FERRARA, 7 FEBBRAIO 2018 E FFICIENZA E NERGETICA E C ONTENIMENTO DELLE E MISSIONI I NQUINANTI NEI P ROCESSI I NDUSTRIALI : IL S ETTORE C ERAMICO Luca Montorsi UNIVERSITÀ DI MODENA E REGGIO EMILIA
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
FERRARA, 7 FEBBRAIO 2018
… 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
FERRARA, 7 FEBBRAIO 2018
… 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.
FERRARA, 7 FEBBRAIO 2018
… 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
FERRARA, 7 FEBBRAIO 2018
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
FERRARA, 7 FEBBRAIO 2018
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
Development of Innovative CHP Systems
Energy efficiency of industrial processes
Fossil & Renewable Energy SourcesConsumption CurvesElectric & Thermal Energy Storage
System OptimizationROI/NPV
Poly-generation Systems Modeling
Energy Recovery from Biomass/Waste
ENERGY CONVERSION SYSTEMS: Research activities
FERRARA, 7 FEBBRAIO 2018
Anaerobic DigestionGasificationPyrolysis
CombustionWater Treatment
Waste Tires Pyrolysis: Scaled Prototype
Development of Innovative CHP Systems
Energy efficiency of industrial processes
Fossil & Renewable Energy SourcesConsumption CurvesElectric & Thermal Energy Storage
System OptimizationROI/NPV
Poly-generation Systems Modeling
Energy Recovery from Biomass/Waste
ENERGY CONVERSION SYSTEMS: Research activities
FERRARA, 7 FEBBRAIO 2018
Anaerobic DigestionGasificationPyrolysis
CombustionWater Treatment
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
Aluminum = Energy Carrier
From renewables to H2
MSE – INDUSTRIA 2015ENERCLEAN – 2010/2013
Al(l) - LIQUID
INJECTION
SYSTEM
Liquid aluminum injection
Development of Innovative CHP Systems
Energy efficiency of industrial processes
Fossil & Renewable Energy SourcesConsumption CurvesElectric & Thermal Energy Storage
System OptimizationROI/NPV
Poly-generation Systems Modeling
Energy Recovery from Biomass/Waste
ENERGY CONVERSION SYSTEMS: Research activities
FERRARA, 7 FEBBRAIO 2018
Anaerobic DigestionGasificationPyrolysis
CombustionWater Treatment
Heat recovery efficiency for the post-combustion flue gas treatment in a coffee roaster plant
Aluminum = Energy Carrier
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
Development of Innovative CHP Systems
Energy efficiency of industrial processes
Fossil & Renewable Energy SourcesConsumption CurvesElectric & Thermal Energy Storage
System OptimizationROI/NPV
Poly-generation Systems Modeling
Energy Recovery from Biomass/Waste
ENERGY CONVERSION SYSTEMS: Research activities
FERRARA, 7 FEBBRAIO 2018
Energy efficiency and pollutant emission reduction in industrial processes: the ceramic sector
Anaerobic DigestionGasificationPyrolysis
CombustionWater Treatment
Aluminum = Energy Carrier
System and Component AnalysisConsumption Reduction & Energy Recovery
Energy Efficiency and EmissionsProduct QualitySystem Control Strategy
Development of Innovative CHP Systems
Energy efficiency of industrial processes
Fossil & Renewable Energy SourcesConsumption CurvesElectric & Thermal Energy Storage
System OptimizationROI/NPV
Poly-generation Systems Modeling
Energy Recovery from Biomass/Waste
ENERGY CONVERSION SYSTEMS: Research activities
INSTITUTO DE
TECNOLOGÍA CERÁMICA
BRUNEL UNIVERSITY
LONDON
FERRARA, 7 FEBBRAIO 2018
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
FERRARA, 7 FEBBRAIO 2018
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
FERRARA, 7 FEBBRAIO 2018
Kiln design: Real Geometry
Tiles direction
Cooling air directionHot air direction
AE-T100 CHPTurbine Natural Gas
(ANSALDO)
Electrical output:100 kW
FERRARA, 7 FEBBRAIO 2018
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
FERRARA, 7 FEBBRAIO 2018
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)
FERRARA, 7 FEBBRAIO 2018
Results: temperature distributionTiles top surface
With exhausts recoveryRegular operation
Module #4
MODULE #4 INLET MODULE #4 OUTLET
Regular operation
With exhausts recovery
FERRARA, 7 FEBBRAIO 2018
Results: heat transfer time historiesTiles’ heat exchange
Modules #3 & #4
MODULE #3 INLET MODULE #4 OUTLET
MODULE #3 INLET MODULE #4 OUTLET
Regular operation
With exhausts recovery
Contribution of radiation to total heat transfer
Regular operation
With exhausts recovery
Heat transfer
FERRARA, 7 FEBBRAIO 2018
Results: energy savingTiles’ heat exchange
Modules #3 & #4
MODULE #3 INLET MODULE #4 OUTLET
MODULE #3 INLET MODULE #4 OUTLET
Regular operation
With exhausts recovery
Contribution of radiation to total heat transfer
Regular operation
With exhausts recovery
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 !
FERRARA, 7 FEBBRAIO 2018
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
FERRARA, 7 FEBBRAIO 2018
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
FERRARA, 7 FEBBRAIO 2018