricas medidas. O modelo utilizado para o sistema em questão apresenta forte grau de correlação com o sistema real, retratado através das medições elétricas efetuadas. De posse do modelo é realizada uma análise comparativa por meio de simulação entre duas topologias de filtragem híbrida, o filtro híbrido série e o filtro híbrido paralelo, para a compensação harmônica e amortecimento da ressonância. Os resultados das simulações e das análises das ressonâncias mostraram que o filtro híbrido paralelo é a topologia que permite a maior redução das distorções harmônicas de corrente e de tensão no PAC, utilizando-se um filtro ativo com a menor potência nominal. Contudo, a filtragem híbrida paralela não provê a eliminação por completo da ressonância paralela. E, quanto à ressonância série, o filtro utilizado não possui a capacidade de interferir na condição de amplificação harmônica existente no sistema elétrico. Finalmente, o estudo propõe que a definição da melhor alternativa de filtragem leve em consideração a escolha do ganho do filtro ativo e, consequentemente, a sua potência, de forma bem alinhada aos objetivos de melhoria na qualidade de energia elétrica que são esperados para o sistema em questão / A steelmaking plant is characterized for having in its productive process non linear loads of high power. For these loads, the steelmaking industries called mini-mill normally have Electric Arc Furnace (EAF) in its initial steel production phase that happen with metallic scrap melting being the principal raw material used. The EAF absorb a distorted current from the electric main, causing voltage distortion in its point of common coupling (PCC) and many problems with respects the electric power quality. A standard solution used for the harmonic mitigation in this application is obtained through the use of composite passive filter. However this is a solution that can cause harmonic resonance, increasing the harmonic distortion in the electrical system and causing overload in the filtering system. In this work, a case in a non integrated steel industry, located at Grande Vitoria region, is presented. Through measurements in the main substation of the plant, the main current and voltage waveforms are presented, along with its harmonic spectrum, that confirm the existence of harmonic resonance phenomenon, mainly from Electric Arc Furnace current. The measurement considered in this work to simulate the hybrid filters models, was that originated from operational condition with higher process criticism, under viewpoint of the moment where the behavior of the load brings to a major deviation regarding the power quality at the measured variables. The model used for the system under study shows strong correlation with the real system portrayed through the electrical measurements done. Using the model, a comparative simulation analysis is done, between two hybrid topologies, the series hybrid filter and the parallel hybrid filter, with the objective of harmonic compensation and resonance damping. The results of simulations and resonance analysis showed that the parallel hybrid filter is the topology that allows the greatest reduction in harmonic distortion of current and voltage in the PCC (Point of Common Coupling), using an active filter with the lowest nominal power rating. However, the parallel hybrid filtering does not provide the complete elimination of parallel resonance, and for the series resonance, the filter used does not have the ability to interfere in the harmonic amplification condition existing in the electrical system. Finally, the study proposes that the best filtering alternative takes into account the choice of the active filter gain and consequently its power, so well aligned with the objectives of improving the power quality that are expected for the system under analysis

