This diploma thesis focuses on the unconventional method of metal separation, namely on the cutting technology based on the plasma arc. The introductory part deals with studies which focus on the given issue from a theoretical point of view. The core of the work rests in the practical part which is dedicated to the production of samples using a plasma burning machine called Hypertherm HPR 260. The burned samples are monitored and assessed for the surface quality and dimensional accuracy for every created part. The final part of the work is dedicated to the techno-economic assessment of the burned parts. In the end, the evaluation of the attained results is made.

Increasing resource efficiency by utilising secondary raw material is one of the key characteristics of a circular economy. Textile dust fibre, a waste generated from textile mechanical recycling has the prospect to be utilised as secondary raw material for producing novel material: textile paper suitable for packaging and other applications. A comparative Life Cycle Assessment (LCA) of carrier bags made from one ton of virgin paper, recycled paper and novel textile paper (~22584paper bags with grammage of 100 g/m2 and same dimensions for all 3 types of bags) showed that textile paper bag is more environmentally friendly in terms of carbon footprint. The largest environmental contributors were energy consumed in the pulping and paper making processes, followed by the use of adhesives and printing ink in the conversion process of paper to papercarrier bags. A comparative Techno-economic Assessment (TEA) was carried out for the operating cost of producing the three selected carrier bag types. The analysis conveyed that textile paper bags are more economically attractive, mainly due to the partial substitution of paper fibre with low-cost textile dust fibre. Furthermore, a simple tool was developed with an attempt to assess and compare materials suitability for the circular economy considering life cycle thinking and business perspectives. Assessment of textile paper using the Circular material assessment tool indicated that there is still scope for improvement on the following circularity characteristics of circular material: scarcity of raw material, local supply of resources, clean and non-toxic resources. Textile paper material scored high in the following circularity characteristics: secondary raw material, industrial symbiosis, recycling, resource efficiency in manufacturing and use. In the final step, the textile paper bag was eco-designed through the combined and iterative LCA and TEA approach with the aim to achieve improved scores as a circular material. In order to understand the overall sustainability advantages and trade-offs, further research is recommended on different textile dust fibre grades as well as textile paper performance based on mechanical properties. It is also recommended to investigate textile paper in other applications like one time fashion clothes, reusable paper bags as textile hangers etc.

Research has shown that three-phase balancing alone can improve the operation of secondary distribution networks and that the addition of energy storage to the phase balancing power electronics further helps to alleviate the negative effects of phase unbalances. However, less attention has been paid to the economic potential of said technologies and particularly for loadside implementation. It appears that the deployment of phase balancers, with or without energy storage, is indeed hampered by uncertainty related to its economic feasibility, despite both technologies being commercially available. This thesis therefore aims to assess and compare the economic feasibility of the two configurations for peak shaving purposes in the context of residential property loads in Sweden. The assessment was performed using a specially developed deterministic techno-economic model taking into consideration historical load data from three Swedish real estate, cost estimations for a range of alternatives used when sizing the systems, applicable tariffs and fees for electricity and its distribution as well as technical parameters such as the capacities and efficiencies of the involved components. A novel approach was taken by linearly extrapolating the three load profiles into three sets of 91 synthesized load profiles to enable a larger dataset for analysis. The net present values generated for each set were then graphed and analyzed per original real estate. The results showed that both configurations can be economically feasible, but only under certain conditions. A phase balancer alone was found to be feasible for real estate whose peak currents are distinctly unbalanced and exceed 50 A, with the best