Abstract: The present work is dealing with 2% Si-steel alloy. The alloy contains 0.05% C as well as 0.85% Al. The alloy under investigation would be used for electrical transformation purposes. A heating (expansion) - cooling (contraction) dilation investigation was executed to detect the a, a+g, and g transformation temperatures at the inflection points of the dilation curve. On heating, primary a was detected at a temperature range between room temperature and 687 oC. The domain of a+g was detected in the range between 687 oC and 746 oC. g phase exists in the closed g region at the range between 746 oC and 1043 oC. The domain of a phase appears again at a temperature range between 1043 and 1105 oC, and followed by secondary a at temperature higher than 1105 oC. A physical simulation of thermo-mechanical processing on the as-cast alloy was carried out. The simulation process took into consideration the hot flat rolling pilot plant parameters. The process was executed on the thermo-mechanical simulator (Gleeble 3500). The process was designed to include seven consecutive passes. The 1st pass represents the roughing stage, while the remaining six passes represent finish rolling stage. The whole process was executed at the temperature range from 1100 oC to 900 oC. The amount of strain starts with 23.5% at the roughing pass and decreases continuously to reach 7.5 % at the last finishing pass. The flow curve of the alloy can be abstracted from the stress-strain curves representing simulated passes. It shows alloy hardening from a pass to the other up to pass no. 6, as a result of decreasing the deformation temperature and increasing of cumulative strain. After pass no. 6, the deformation process enhances the dynamic recrystallization phenomena to appear, where the z-parameter would be high.
Abstract: The world crude oil demand is projected to rise to 108.5 million bbl/d by the year 2035. With reserves estimated at 869 billion tonnes worldwide, coal remains an abundant resource. The aim of this work was to produce a high value hydrocarbon liquid product using a Direct Coal Liquefaction (DCL) process at, relatively mild operating conditions. Via hydrogenation, the temperature-staged approach was investigated in a dual reactor lab-scale pilot plant facility. The objectives included maximising thermal dissolution of the coal in the presence of tetralin as the hydrogen donor solvent in the first stage with 2:1 and 3:1 solvent: coal ratios. Subsequently, in the second stage, hydrogen saturation, in particular, hydrodesulphurization (HDS) performance was assessed. Two commercial hydrotreating catalysts were investigated viz. NickelMolybdenum (Ni-Mo) and Cobalt-Molybdenum (Co-Mo). GC-MS results identified 77 compounds and various functional groups present in the first and second stage liquid product. In the first stage 3:1 ratios and liquid product yields catalysed by magnetite were favoured. The second stage product distribution showed an increase in the BTX (Benzene, Toluene, Xylene) quality of the liquid product, branched chain alkanes and a reduction in the sulphur concentration. As an HDS performer and selectivity to the production of long and branched chain alkanes, Ni-Mo had an improved performance over Co-Mo. Co-Mo is selective to a higher concentration of cyclohexane. For 16 days on stream each, Ni-Mo had a higher activity than Co-Mo. The potential to cover the demand for low–sulphur, crude diesel and solvents from the production of high value hydrocarbon liquid in the said process, is thus demonstrated.
Abstract: Brass terminal, one of the several crude oil and
petroleum products storage/handling facilities in the Niger Delta was
built in the 1980s. Activities at this site, over the years, released
crude oil into this 3 m-deep, 1500 m-long canal lying adjacent to the
terminal with oil floating on it and its sediment heavily polluted. To
ensure effective clean-up, three major activities were planned: site
characterization, bioremediation pilot plant construction and testing
and full-scale bioremediation of contaminated sediment / bank soil by
land farming. The canal was delineated into 12 lots and each
characterized, with reference to the floating oily phase, contaminated
sediment and canal bank soil. As a result of site characterization, a
pilot plant for on-site bioremediation was designed and a treatment
basin constructed for carrying out pilot bioremediation test.