Submitted by Silvana Teresinha Dornelles Studzinski (sstudzinski) on 2016-12-22T12:03:13Z No. of bitstreams: 1 Josué Claudio Metz_.pdf: 3580473 bytes, checksum: 4bb7f81d4d0a95ef4e39a7d4dffb0599 (MD5) / Made available in DSpace on 2016-12-22T12:03:13Z (GMT). No. of bitstreams: 1 Josué Claudio Metz_.pdf: 3580473 bytes, checksum: 4bb7f81d4d0a95ef4e39a7d4dffb0599 (MD5) Previous issue date: 2016-09-19 / Nenhuma / A concepção de desenvolvimento sustentável tem resultado no aumento de pressões ambientais para a melhoria da eficiência na utilização de recursos, e para a redução das emissões e da geração de resíduos. No processo de fabricação de aço, nas siderúrgicas com fornos elétricos a arco (FEA), ocorre a geração do resíduo sólido denominado pó de aciaria elétrica (PAE). O PAE é constituído por diferentes óxidos metálicos. Contém os elementos químicos cromo (Cr), chumbo (Pb) e cádmio (Cd) e, por isso, é classificado como resíduo classe I – Perigoso pela NBR 10004. Gerado em grandes quantidades diariamente em todo o país, o PAE ainda tem como principal destinação final o aterro industrial. A indústria de papel e celulose, outra atividade de destaque na indústria nacional, gera uma grande quantidade de resíduos em diferentes etapas do processo, entre os quais está o resíduo do forno de cal (RFC), cuja geração está associada a interrupções no funcionamento do forno de cal. A indústria da construção civil, devido a quantidade de matérias-primas consumida e variedade de materiais empregados – cimento, concreto, agregados, cerâmica, entre outros – apresenta-se como alternativa para a reciclagem de resíduos gerados em outros setores da economia. A incorporação do PAE no cimento e concreto produz retardo no tempo de pega em razão da presença de zinco (Zn) no resíduo. Estudos sugerem que em quantidades próximas a 1%, a incorporação de PAE não afeta de forma significativa as propriedades do cimento. O objetivo deste trabalho foi avaliar a influência do uso combinado de PAE e RFC no processo de endurecimento e evolução da hidratação de pastas de cimento. Para tanto, foi realizada a caracterização dos resíduos através dos ensaios de distribuição granulométrica, perda ao fogo, massa específica, área superficial específica, análise química elementar, difração de raios X com refinamento por Rietveld e microscopia eletrônica de varredura. A influência dos resíduos nas pastas de cimento foi avaliada através do ensaio de tempo de pega de acordo com a NBR NM 65 (ABNT, 2003b) e evolução da temperatura semi-adiabática das pastas em estado fresco, além de DRX, com refinamento por Rietveld, e microscopia eletrônica de varredura nas pastas de cimento com diferentes teores de substituição de resíduos (REF, 1%, 2%, 3%, 5% e 10%) em diferentes idades (1, 4 e 7 dias). Os resultados de tempo de pega e evolução da temperatura semi-adiabática indicaram a influência do PAE na hidratação das pastas de cimento. Nas pastas de cimento com substituição de 1% de PAE combinado ou não com RFC, não foram verificados retardos significativos no tempo de pega, demonstrando o potencial do uso de PAE e do RFC na produção de artefatos de cimento. / The sustainable development conception has resulted in increased environmental pressures to improve the efficient use of resources and reduction of emissions and waste generation. In the steelmaking process through electric arc furnaces (EAF), dust generation occurs which is called electric arc furnace dust (EAFD). EAFD is composed by different metal oxides. Some common elements those constitute this dust is chromium, lead and cadmium, and therefore, waste is classified as class I – hazardous by NBR 10004. EAFD has been generated in large quantities every day across the country and it still has mainly landfilled. The pulp and paper industry, another important activity in the domestic industry, generates a lot of waste in different stages of the process, among which is the lime kiln waste (LKW), whose generation is associated with disruptions in the lime oven. Due to expressive amount of raw materials consumed in civil construction industry and also the variety of products available - cement, concrete, aggregates, ceramics, among others - this seems to be an alternative for waste recycling generated in other sectors. The incorporation of EAFD in the cement and concrete produces delayed setting time due to the presence of zinc (Zn) in the waste. Studies suggest that in amounts up to 1%, EAFD incorporation does not affect significantly cement properties. The aim of this work was to evaluate the influence of the combined use of EAFD and LKW in the process of hardening and evolution of the cement pastes hydration. Therefore, were evaluated the characterization of the waste performed through the grain size distribution, loss on ignition, specific gravity, specific surface area, elemental chemical analysis, pH, X ray powder diffraction with refinement by Rietveld and scanning electron microscopy.. The influence of the waste on the cement pastes was evaluated through the setting time tests in accordance with the NBR NM 65 (ABNT, 2003b) and evolution of semi-adiabatic temperature in fresh conditions, XRD with refinement by Rietveld, and SEM in cement pastes with different levels of waste substitution (REF, 1%, 2%, 3%, 5% e 10%) at different ages (1, 4 and 7 days). The setting time results and evolution of semi-adiabatic temperature indicated an increase in the setting time with the increase of the EAFD in cement pastes. In cement pastes with replacement of 1% EAFD combined or not with LKW, significant delays were not verified in the setting time, demonstrating the potential use of EAFD in the production of cement artifacts.