expected rate of return for profiles exceeding 63 A since they enable a tariff switch. The combined system was found to be even more contingent on the tariff switch and therefore only feasible for peaks above 63 A. A substantial difference in the initial investment further makes the single phase balancer the preferred choice, unless the discount rate is as low as 2 % or less. On this basis, potential investors need to assess the state of unbalance of their loads and perform their own calculation based their load profile, cost of capital and applicable tariffs. / Tidigare forskning har visat att fasbalansering enskilt kan förbättra driften hos lokala distributionsnät och att ett batterisystem i tillägg till fasbalanserarens kraftelektronik ytterligare kan minska de negativa effekterna av fasobalanser. Däremot har mindre uppmärksamhet riktats mot den ekonomiska genomförbarheten hos dessa teknologier och i synnerhet för implementation på lastens sida av elmätaren. Det tycks vara så att spridningen av fasbalanserare, med eller utan energilagring, hindras av osäkerheten kring dess ekonomiska potential trots att båda teknologierna är kommersiellt tillgängliga. Detta arbete ämnar därför att värdera och jämföra den ekonomiska nyttan hos de två konfigurationerna vid toppreducering av fastighetselen i svenska bostadsfastigheter. Värderingen utfördes med hjälp av en särskilt utvecklad deterministisk tekno-ekonomisk modell som beaktade historiska lastdata från tre svenska fastigheter, kostnadsuppskattningar för en uppsättning av konfigurationer som användes vid dimensionering av systemen, applicerbara tariffer och avgifter för elektricitet och dess distribution samt tekniska parametrar såsom kapaciteter och verkningsgrader för de olika komponenterna. Ett annorlunda tillvägagångssätt tillämpades vidare för att utöka datamängden genom linjär extrapolation av lastprofilerna, vilket resulterade i tre uppsättningar av 91 syntetiserade lastprofiler. Nettonuvärdet beräknades följaktligen för varje profil och investeringsalternativ för att sedan plottas och analyseras per ursprunglig fastighet. Resultaten visade att båda konfigurationerna kan uppvisa lönsamhet, men endast under särskilda förutsättningar. Den enskilda fasbalanseraren bedömdes som lönsam för fastigheter vars strömtoppar är påtagligt obalanserade och som överstiger 50 A, med största möjliga lönsamhet för profiler som överstiger 63 A då dessa möjliggör ett tariffbyte. Det kombinerade systemets lönsamhet bedömdes vara ännu mer beroende av tariffbytet och därför endast lönsamt för strömtoppar över 63 A. En betydligt större grundinvestering för det kombinerade systemet gör vidare att den enskilda fasbalanseraren i regel är att föredra, såvida inte kalkylräntan är så låg som 2 % eller mindre. Baserat på detta uppmanas potentiella investerare att undersöka balanstillståndet hos deras laster och att utföra en egen kalkyl baserat på deras specifika last, kapitalkostnad och nätföretag.

[ES] El sector industrial es responsable de una cantidad significativa de emisiones anuales de carbono, en gran parte debido a su elevado consumo de energía y a su dependencia de los combustibles fósiles para la producción de calor. Por tanto, es evidente que la utilización de fuentes de calor alternativas y renovables, como los colectores solares de concentración, representa una oportunidad prometedora para la descarbonización de este sector. Sin embargo, los sistemas de colectores solares dependen del recurso solar, que es una fuente de energía intermitente. Por ello, es necesario disponer de un sistema de almacenamiento de energía térmica (AET) que facilite el almacenamiento de la energía sobrante y su posterior utilización cuando sea necesario, garantizando así un suministro de calor más constante. Con el fin de demostrar la viabilidad de los sistemas solares térmicos para aplicaciones industriales, la empresa Solatom CSP instaló un campo solar experimental dentro del proyecto SOLPINVAP. Está compuesto por una serie de colectores modulares lineales Fresnel (CLF) y un kettle reboiler, que es un tipo de intercambiador de calor de carcasa y tubos. Esta tesis analiza el rendimiento del sistema en modo de generación indirecta de vapor. En este modo, el calor se absorbe en el interior de los tubos absorbedores mediante un fluido caloportador y se transfiere a la carcasa del kettle reboiler, donde se produce vapor. Además, esta tesis examina los circuitos hidráulicos y sus componentes del campo solar experimental, así como el sistema de control y el sistema de monitorización asociados al mismo. Además, se presenta el desarrollo de un modelo de sistema CLF de calor solar para procesos industriales (CSPI). El modelo se desarrolló en el entorno MATLAB orientado