Following a designed sampling protocol, samples from this pilot
plant were collected for analysis at two laboratories as a quality
assurance / quality control check. Results showed that Brass Canal
upstream is contaminated with dark, thick and viscous oily film with
characteristic hydrocarbon smell while downstream, thin oily film
interspersed with water was observed. Sediments were observed to be
dark with mixture of brownish sandy soil with TPH ranging from
17,800 mg/kg in Lot 1 to 88,500 mg/kg in Lot 12 samples. Brass
Canal bank soil was observed to be sandy from ground surface to 3m,
below ground surface (bgs) it was silty-sandy and brownish while
subsurface soil (4-10m bgs) was sandy-clayey and whitish/grayish
with typical hydrocarbon smell. Preliminary results obtained so far
have been very promising but were proprietary. This project is
considered, to the best of technical literature knowledge, the first
large-scale on-site bioremediation project in the Niger Delta region,
Nigeria.
Abstract: This paper deals with the issue of biomass and sorted
municipal waste gasification and cogeneration using hot-air turbo-set.
It brings description of designed pilot plant with electrical output 80
kWe. The generated gas is burned in secondary combustion chamber
located beyond the gas generator. Flue gas flows through the heat
exchanger where the compressed air is heated and consequently
brought to a micro turbine. Except description, this paper brings our
basic experiences from operating of pilot plant (operating parameters,
contributions, problems during operating, etc.). The principal
advantage of the given cycle is the fact that there is no contact
between the generated gas and the turbine. So there is no need for
costly and complicated gas cleaning which is the main source of
operating problems in direct use in combustion engines because the
content of impurities in the gas causes operation problems to the units
due to clogging and tarring of working surfaces of engines and
turbines, which may lead as far as serious damage to the equipment
under operation. Another merit is the compact container package
making installation of the facility easier or making it relatively more
mobile. We imagine, this solution of cogeneration from biomass or
waste can be suitable for small industrial or communal applications,
for low output cogeneration.
Abstract: The heavy metals pollution in water, sediments and fish of Lake Manzala affected form the disposal of wastewater, industrial and agricultural drainage water into the lake on the environmental situation. A pilot plant with an industrial discharge flow of 135L/h designed according to the activated sludge plant to simulate between the biological and chemical treatment with the addition of alum to the aeration tank with dosages of 100, 150, 200 and 250 mg/L. The industrial discharge had concentrations of Lead and BOD5 with an average range 1.22, 145mg/L respectively. That means the average Pb was high up to 25 times than the allowed permissible concentration. The optimization of the chemical-biological process using 200mg/L Alum dosage compared has improvement of Lead and BOD5 removal efficiency to 61.76% and 56% respectively.
Abstract: Molasses is one of the most important by-products in sugar industry, which contains a large amount of sucrose. The routine way to separate the sucrose from molasses is using steffen method. Whereas this method is very usual in sugar factories, the aim of this research is optimization of this method. Mentioned optimization depends to three factors of reactor alkality, reactor temperature and diluted molasses brix. Accordingly, three different stages must be done:
Construction of a pilot plant similar to actual steffen system in sugar factories
Experimenting using the pilot plant
Laboratory analysis
These experiences included 27 treatments in three replications. In each replication, brix, polarization and purity characters in Saccharate syrup and hot and cold waste were measured. The results showed that diluted molasses brix, reactor alkality and reactor temperature had many significant effects on Saccharate purity and efficiency of molasses desugarization. This research was performed in "randomize complete design" form & was analyzed with "duncan multiple range test". The significant difference in the level of α = 5% is observed between the treatments. The results indicated that the optimal conditions for molasses desugarization by steffen method are: diluted molasses brix= 10, reactor alkality= 10 and reactor temperature=8˚C.
Abstract: This paper presents the prediction of air flow,
humidity and temperature patterns in a co-current pilot plant spray
dryer fitted with a pressure nozzle using a three dimensional model.
