Le rejet des nutriments (phosphates et nitrates) issues des eaux usées domestiques entraînent la dégradation des écosystèmes (74 % du territoire français concerné en 2006). Compte tenu de la situation, l’Etat français a promulgué la Loi sur l’Eau et les Milieux Aquatiques le 30décembre 2006 qui vise à atteindre le « bon état écologique des eaux et des milieux aquatiques » d’ici 2015. Cette notion bien que difficilement intégrable a généré des normes plus strictes pour les stations d’épuration en termes de rejet de nutriments vers le milieu récepteur (jusque 15 mg NTOT.L-1 et 2 mg PTOT.L-1). Depuis la fin des années 1990, la technologie des filtres plantés de roseaux (FPR) est de plus en plus employée(> 2500 unités en 2012) pour le traitement des eaux usées domestiques des petites collectivités inférieures à 2000 Equivalent-Habitants. Cependant, des limites de traitement existent sur les concentrations résiduelles en azote (rejet de 70-80 mg NTOT.L-1) et en phosphore (rejet> 10 mg PTOT.L-1), en vue de répondre à la réglementation future. Ce travail a eu pour objectif de mettre en oeuvre des améliorations telles que la recirculation sur un étage de traitement pour le traitement de l’azote d’une part et l’emploi de matériaux réactifs pour piéger le phosphore d’autre part. La démarche scientifique expérimentale déployée a consisté à suivre des pilotes sur site réel et en laboratoire pendant 2 années. Le suivi des performances épuratoires et hydrauliques a été réalisé au cours du temps. Pour l’azote, 2 FPR (2,5 m²) garnis de schiste expansé (Mayennite®) ont été alimentés en effluent brut. L’effet de la hauteur de saturation en eau dans la partie drainante ainsi que l’effet de la recirculation ont été étudiés. Les résultats obtenus ont montré : une couche saturée à 38 % (rapporté à la hauteur totale) et un ratio de recirculation de 100 % permettent une meilleure élimination de la matière particulaire-carbonée (Arrêté du22 juin 2007) et de l’azote (< 20 mg NTK.L-1 ; < 45 mgNTOT.L-1). Deux laitiers de four à arc électrique ont été sélectionnés pour le traitement du phosphore. Ceux-ci ont été mis en œuvre dans 5 colonnes (6 L) en laboratoire alimentées en effluent synthétique en phosphore puis secondaire et dans 4 filtres réactifs pilote (0,3 m² ; 34 L) à flux horizontal sous surfacique alimentés en effluent secondaire. Il ressort de ces expériences: (i) des disparités existent entre les deux échelles en termes de performances (< 2 mg P.L-1 pendant 20 mois en colonne et variation saisonnière des performances en pilote) et mécanismes épuratoires (adsorption/précipitation P-Caen colonne ; P-Ca + P-Fe en pilote), (ii) l’augmentation de la température (> 15 °C) et/ou du temps de séjour (48h et plus) améliore la cinétique d’élimination du phosphore à échelle pilote et (iii) l’implantation d’un filtre réactif garni de laitier de four à arc électrique est limité par le degré de traitement souhaité et la distance du futur chantier (coût du transport). / Nutrient (phosphorus and nitrogen) discharges from wastewater lead to water quality degradation (74 % of the total French territory in 2006). According to the actual situation, the French government has adopted a Water Framework on December 30, 2006 to achieve a“good ecological status of water” in 2015. Therefore,more stringent standards on nutrients removal for raw wastewater treatment plants are expected (down to 15mg TN.L-1 and 2 mg TP.L-1). However, standards actually remain under the responsibility of departmental authorities according to the water quality of the receiving environment. Since 1990s, Vertical Flow Constructed Wetlands(VFCWs) have been more and more popular in treating raw domestic wastewater for small collectivities of less than 2000 person equivalent (> 2500 units in 2012). However, nitrogen and phosphorus removal are limited in VFCWs (70-80 mg TN.L-1; > 10 mg TP.L-1) according to the new legislation. The aim of this work was on the one hand to implement a recirculation of treated effluent on a VFCW for better nitrogen removal and on the other to use reactive materials to improve phosphorus removal. The experimental scientific approach consisted in monitoring both laboratory and field pilot scale systems under process conditions during 2 years. Treatment and hydraulic performances were monitored over time. Two VFCWs (2,5 m²) filled with expanded schist (Mayennite®) were fed with raw domestic wastewater. The effect of a saturated layer and of the recirculation of treated effluent were studied. Results showed that 38 % of a saturated layer and 100 % of recirculation enabled to improve nitrogen treatment performances (< 20 mgTKN.L-1; < 45 mg TN.L-1) and to meet the French standard D4. Electric arc furnace slags were selected as reactive materials to improve phosphorus treatment performance of the VFCWs in laboratory and field pilot scale systems. Five laboratory-scale column experiments (6L) were fed with a phosphorus synthetic effluent then with a secondary effluent. Four horizontal subsurface flow active filters (0,3 m²; 34 L) were fed with a secondary effluent. The main results showed : (i)differences exist between laboratory and pilot scale regarding treatment performance (< 2 mg P.L-1 during20 months in the laboratory ; seasonal variations at pilot scale) and removal mechanisms (adsorption/precipitation Ca-P in laboratory ; Ca-P + Fe-P at pilot scale), (ii) an increase of temperature (> 15°C) and/or hydraulic retention time (more than 2 days) improved the kinetics of phosphorus removal at pilot scale, (iii) the active filter implementing is limited by the discharge standard required (> 3 mg PTOT.L-1) and the distance to the steel factory (transport costs).