a objetos. Se desarrolló un modelo 3D del campo solar CLF dentro del entorno Tonatiuh (un software de trazado de rayos), lo que permitió estimar la eficiencia óptica máxima y los correspondientes modificadores del ángulo de incidencia de los colectores Fresnel. Los resultados demuestran que el calor absorbido en los colectores presenta una incertidumbre del 12%, mientras que el calor generado presenta una incertidumbre del 3%. Para reducir la incertidumbre inherente al cálculo del calor absorbido y generado, se realizó un estudio para seleccionar sensores y equipos de monitorización más precisos. Además, se realizó un trabajo de campo para instalar los equipos seleccionados, más precisos, en el campo solar SOLPINVAP. Los resultados de la monitorización demuestran que la incertidumbre en el calor absorbido se redujo en un 79% como consecuencia de la mejora en la instrumentación de medida. Como parte de este proyecto de tesis, se realizó una estancia de investigación en el Departamento de Ingeniería de Mecánica y Metalúrgica de la Pontificia Universidad Católica de Chile, en Santiago. El equipo de investigación anfitrión ha estado investigando la posible aplicación de AET de lecho compacto sólido con escoria de cobre, un subproducto del proceso pirometalúrgico del mineral de cobre, como medio de almacenamiento. Además, el equipo de investigación ha desarrollado un modelo matemático que simula el proceso termodinámico y de transferencia de calor asociado al flujo de aire y a las partículas sólidas. En consecuencia, el modelo del sistema de AET de lecho compacto sólido se ha integrado en el modelo del sistema CSPI para examinar su efecto en el rendimiento del sistema. Además, esta tesis examina la dinámica entre las temperaturas de los distintos componentes del sistema. En consecuencia, esta tesis presenta un diseño para un sistema integrado CSPI con AET de lecho compacto sólido. Los resultados demuestran que el sistema con el AET de lecho compacto sólido es capaz de generar un 18% más de energía que el sistema sin el AET de lecho compacto sólido. / [CA] El sector industrial és responsable d'una quantitat significativa d'emissions anuals de carboni, en gran part a causa del seu alt consum d'energia i la dependència dels combustibles fòssils per a la producció de calor. Per tant, és evident que la utilització de fonts de calor alternatives i renovables, com la concentració de col·lectors solars, representa una oportunitat prometedora per a la descarbonització d'aquest sector. No obstant això, els sistemes de col·lectors solars depenen del recurs solar, que és una font d'energia intermitent. Per tant, és necessari disposar d'un sistema d'emmagatzematge d'energia tèrmica (TES) per facilitar l'emmagatzematge de l'energia sobrant i la seva posterior utilització quan sigui necessari, assegurant així un subministrament de calor més consistent. Per tal de demostrar la viabilitat dels sistemes solars tèrmics per a aplicacions industrials, l'empresa Solatom CSP va instal·lar un camp solar experimental dins del projecte SOLPINVAP. Comprèn una sèrie de col·lectors lineals modulars de Fresnel i un Kettle Reboiler, que és un tipus d'intercanviador de calor de carcassa i tubs. Aquesta tesi analitza el rendiment del sistema en mode de generació de vapor indirecte. En aquest mode, la calor s'absorbeix a l'interior dels tubs absorbents mitjançant l'ús d'un fluid de transferència de calor, i es transfereix a la capa del Reboiler, on es produeix vapor. A més, aquesta tesi examina els circuits hidràulics i els seus components del camp solar experimental, així com el sistema de control i el sistema de monitoratge associat a aquest. A més, es presenta el desenvolupament d'un model de sistema LFC per a processos industrials (SHIP). El model es va desenvolupar dins de l'entorn MATLAB orientat a objectes. Es va desenvolupar un model 3D del camp solar LFC dins de l'entorn Tonatiuh (un programari de rastreig de raigs), que permet estimar l'eficiència òptica màxima i els corresponents modificadors d'angle d'incidència dels col·lectors Fresnel. Els resultats demostren que la calor absorbida en els col·lectors mostra una incertesa del 12%, mentre que la calor generada mostra una incertesa del 3%. Per tal de reduir la incertesa inherent al càlcul de la calor absorbida i generada, es va realitzar un estudi per seleccionar sensors i equips de monitoratge més precisos. A més, es va realitzar un treball de camp per a instal·lar els equips seleccionats i més precisos en el camp solar SOLPINVAP. Els resultats de seguiment demostren que la incertesa en la calor absorbida es va reduir en un 79% com a conseqüència de la millora en la instrumentació de mesura. En el marc d'aquest projecte de tesi, es va realitzar