The modelling was done with a Computational Fluid Dynamic
package (Fluent 6.3), in which the gas phase is modelled as
continuum using the Euler approach and the droplet/ particle phase is
modelled by the Discrete Phase model (Lagrange approach).Good
agreement was obtained with published experimental data where the
CFD simulation correctly predicts a fast downward central flowing
core and slow recirculation zones near the walls. In this work, the
effects of the air flow pattern on droplets trajectories, residence time
distribution of droplets and deposition of the droplets on the wall also
were investigated where atomizing of maltodextrin solution was
used.
Abstract: A feasibility study for the design and construction of a
pilot plant for the extraction of castor oil in South Africa was
conducted. The study emphasized the four critical aspects of project
feasibility analysis, namely technical, financial, market and
managerial aspects. The technical aspect involved research on
existing oil extraction technologies, namely: mechanical pressing and
solvent extraction, as well as assessment of the proposed production
site for both short and long term viability of the project. The site is
on the outskirts of Nkomazi village in the Mpumalanga province,
where connections for water and electricity are currently underway,
potential raw material supply proves to be reliable since the province
is known for its commercial farming. The managerial aspect was
evaluated based on the fact that the current producer of castor oil will
be fully involved in the project while receiving training and technical
assistance from Sasol Technology, the TSC and SEDA. Market and
financial aspects were evaluated and the project was considered
financially viable with a Net Present Value (NPV) of R2 731 687 and
an Internal Rate of Return (IRR) of 18% at an annual interest rate of
10.5%. The payback time is 6years for analysis over the first 10
years with a net income of R1 971 000 in the first year. The project
was thus found to be feasible with high chance of success while
contributing to socio-economic development. It was recommended
for lab tests to be conducted to establish process kinetics that would
be used in the initial design of the plant.
Abstract: In this research, a systematic investigation was carried out to determine the optimum conditions of HDS reactor. Moreover, a suitable model was developed for a rigorous RTO (real time optimization) loop of HDS (Hydro desulfurization) process. A systematic experimental series was designed based on CCD (Central Composite design) and carried out in the related pilot plant to tune the develop model. The designed variables in the experiments were Temperature, LHSV and pressure. However, the hydrogen over fresh feed ratio was remained constant. The ranges of these variables were respectively equal to 320-380ºC, 1- 21/hr and 50-55 bar. a power law kinetic model was also developed for our further research in the future .The rate order and activation energy , power of reactant concentration and frequency factor of this model was respectively equal to 1.4, 92.66 kJ/mol and k0=2.7*109 .
Abstract: A pilot plant for continuous flow microwave-assisted
chemical reaction combined with microreactors was developed and
water heating tests were conducted for evaluation of the developed
plant. We developed a microwave apparatus having a single
microwave generator that can heat reaction solutions in four reaction
fields simultaneously in order to increase throughput. We also
designed a four-branch waveguide using electromagnetic simulation,
and found that the transmission efficiency at 99%. Finally, we
developed the pilot plant using the developed microwave apparatus
and conducted water heating tests. The temperatures in the respective
reaction fields were controlled within ±1.1 K at 353.2 K. Moreover,
the energy absorption rates by the water were about 90% in the
respective reaction fields, whereas the energy absorption rate was
about 40% when 100 cm3 of water was heated by a commercially
available multimode microwave chemical reactor.
Abstract: In a pilot plant scale of a fluidized bed reactor, a
reduction reaction of sodium sulfate by natural gas has been
investigated. Natural gas is applied in this study as a reductant. Feed
density, feed mass flow rate, natural gas and air flow rate
(independent parameters)and temperature of bed and CO
concentration in inlet and outlet of reactor (dependent parameters)
were monitored and recorded at steady state. The residence time was
adjusted close to value of traditional reaction [1]. An artificial neural
network (ANN) was established to study dependency of yield and
carbon gradient on operating parameters. Resultant 97% accuracy of
applied ANN is a good prove that natural gas can be used as a
reducing agent. Predicted ANN model for relation between other
sources carbon gradient (accuracy 74%) indicates there is not a
meaningful relation between other sources carbon variation and
reduction process which means carbon in granule does not have
significant effect on the reaction yield.
