FFICIENZA ENERGETICA E CONTENIMENTO DELLE MISSIONI ... · ferrara, 7 febbraio 2018 rsar projts …...

FERRARA, 7 FEBBRAIO 2018

EFFICIENZA ENERGETICA E CONTENIMENTO DELLE

EMISSIONI INQUINANTI NEI PROCESSI INDUSTRIALI: IL SETTORE CERAMICO

Luca Montorsi

UNIVERSITÀ DI MODENA E REGGIO EMILIA


… RESEARCH PROJECTS …

FP VII – RELSOR “WASTE COMBUSTION” – 2010/2013

RER TECNOPOLO - INTERMECHWP “FLIUDPOWER AND MECHATRONICS” – 2010/2014

RER TECNOPOLO – EN&TECHWP “ALTERNATIVE ENERGIES” – 2010/2014

HORIZON2020DREAM – 2016/2019

POR-FESR-ERJUMP – 2016/2018

MSE – INDUSTRIA 2015ENERCLEAN – 2010/2013

(Local Government Funding)

(EU Funding)

(National Government Funding)

HORIZON2020ETEKINA – 2017/2021


… T

EC

HN

OL

OG

Y T

RA

NS

FE

R …

… P

AR

TN

ER

S…

INDUSTRIAL SYSTEMS

AUTOMOTIVE

OFF-HIGHWAY

ENERGYFIRA S.p.A.

http://www.lmsintl.com/


… PARTNER RESEARCH CENTERS …

BRUNEL UNIVERSITY LONDONRCUK NATIONAL CENTRE FOR SUSTAINABLE ENERGY USE IN FOOD CHAINS (CSEF)INSTITUTE OF ENERGY FUTURES (ENERGY EFFICIENT TECHNOLOGIES)GREAT BRITAIN

JOHANNES KEPLER UNIVERSITY LINZINSTITUTE OF MACHINE DESIGN AND HYDRAULIC DRIVES

AUSTRIA

INSTITUTO DE TECNOLOGÍA CERÁMICA (ITC)UNIDAD DE MEDIO AMBIENTE

AREA DE SOSTENIBILIDAD

SPAIN

PURDUE UNIVERSITYMAHA FLUID POWER RESEARCH CENTER

USA

IMAMOTER - CNRINSTITUTE FOR EARTH-MOVING MACHINERY

ITALY


Development of Innovative CHP Systems

ENERGY CONVERSION SYSTEMS: Research activities

Energy efficiency of industrial processes

Fossil & Renewable Energy SourcesConsumption CurvesElectric & Thermal Energy Storage

System OptimizationROI/NPV

Optimization analysis

OpenModelicaBond graph – power port approach

NPV

Cycles

Electric energy

profile

Thermal

energy

profile

Hour

Month Year

Generic Energy System

Fully time-dependent

analysis

Poly-generation Systems Modeling

Energy Recovery from Biomass/Waste


Anaerobic DigestionGasificationPyrolysis

CombustionWater Treatment

Fully-dynamic numerical approach

Combined Waste to Energy System: Anaerobic Digestion – Gasification – Water Treatment

Detailed analysisof the systemparameters

Pay back Evaluation

Urban sewage treatment plant

Taormina - Italy











Waste Tires Pyrolysis: Scaled Prototype











Numerical Analysis - Scaled Prototype

Aluminum = Energy Carrier

Exploitation of aluminum-water reaction

High purity hydrogen

High grade alumina

Heat for electric & thermal

power generation

PRODUCTS:

H2 autonomous refueling station


From renewables to H2

MSE – INDUSTRIA 2015ENERCLEAN – 2010/2013

Al(l) - LIQUID

INJECTION

SYSTEM

Liquid aluminum injection











Heat recovery efficiency for the post-combustion flue gas treatment in a coffee roaster plant


System and Component AnalysisConsumption Reduction & Energy Recovery

Energy Efficiency and EmissionsProduct QualitySystem Control Strategy

1D-SIMULATION OF THE ENTIRE

PLANT

THROTTLE VALVES BURNER

Type#1

Type#2

PLENUM

FUEL CONSUMPTION









Energy efficiency and pollutant emission reduction in industrial processes: the ceramic sector