Η επεξεργασία των νικελιούχων λατεριτικών μεταλλευμάτων της χώρας μας για την παραγωγή σιδηρονικέλιου στη Λάρυμνα συνοδεύεται με την εκπομπή 200000t/y λεπτομερούς σκόνης που συλλέγεται στα συστήματα αντιρρύπανσης των περιστροφικών κάμινων (Π/Κ), μέσης περιεκτικότητας 1.2-1.5% σε Ni και 4-5% σε C. Η διατριβή αυτή συνέβαλε στην ανάπτυξη μεθόδου ανακύκλωσης της σκόνης αυτής με απευθείας αναγωγική της τήξη σε ηλεκτρική κάμινο συννεχούς ρεύματος (DC-HEP) με εμφυσησή της μέσω του κεντρικού διάτρητου γραφιτικού ηλκετρόδιου. Την προκαταρκτική θεωρητική διερεύνηση και τις εργαστηριακές προδοκιμές ακολούθησαν βιομηχανικές δοκιμές στην κάμινο 125t DC-HEP στη χαλυβουργία Georgsmarienhutte της Γερμανίας, όπου έλαβε χώρα τήξη 70t σκόνης και 2.5t φιλομερούς μεταλλεύματος.Η ανάκτηση Ni ήταν πολύ υψηλή 93-99%. Παρήχθησαν χάλυβες χαμηλής κραμάτωσης σε σε Ni καθώς και ποικίλοι τύποι σκωρίας προς διερεύνηση της χρήσης τους στην παραγωγή σύνθετων τσιμέντων Portland και σκωριωτσιμέντων. Πραγματοποιήθηκε μεταλλουργική αξιολόγηση των δοκιμών και αναπτύχθηκε μοντέλο προσομοίωσης της αναγωγικής τήξης της σκόνης. / The tratment of the laterite nickel ferrous ores in Hellas for the production of ferronickel at Larymna is associated with the emission of 200000t/y of fine dust collected in the gas cleaning systems of the rotary kilns (R/Ks), with 1.2-1.5% and 4-5% . Average Ni and C contents respectively . This thesis contributed to the development of a method for the recycling of this dust by means of its direct reduction smelting in a DC-HEP furnace (Direct Current-Hollow Electrode Powder) by its injection through the central hollow graphite electrode. The preliminary theoretical study and the laboratory trials were followed by industrial heat campaigns in the 12st DC-HEP furnace at georgsmarienhutte steelwork in Germany, where around 70t of dust and 2.5t of ore fines were smelted. The Ni-recovery was very high 93-99.9%. Low Nickel alloyed steel grades were produced and various slag types for the investigation of their utilization for the production of composite-portland cements and slag cements. The metallurgical evaluation of the trials was performed and model for the dust reduction smelting process was developed.

Le mécanisme de la transition préarc-arc dans les éléments de coupure du type fusible est encore mal connu à ce jour. La compréhension du phénomène requiert encore de nombreuses données fondamentales tels que la température ou la densité des vapeurs métalliques créées. Des hypothèses sont avancées pour expliquer la différence du temps de préarc prévue par les modélisations effectuées au sein du LAEPT avec celui constaté lors des expérimentations menées dans ce même laboratoire. Cet ouvrage tente de les vérifier par une approche expérimentale menées sur des fils explosés et des rubans fusibles. L’étude expérimentale est complétée par une recherche bibliographique sur les fils explosés. Ce complément propose de nouvelles pistes d’investigation pour la compréhension de l’amorçage de l’arc électrique sur les rubans fusibles. Enfin, toutes les méthodes de diagnostic et les grandeurs obtenues dans les tests les plus représentatifs sont données en fin d’ouvrage. / Transition between prearcing and arcing stage remains not well known. Several fundamental data are needed as temperature or density of metalic vapour created to better understand the phenomenon. Hypothesis are mentioned to explain the difference of prearc time between modelisations and experiences that have been made in LAEPT. This study try to verificate them among experiences made on exploding wire and fuses ribbon. Experimental study is completed by a bibliographic review on exploding wires. This review permits to show other lines of investigation to understand the transition between prearcing and arcing stage on fuses ribbon. Finally, all the methods of diagnostic and the results obtained with the most representative tests are given at the end of the thesis.

No description available.