O pó de forno elétrico a arco (FEA) é gerado durante a fusão de sucata ferrosa nos fornos elétricos a arco e coletado predominantemente através de filtros de mangas. Esta substância é listada como resíduo sólido perigoso de fonte específica, K061, conforme a Norma ABNT NBR 10004:2004. As maiores empresas siderúrgicas semi-integradas do mundo têm adotado para o tratamento de pó de FEA, fundamentalmente três rotas: a recuperação de zinco e chumbo, através de dois processos complementares, um piro-metalúrgico, o Wäelz kiln e outro hidro-metalúrgico, o processo de dupla lixiviação Óxido de Wäelz; a inertização através da blendagem com a cal, aditivos e água, de forma a alcançar o pH da mistura >11, o que garante que metais pesados como o chumbo, cádmio e o zinco, presentes no pó de forno elétrico, não possam se tornar solúveis, evitando consequentemente, a sua lixiviação e a disposição em aterros industriais de resíduos sólidos perigosos. Sob a perspectiva da sustentabilidade, deve ser considerada a rota da recuperação de zinco e chumbo, que para ser viável necessita reunir a geração de pó de FEA de varias plantas, o que para um país com dimensões continentais pode ser um fator de insucesso. Esse trabalho trata da reciclagem do pó de FEA através do processo de sinterização de um compósito constituído de pó de FEA aglomerado com coque, carepa e fluorita cerâmica em pelotas, aplicável a uma planta unitária. Como resultado deste processo foram obtidos dois coprodutos, o aglomerado pré-fundido, APF, com teor de óxido de ferro superior a 70%, objeto do processo de sinterização e o concentrado de zinco, com teor de óxido de zinco maior que 50%, resultante da volatilização deste metal durante o processo de sinterização e coletado através de filtro de mangas. Complementarmente foi extraído aproximadamente 90% dos óxidos de chumbo e cádmio contidos no pó de FEA inicial. A produção do APF ocorreu em escala experimental dividida em três fases, a primeira fase foi efetuada com oito formulações distintas e comprovou através de análises químicas de espectrometria por fluorescência de raios X e difratometria de raios X, a viabilidade técnica da utilização somente de resíduos sólidos industriais para fabricação do APF. A segunda fase, também com oito formulações, definidas conforme planejamento de experimentos com delineamento fatorial, teve como objetivo identificar os principais efeitos das interações entre os componentes do APF, para obtenção da mistura com formulação ótima. A terceira fase testou a intensidade das variáveis, coque e fluorita cerâmica, para a extração do zinco. As duas primeiras fases dos testes de produção em escala experimental foram realizadas em uma planta piloto de sinterização de fluxo descendente e a terceira fase em uma planta piloto de fluxo ascendente, ambas instaladas na usina ArcelorMittal Piracicaba. O APF, com a formulação ótima, foi produzido em escala industrial na planta de sinterização Metalflexi, também instalada na usina ArcelorMittal Piracicaba, e testado em alto-forno de pequeno porte. O concentrado de zinco foi caracterizado quimicamente para se avaliar o uso em segmentos industriais que utilizem este elemento. / The electric arc furnace (EAF) dust is generated during melting of steel scrap in electric arc furnaces and collected mainly through bag filters. The EAF dust is listed as hazardous waste from specific source, K061, according to ABNT 10004:2004. The major semi-integrated steel companies in the world have adopted for the treatment of EAF dust, basically three routes: the recovery of zinc and lead, through two complementary processes, a pyro-metallurgy, Waelz kiln and other hydro-metallurgical the leaching process of double oxide Waelz; the blanketing by blending with lime, water and additives in order to achieve the pH of the mixture>11, which ensures that heavy metals like lead, cadmium and zinc, present in furnace residue, can not become soluble, thereby avoiding the leaching and disposal in landfills of hazardous waste. This work suggests recycling of the EAF dust by sintering of a composite consisting of EAF dust agglomerate to coke