Abstract: The implementation of the new software and hardware-s technologies for tritium processing nuclear plants, and especially those with an experimental character or of new technology developments shows a coefficient of complexity due to issues raised by the implementation of the performing instrumentation and equipment into a unitary monitoring system of the nuclear technological process of tritium removal. Keeping the system-s flexibility is a demand of the nuclear experimental plants for which the change of configuration, process and parameters is something usual. The big amount of data that needs to be processed stored and accessed for real time simulation and optimization demands the achievement of the virtual technologic platform where the data acquiring, control and analysis systems of the technological process can be integrated with a developed technological monitoring system. Thus, integrated computing and monitoring systems needed for the supervising of the technological process will be executed, to be continued with the execution of optimization system, by choosing new and performed methods corresponding to the technological processes within the tritium removal processing nuclear plants. The developing software applications is executed with the support of the program packages dedicated to industrial processes and they will include acquisition and monitoring sub-modules, named “virtually" as well as the storage sub-module of the process data later required for the software of optimization and simulation of the technological process for tritium removal. The system plays and important role in the environment protection and durable development through new technologies, that is – the reduction of and fight against industrial accidents in the case of tritium processing nuclear plants. Research for monitoring optimisation of nuclear processes is also a major driving force for economic and social development.
Abstract: This work presents the experimental results obtained
at a pilot plant which works with a slow, wet and catalytic pyrolysis
process of dry fowl manure. This kind of process mainly consists in
the cracking of the organic matrix and in the following reaction of
carbon with water, which is either already contained in the organic
feed or added, to produce carbon monoxide and hydrogen. Reactions
are conducted in a rotating reactor maintained at a temperature of
500°C; the required amount of water is about 30% of the dry organic
feed. This operation yields a gas containing about 59% (on a volume
basis) of hydrogen, 17% of carbon monoxide and other products such
as light hydrocarbons (methane, ethane, propane) and carbon
monoxide in lesser amounts. The gas coming from the reactor can be
used to produce not only electricity, through internal combustion
engines, but also heat, through direct combustion in industrial
boilers. Furthermore, as the produced gas is devoid of both solid
particles and pollutant species (such as dioxins and furans), the
process (in this case applied to fowl manure) can be considered as an
optimal way for the disposal and the contemporary energetic
valorization of organic materials, in such a way that is not damaging
to the environment.
Abstract: A mathematical model for the hydrodynamics of a
surface water treatment pilot plant was developed and validated by
the determination of the residence time distribution (RTD) for the
main equipments of the unit. The well known models of ideal/real
mixing, ideal displacement (plug flow) and (one-dimensional axial)
dispersion model were combined in order to identify the structure
that gives the best fitting of the experimental data for each equipment
of the pilot plant. RTD experimental results have shown that pilot
plant hydrodynamics can be quite well approximated by a
combination of simple mathematical models, structure which is
suitable for engineering applications. Validated hydrodynamic
models will be further used in the evaluation and selection of the
most suitable coagulation-flocculation reagents, optimum operating
conditions (injection point, reaction times, etc.), in order to improve
the quality of the drinking water.
Abstract: The technique of inducing micro ecosystem
restoration is one of aquatic ecology engineering methods used to
retrieve the polluted water. Batch scale study, pilot plant study, and
field study were carried out to observe the eutrophication using the
Inducing Ecology Restorative Symbiosis Agent (IERSA) consisting
mainly degraded products by using lactobacillus, saccharomycete,
and phycomycete. The results obtained from the experiments of the
batch scale and pilot plant study allowed us to development the
parameters for the field study. A pond, 5 m to the outlet of a lake,
with an area of 500 m2 and depth of 0.6-1.2 m containing about 500
tons of water was selected as a model. After the treatment with 10
mg IERSA/L water twice a week for 70 days, the micro restoration
mechanisms consisted of three stages (i.e., restoration, impact
maintenance, and ecology recovery experiment after impact). The
COD, TN, TKN, and chlorophyll a were reduced significantly in the
first week. Although the unexpected heavy rain and contaminate
from sewage system might slow the ecology restoration. However,
the self-cleaning function continued and the chlorophyll a reduced
for 50% in one month. In the 4th week, amoeba, paramecium, rotifer,
and red wriggle worm reappeared, and the number of fish flies
appeared up to1000 fish fries/m3. Those results proved that inducing
restorative mechanism can be applied to improve the eutrophication
and to control the growth of algae in the lakes by gaining the selfcleaning
through inducing and competition of microbes. The
situation for growth of fishes also can reach an excellent result due to
the improvement of water quality.