una estada de recerca al Departament d'Enginyeria de Mecànica i Metalúrgica de la Pontifícia Universitat Catòlica de Xile, a Santiago. L'equip d'investigació amfitrió ha investigat la potencial aplicació de PBTES sòlids amb escòria de coure, un subproducte del procés pirometal·lúrgic del mineral de coure, com a medi d'emmagatzematge. A més, l'equip d'investigació ha desenvolupat un model matemàtic que simula el procés de transferència de calor i termodinàmica associat al flux d'aire i les partícules sòlides. En conseqüència, el model del sistema PBTES s'ha integrat en el model del sistema SHIP per a l'examen del seu efecte sobre el rendiment del sistema. A més, aquesta tesi examina la dinàmica entre les temperatures dels diferents components del sistema. En conseqüència, aquesta tesi presenta un disseny per a un sistema solar integrat amb sistema PBTES. Els resultats demostren que el sistema amb el PBTES és capaç de generar un 18% més d'energia que el sistema sense el PBTES. A més, es va dur a terme una anàlisi tecnoeconòmica utilitzant el sistema SHIP dissenyat amb PBTES. / [EN] The industry sector is responsible for a significant amount of annual carbon emissions, largely due to its high energy consumption and reliance on fossil fuels for heat production. It is therefore evident that the utilisation of alternative and renewable heat sources, such as concentrating solar collectors, represents a promising opportunity for the decarbonisation of this sector. Nevertheless, solar collector systems are dependent on the solar resource, which is an intermittent source of energy. It is therefore necessary to have a thermal energy storage (TES) system to facilitate the storage of surplus energy and its subsequent utilisation when required, thereby ensuring a more consistent heat supply. In order to demonstrate the viability of solar thermal systems for industrial applications, the company Solatom CSP installed an experimental solar field within the SOLPINVAP project. It comprises a series of modular linear Fresnel collectors (LFC) and a kettle reboiler, which is a type of shell and tube heat exchanger. This thesis analyses the performance of the system in Indirect Steam Generation mode. In this mode, heat is absorbed inside the absorber tubes by using a heat transfer fluid, and transferred to the shell of the kettle reboiler, where steam is produced. Additionally, this thesis examines the hydraulic circuits and their components of the experimental solar field, as well as the control system and the monitoring system associated with it. Moreover, it is presented the development of a LFC solar heat for industrial process (SHIP) system model. The model was developed within the object-oriented MATLAB environment. A 3D model of the LFC solar field was developed within the Tonatiuh environment (a ray-tracing software), allowing for an estimation of the peak optical efficiency and the corresponding incidence angle modifiers of the Fresnel collectors. . The results demonstrate that the absorbed heat in the collectors exhibits an uncertainty of 12%, while the generated heat exhibits an uncertainty of 3%. In order to reduce the uncertainty inherent in the calculation of the absorbed and generated heat, a study was conducted to selected more precise sensors and monitoring equipment. Moreover, fieldwork was conducted to install the selected, more precise equipment at the SOLPINVAP solar field. The monitoring results demonstrate that the uncertainty in the absorbed heat was reduced by 79% as a consequence of the improvement in the measurement instrumentation. As part of this thesis project, a research stay was conducted at the Departamento de Ingeniería de Mecánica y Metalúrgica of the Pontificia Universidad Católica de Chile, in Santiago. The host research team has been investigating the potential application of solid PBTES with copper slag, a by-product of the pyrometallurgical process of the copper ore, as a storage medium. Moreover, the research team has developed a mathematical model that simulates the thermodynamic and heat transfer process associated with the airflow and solid particles. Accordingly, the PBTES system model has been integrated into the SHIP system model for examination of its effect on the system performance. Furthermore, this thesis examines the dynamics between the temperatures of the different system components. Consequently, this thesis presents a design for an integrated SHIP with PBTES system. Moreover, it was determined that by modifying the air mass flow and the makeup water flow, the system is capable of maintaining a consistent and uninterrupted heat output throughout the operational duration. The results demonstrate that the system with the PBTES is capable of generating 18% more energy than the system without the PBTES. / I would like to thank the Universitat Politècnica de València through the Research and Development Aid Program (PAID-01-20) for receiving the Research Fellowship FPI-UPV-2020. I would also like to acknowledge the "Programa de Movilidad para estudiantes de doctorado" of the Universitat Politècnica de València for providing financial support for my research stay. / David Hernández, MA. (2024). Fresnel Solar Collector System for Indirect Steam Generation for Industrial Processes with Thermal Energy Storage [Tesis doctoral]. Universitat Politècnica de València. https://doi.org/10.4995/Thesis/10251/213678