particles (carbon source), mill scale (iron source) and ceramic fluorite (adictive agent used like fluxant) into pellets, a process known as sintering. As a result of the process is expected to obtain two by-products, the pre-cast agglomerated, PCA, with iron oxide content exceeding 70%, object of the process of sintering and zinc dust, containing more than 50% zinc oxide resulting from volatilization of this metal during the sintering process and collected by bag filter. Addition is expected to extract approximately 90% of lead and cadmium oxide contained in the initial EAF dust. The production of the PCA occurred in experimental scale divided into three stages, the first stage was performed with eight different formulations and checked by chemical analysis by X-ray fluorescence spectrometer and X-ray diffraction, the technical viability of using only solid waste industrial manufacturing PCA. The second phase, also with eight formulations, defined as planning experiments with factorial design, was tested the main effects and the double and triple interactions between the components of the PCA, to obtain the optimal formulation. The third phase was checked the intensity of the variables, coke fluorite ceramics, for removing zinc of PCA. The first two stages of the production tests were carried out on a pilot scale in a pilot plant sintering downstream and the third phase in a pilot plant xii upstream, both installed in the plant ArcelorMittal Piracicaba. The PCA, with the optimal formulation was produced on an industrial scale in the sinter plant Metalflexi also installed at the plant ArcelorMittal Piracicaba, and tested in small blast furnace. The zinc dust was characterized chemically for application in industries that use this element.

Orientador: Pedro Magalhães Sobrinho / Resumo: O aço é um dos materiais mais utilizados em todo o mundo, é possível ser 100% reciclado, obtendo novo aço sem perda de qualidade e quantas vezes for necessário. O setor siderúrgico é o maior consumidor de energia final destinado a indústria. Para produção do aço existem diversas alternativas possíveis. Neste trabalho é destacada a do forno elétrico a arco, a mais eficiente em termos de energia consumida e a única a qual pode-se utilizar como matéria-prima até 100% de material reciclado. Sendo o aço uma commodity, uma mercadoria básica facilmente intercambiável e utilizada como insumo para produção de outros produtos, tem seu preço regulado pelo mercado e trabalhos em eficiência energética são essenciais para a competitividade das empresas. O presente trabalho visa elaborar sugestões de métodos e tecnologias que possibilitem a redução do consumo específico de energia elétrica em kWh/t (quilowatt hora por tonelada de aço) para o processo de fusão do aço de um forno elétrico a arco, localizado na região do Vale do Paraíba. A metodologia empregada foi a pesquisa-ação, tendo um forno elétrico a arco real, disponível para estudos e captura de dados. As soluções encontradas estão desde técnicas operacionais de produção, até tecnologias em reaproveitamento de gases de exaustão, utilizados para o pré-aquecimento de sucata. Como resultado da pesquisa, obteve-se um conjunto de possibilidades tecnológicas com ganhos de até 143 kWh/t, o que representa cerca de 34% de redução no consumo es... (Resumo completo, clicar acesso eletrônico abaixo) / Abstract: Steel is one of the most widely used materials worldwide, and it is possible to recycle 100% of it so as to generate new steels without quality loss and as many times as needed, however, the steel sector is the largest final energy consumer. There are several possible routes for steel production, but the Electric Arc Furnace has been selected for the present work due to being the most efficient in terms of energy consumption and it is the only one that can use up to 100% of recycled matter as raw material. As steel is a commodity, a basic goods easily interchangeable and used as input for the production of other products, its price is set by the market and energy efficiency studies are essential for the competitiveness of companies. The present work