The process industries span multiple industrial sectors and constitute a substantial part of the entire manufacturing industry. Since companies belonging to this family of industries are often very asset intensive, their ability to respond to changes is often limited in the short term. The adaptation of the capabilities of existing processes, and conversely finding products and market segments to match the production system capabilities, are an important part of product- and market development activities in the process industry. The importance to companies in the process industry of having a well-articulated manufacturing strategy congruent with the business strategy is second to none. However, to facilitate manufacturing strategy developments, it is essential to start with an improved characterization and understanding of the material transformation system. To that end an extensive set of variables was developed and related measures and scales were defined. The resulting configuration model, focusing on company generic process capabilities in the process industries, is to be regarded as a conceptual taxonomy and as a proposition available for further testing. The usability of the model was subsequently assessed using “mini-cases” in the forestry industry, where the respondents confirmed that the company’s overall strategy could benefit from this kind of platform as a possible avenue to follow. The model was deployed as an instrument in the profiling of company material transformation systems to facilitate the further development of companies' functional and business strategies. The use of company-generic production capabilities was studied in three case companies representing the mineral, food and steel industries. The model was found by the respondents to be usable as a knowledge platform to develop production strategies. In the final analysis of the research results, a new concept emerged called “production capability configuration": A process-industrial company’s alignment of its generic production capabilities in the areas of raw materials, process technology and products to improve the consistency among the variable elements that define operations and improve the congruence between operations and its environment. From the perspective of value creation and capture, firms must be able to manufacture products in a competitive cost structure within the framework of a proper business model. By using the configuration model, the relationship between manufacturing and innovation activities has been studied in the previously mentioned three case studies. In many cases the gap in capability appears as a limitation in the production system, requiring development efforts and sometimes investments to overcome. This is illustrated with two examples from the steel industry, where development efforts of the production system capabilities are initiated to better match the market demands. One example is the increase the volume- and product flexibility of an existing stainless steel melt shop, resulting in a proposed oblong Argon Oxygen Decarburisation (AOD) converter configuration that was subsequently verified using water modelling. The second example is from a carbon steel mill, where the target was to increase the raw material- and volume flexibility of another melt shop, by modifying the capabilities of the Electric Arc Furnace (EAF). Enabling EAF technologies are further described and evaluated using operational data and engineering type of estimates. / <p>QC 20170116</p>

This diploma thesis is resolving all the possibilities of enhancing the efficiency of furnace structures welding. Small batch production does not offer many possibilities for implementing mechanization or automation. On the other hand, when using a big batch production, efficiency can be enhanced by means of a robotic workstation. When the production batch is big enough, we will see a costs save after a short time, mainly in labor costs. This means the return of investments will be in short time period. In the LAC company there are three types of products made. At laboratory furnaces the efficiency can be enhance by using fixtures. At other standard and atypical furnaces is very difficult to design fixtures or positioners because of their different sizes. Big complication can be also a company location on second floor. The most suitable product regarding to welding efficiency enhancement is big batch production of heaters. For this type the welding time can be shortened by means of a robotic workstation.

Diploma thesis describes design and function verification of device for filling tap hole of electric arc furnace with tap hole diameter from 190 mm to 250 mm. The theses includes drive design calculation of chute swinging movement and bearing calculations. Another part of the thesis deals with verification of device functions which it is completed with process description of creating DEM simulation in program YADE. The thesis also includes basic experiments for determination angle of internal friction, angle of repose, coefficient of restitution and angle of material friction on a steel surface. Drawing documentation of selected assemblies is part of the thesis.

This master´s thesis si focused on determinig methodology of optical diagnostics of the switching arc using the high-speed camera Photron SA-X2. The thesis contains basic rules for proper setup of the measurement system and the rules to adjust the camera exposure. The experiments were performed on the prototype of a parametric switching chambre, while the majority of source materials was derived from the requirements of another study which was aimed on the movement of the electode spots. The process of the first adjustment of the camera, a record edit options for the presentation purposes and the process of the 3D model design of the switching arc in SketchUp software was stated. Paper contains a comparsion of the spectral filter effect and neutral density filter effect on the final record as well. The part of the work outputs are the 3D model of the switching arc and the supporting record editing software. The paper results show a degree of the inaccuracies in a optical diagnostics made from only one direction caused by the lack of the information about third dimension.

Thesis focuses on the basic characteristics of plasma, problems about origin of electrode spots and electrodynamics force acts on the electric arc. In the practical part was realized and produced model of a LV quenching system. Using optical diagnostics was received necessary data to analyze the movement of the electrode spots. The movements of the electrode spots were analyzed in terms of value RMS current passing through the electric arc, value of absolute pressure model in the LV quenching system and distance from each electrode.