System and Component AnalysisConsumption Reduction & Energy Recovery

Energy Efficiency and EmissionsProduct QualitySystem Control Strategy








INSTITUTO DE

TECNOLOGÍA CERÁMICA

BRUNEL UNIVERSITY

LONDON


Module #3

Module #4

Module #5

ENERGY EFFICIENCY AND POLLUTANT EMISSION REDUCTION IN INDUSTRIAL PROCESSES

0D/1D - CFD simulations of entire industrial systems: CERAMIC KILN

Temperature distribution

MODULE #3 INLET MODULE #4 OUTLET

Regular operation

With exhausts recovery

Radiation contribution to

heat transferThermal power

time histories

0D/1Dmodeling

CFD modeling


Heating section Cooling section

Pre-Heating(no-burners)

Firing(8-16 burners/module)

Fast-cooling(Cold air inj.)

Slow-cooling(Indirect cooling)

Kiln design: Real Geometry

Tiles direction

Cooling air directionHot air direction


Kiln design: Real Geometry

Tiles direction

Cooling air directionHot air direction

AE-T100 CHPTurbine Natural Gas

(ANSALDO)

Electrical output:100 kW


Tiles’ initial positionThermal Energy Exchange Modelling: numerical model of the tiles

Module #3 Module #4 Module #5

Tile #4b Tile #3b Tile #2b Tile #1b

Tile #4a Tile #3a Tile #2a Tile #1a

Tiles velocity

Hot air flow

Tin_module#3 = 100°CTiles’ inlet temperature

1.2m x 1.2m x 9mmTiles’ size

0.028 m/s

Fluid Gaps Between Tiles


Thermal Energy Exchange Modelling: exhaust gases recovery

Module #3

Module #4

Module #5

Tile surface

Blower tubes

Reference values from turbine’s datasheet

3-module approach Upper chamber of module #4 replaced with new geometry

Blower tubes Number: 140

Diameter: 1”

Flow rate: 0.8 kg/s

Exhaust temperature: 270°C

(Air injection speed: ~ 14.5 m/s)


Results: temperature distributionTiles top surface

With exhausts recoveryRegular operation

Module #4


Regular operation



Results: heat transfer time historiesTiles’ heat exchange

Modules #3 & #4



Regular operation


Contribution of radiation to total heat transfer

Regular operation


Heat transfer


Results: energy savingTiles’ heat exchange

Modules #3 & #4



Regular operation


Contribution of radiation to total heat transfer

Regular operation


Heat transfer

Assuming it as burners’ fuel savings

Natural Gas savings:

0.007 Sm3/tile

1.17 Sm3/h

Energy Recovery

Efficiency:5%

ROI > 10 years !


0D/1D - CFD simulations of entire industrial systems: SOFTWARE IN THE LOOP

0D/1Dmodeling

Analysis of control strategies for

CERMIC KILNS

Sensitivity analysis of main control parameters

Preliminary analysis of control strategies

Definition of operating maps for PLC implementation

Construction of ad-hoc numerical models for PLC

implementation

Realsystem

Warm-up Cool-down Stand-by Stochastic event handling …

ENERGY EFFICIENCY AND POLLUTANT EMISSION REDUCTION IN INDUSTRIAL PROCESSES: THE CERAMIC SECTOR

Cooperation with


ENERGY EFFICIENCY AND POLLUTANT EMISSION REDUCTION IN INDUSTRIAL PROCESSES: THE CERAMIC SECTOR

0D/1D - CFD simulations of entire industrial systems: POLLUTANT EMISSIONS REDUCTION

Emissions control strategies forCERMIC KILNS

CH4 formation

0D/1Dmodeling

CFD modeling

Catalyser

grid

Radial H2

injectors

Exhausts inlet

(Swirl motion)

5.8

m

Ø 2 m

CH4 from CO2 in kiln’s exhaust gases

FFICIENZA ENERGETICA E CONTENIMENTO DELLE MISSIONI ... · ferrara, 7 febbraio 2018 rsar projts …...

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