aims to elaborate suggestions of methods and technologies that allow the reduction of the specific electric energy consumption in kWh/t (kilowatt hour per ton of steel) by the steel melting process of an electric arc furnace located in the region of the Paraíba Valley. The methodology used was the action research, having an electric arc furnace, available for studies and data capture. The identified solutions range from operational production techniques to exhaust gas recovery technologies for scrap preheating. As a result, a set of technological possibilities with savings of up to 143 kWh/t have been obtained, which represents about 34% reduction in specific electric energy consumption by taking into account an average consumptio... (Complete abstract click electronic access below) / Mestre

Utsläppen av växthusgaser ökar över hela världen och nya tekniker används för att minska utsläppen. 7% av utsläppen kommer från stålsektorn. 25% av världens stålproduktion görs via återvinningstekniken ljusbågsugn. Genom återvinningsprocessen släpps det ut 500kg CO2 per ton producerat flytande stål. En möjlighet att sänka dessa direkta utsläppär att koppla ljusbågsugnsprocessen med biomassa förgasnings och koldioxidavskiljning. Den föreslagna lösningen i denna avhandling är att utnyttja avgaserna från stålsmältningen i förgasningsprocessen och skapa värdefulla produkter. Projektet utvärderar den tekniska genomförbarheten i form av energieffektivitet och kolutnyttjande. Den föreslagna processen simulerades med Aspen Plus. Ett problem med ljusbågsugnens avgaser är fluktuationen i sammansättningen. Tre fall avavgassammansättning undersöktes. Fall 1 var den genomsnittliga avgassammansättningen, medan fall 2 och 3 var extrema med högt CO- respektive CO2-innehåll. Resultatet visade att syntetsgassammansättningen starkt beror på förgasningsmedlet. I samtliga fall ökade energieffektiviteten och de direkta utsläppen minskade, jämfört med nuvarande process. Fall 1 visade generellt högst effektivitet och kolutnyttjande, medan det CO2 rika fallet (fall 3) hade lägst. Ett kontinuerligt flöde av förgasningsmedel krävs för att driva förgasningsprocessen. Eftersom ljusbågsugn är en satsvis process, sker luftförgasning när avgaser inte är tillgängliga. Det önskade resultatet av luftförgasning är att producera syntetsgas som liknar avgasförgasningens syntesgas. Resultaten visade att luftinfiltration i avgaser är gynnsamt för mer liknande syntesgas . / Greenhouse gas emissions are increasing worldwide, and new techniques are being adopted to suppress the emissions. The steel sector is responsible for 7% of the emissions. 25% ofthe world’s steel production is made through the recycling technique EAF. Throughout the recycling process, 500 kg CO2 gets emitted per ton of liquid steel produced. An opportunity to lower these direct emissions is to couple the EAF process to biomass gasification and CO2 utilisation process. The proposed solution in this thesis is to utilise the off-gases in the gasification process and create high-valuable products. The project evaluates the technical feasibility via energy efficiency and carbon utilisation. The proposed process was simulated using Aspen Plus. A problem with the off-gases from EAF gasification is the fluctuation in composition. Three cases of off-gas composition were therefore investigated. Case 1 was the average off-gas composition, while cases 2 and 3 were extreme with high CO and CO2 content, respectively. The result showed that the syngas composition strongly depends on the gasifying agent. In all cases, the energy efficiency increased, and the direct emissions decreased. Case 1 generally showed the highest efficiency and carbon utilisation, while the CO2 heavily case (case 3) had the lowest. A continuous flow of gasifying agents is required to run the gasification process. Since EAF is a batch process, air gasification runs when off-gases are unavailable. The desired outcome of air gasification is to produce syngas similar to off-gas gasification. The results showed that air infiltration in off-gases is favourable for more similar syngas composition.