<p dir="ltr">In our daily lives, we rely on a multitude of discrete products to meet our needs. Traditional product design approaches have primarily focused on economic and technical aspects, often overlooking the pressing environmental and social challenges facing society. Recognizing the limitations of our ecological systems to cope with the waste generated by our current industrial processes, there is a growing need to anticipate the potential consequences of product design across technical, economic, environmental, and social dimensions to pave the way for a sustainable future. One promising strategy within this context is the integration of sustainability principles into optimization-based design models that consider a product's entire life cycle. While there have been previous efforts to optimize product life cycles, a comprehensive exploration of optimization-based design methods with a focus on multiple objectives for discrete products is essential. This dissertation explores the integration of sustainability principles with optimization-based design by taking the electric traction motor used in electric vehicles as a case study. This complex and environmentally significant technology is ideal for investigating the tradeoffs and benefits of incorporating sustainability objectives into the design process.</p><p dir="ltr">The key tasks undertaken in this study are as follows:</p><ul><li>Development of a parametric design and optimization framework for a surface-mounted permanent magnet synchronous motor. In this task, a special emphasis is placed on reducing reliance on materials with a high supply risk, such as rare earth elements.</li><li>Creation of a parametric life cycle assessment model that combines life cycle assessment and optimization-based design to minimize a single-score environmental impact. This model offers insights into the environmental performance of product design and underscores the importance of minimizing environmental impact throughout a product's life cycle.</li><li>Integration of a life cycle costing model, incorporating techno-economic assessment and total cost of ownership perspectives, into the parametric life cycle assessment and optimization-based design models. This model is used to minimize levelized production and driving costs, shedding light on the trade-offs within this family of cost metrics and the optimization of manufacturing systems for motor production.</li><li>Proposal of a circular economy model/algorithm to assess the advantages of integrating the circular economy paradigm during the early design phase. All the mentioned objective functions are considered to study the impacts of applying the circular economy paradigm.</li></ul><p dir="ltr">The contributions of this research can be summarized as follows:</p><ul><li>Utilized a diverse array of analytical methodologies to parameterize the design process of a motor, incorporating the integration of Life Cycle Assessment (LCA) and Techno-Economic Analysis (TEA) models, as well as the incorporation of disassembly planning for informed decision-making in the early stages of design.</li><li>Proposed a generalized objective function denoted as the Supply Risk-equivalent (SR-eq.), aimed at mitigating the risks associated with the dependency on critical materials in product manufacturing.</li><li>Introduced a novel approach for visualizing non-dominated solutions within a multi-objective framework, with experimentation conducted on up to six distinct objectives.</li><li>Substantiated the significance of decarbonizing the electric grid while maintaining competitive cost structures, the importance of advancing non-destructive evaluation (NDE) procedures for assessing the condition of end-of-life (EoL) subassemblies, and optimizing the collection rate of EoL motors.</li></ul><p dir="ltr">Demonstrated that the optimization of technical metrics as surrogate indicators for economic and environmental performance does not necessarily yield designs that are concurrently optimal in economic and environmental terms.</p>