[pt] Um modelo de descarburação e formação de escórias foi desenvolvido e aplicado ao processo de fabricação de aço em forno elétrico a arco de 120 ton de capacidade, com carga de ferro gusa e de sucata ferrosa. O carregamento de carbono foi significativamente variado para testar a consistência do modelo, considerando a cinética de oxidação do carbono, oxidação do fósforo e de redução do óxido de ferro. Gusa e coque foram empregados como fontes mais relevantes de carbono, resultando na entrada de 15 a 35 kg carbono/ton. As taxas de fusão do gusa e da sucata governam a disponibilidade dos elementos mais relevantes tais como carbono, fósforo e silício em solução, portanto, afetam as taxas de descarburação e de formação de escórias. A principal fonte de fósforo na carga ferrosa é o gusa. Desta forma, a evolução do teor de fósforo na fase metal mostrou-se importante para as estimativas das taxas de fusão do gusa, uma vez que o fósforo pode ser empregado como traçador adicional ao carbono. Modelos cinéticos envolvendo as reações do fósforo e silício operam simultaneamente com os modelos cinéticos referentes às reações do carbono e do ferro. Integrações numéricas associadas a um algoritmo de gradientes reduzidos generalizado foi empregado para o sistema não linear com restrições, de forma a determinar a maioria dos parâmetros cinéticos do modelo. A taxa de fusão global da carga de sucata foi maior do que a taxa de fusão aparente do gusa. Supõe-se que, o gusa apesar de ter relações geométricas desfavoráveis à transferência de calor em relação à sucata, poderia fundir mais rapidamente influenciado pelo seu baixo ponto de fusão. Entretanto, devido à formação de camada solidificada a partir da massa líquida na qual é imerso, é provável que mesmo fundido posteriormente, ocorra um processo de encapsulamento temporário, conferindo-lhe uma taxa aparente de fusão mais baixa. A constante cinética da reação de descarburação quando o teor de carbono é inferior ao carbono crítico de 0.19 por cento em massa e pelo menos 60 por cento da carga ferrosa estão fundidas, foi estimada em 0.74 min-1, taxas comparáveis às obtidas em aciaria a oxigênio. A principal fonte de oxigênio para oxidação do ferro é disponibilizada por lanças supersônicas. Estima-se que 20 por cento do oxigênio injetado via lanças sejam consumidos para a formação de óxido de ferro. Entretanto, cerca de 31 por cento e 26 por cento do oxigênio oriundo de injetores de póscombustão podem contribuir na formação de óxido de ferro ou são captados pelo sistema de exaustão de gases, respectivamente. Os resultados indicam que em torno de 15-30 por cento do carbono injetado podem não reagir no forno, sendo removidos com a escória. Adicionalmente ao estado de não-equilíbrio no sistema Fe-C-O observado, a dispersão nas estimativas de carbono solúvel na fase metal também pode ter sido influenciada pela intensidade de penetração da injeção de coque. O algoritmo proposto se constitui num promissor simulador de práticas que visam otimizar o rendimento metálico do ferro, a partir da dependência da cinética de redução do óxido de ferro com sua atividade química na escória. / [en] A decarburization and slag formation model was developed and applied to a steelmaking process based on scrap and pig iron mixes melted in a conventional AC electric arc furnace (EAF) with 120 ton capacity. The amount of carbon input was varied significantly in order to evaluate the model consistency regarding mainly the kinetics of carbon oxidation, phosphorus oxidation and iron oxide formation and reduction. Pig iron and coke were used as sources of carbon, resulting in variation of total carbon input in the range of 15 to 35 kg carbon/ton. The pig iron and scrap melting rates determine the availability of the most relevant elements such as carbon, phosphorus and silicon in solution in Fe-C melts, and therefore, affecting the decarburization as well the slag formation rates. The pig iron is the main source of phosphorus in the ferrous charge. Hence, the evolution of the phosphorus content in the metal phase is important to predict the pig iron melting rate, since phosphorus can be used as a tracer element in addition to carbon. Kinetic models regarding phosphorus and silicon were applied simultaneously to kinetic models of carbon and iron reactions. A numerical integration method supported a generalized reduced gradient algorithm for non-linear and constrained system (GRG) was applied to determine most of the kinetic model parameters. The scrap melting rates were found to be higher than pig iron apparent melting rates. This is expected that, even though the heat transfer issues related to significant differences in the area to volume ratio compared to scrap, pig iron may melt faster influenced by its low melting point. However, a solidified shell maybe created from the hot heel where pig iron is immersed, even when further melting occur, Fe-rich carbon melts could be encapsulated temporarily and present lower apparent melting rate. The decarburization rate parameter, when at least 60 percent of the charge is melted, was estimated as 0.74 min-1, when carbon content is lower than the critical carbon 0.19 percent wt, which is similar to the rate range observed in oxygen steelmaking facilities. Around 31 percent and 26 percent of the oxygen input through post combustion injectors were addressed to iron oxidation and to the off-gas system, respectively. The main source of oxygen taking part of iron oxidation is available from supersonic lances. Approximately 20 percent of the oxygen input through lancing are consumed to form iron oxide. The results also indicate about 15-30 percent of the injected carbon may not react and leave EAF during slagoff. In addition to the observed non-equilibrium state in Fe-C-O system, the dispersive behavior of the prediction of soluble carbon content in the metal phase could also be influenced by the intensity of penetration coke. The model framework is a promising tool to work preliminarily in what-if process scenario builder as a static model for iron yield optimization, regarding the kinetics of iron oxide reduction reaction and the proposed dependence on its chemical activity in the slag phase.

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.

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>

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.