Abstract: In the present study, a heterogeneous and
homogeneous gas flow dispersion model for simulation and
optimisation of a large-scale catalytic slurry reactor for the direct
synthesis of dimethyl ether (DME) from syngas and CO2, using a
churn-turbulent regime was developed. In the heterogeneous gas flow
model the gas phase was distributed into two bubble phases: small
and large, however in the homogeneous one, the gas phase was
distributed into only one large bubble phase. The results indicated
that the heterogeneous gas flow model was in more agreement with
experimental pilot plant data than the homogeneous one.
Abstract: In this paper the development of a heat exchanger as a
pilot plant for educational purpose is discussed and the use of neural
network for controlling the process is being presented. The aim of the
study is to highlight the need of a specific Pseudo Random Binary
Sequence (PRBS) to excite a process under control. As the neural
network is a data driven technique, the method for data generation
plays an important role. In light of this a careful experimentation
procedure for data generation was crucial task. Heat exchange is a
complex process, which has a capacity and a time lag as process
elements. The proposed system is a typical pipe-in- pipe type heat
exchanger. The complexity of the system demands careful selection,
proper installation and commissioning. The temperature, flow, and
pressure sensors play a vital role in the control performance. The
final control element used is a pneumatically operated control valve.
While carrying out the experimentation on heat exchanger a welldrafted
procedure is followed giving utmost attention towards safety
of the system. The results obtained are encouraging and revealing
the fact that if the process details are known completely as far as
process parameters are concerned and utilities are well stabilized then
feedback systems are suitable, whereas neural network control
paradigm is useful for the processes with nonlinearity and less
knowledge about process. The implementation of NN control
reinforces the concepts of process control and NN control paradigm.
The result also underlined the importance of excitation signal
typically for that process. Data acquisition, processing, and
presentation in a typical format are the most important parameters
while validating the results.
Abstract: For stricter drinking water regulations in the future, reducing the humic acid and disinfection byproducts in raw water, namely, trihalomethanes (THMs) and haloacetic acids (HAAs) is worthy for research. To investigate the removal of waterborne organic material using a lab-scale of bio-activated carbon filter under different EBCT, the concentrations of humic acid prepared were 0.01, 0.03, 0.06, 0.12, 0.17, 0.23, and 0.29 mg/L. Then we conducted experiments using a pilot plant with in-field of the serially connected bio-activated carbon filters and hollow fiber membrane processes employed in traditional water purification plants. Results showed under low TOC conditions of humic acid in influent (0.69 to 1.03 mg TOC/L) with an EBCT of 30 min, 40 min, and 50 min, TOC removal rates increases with greater EBCT, attaining about 39 % removal rate. The removal rate of THMs and HAAs by BACF was 54.8 % and 89.0 %, respectively.
Abstract: Rice husk is one of the alternative fuels for Thailand because of its high potential and environmental benefits. Nonetheless, the environmental profile of the electricity production from rice husk must be assessed to ensure reduced environmental damage. A 10 MW pilot plant using rice husk as feedstock is the study site. The environmental impacts from rice husk power plant are evaluated by using the Life Cycle Assessment (LCA) methodology. Energy, material and carbon balances have been determined for tracing the system flow. Carbon closure has been used for describing of the net amount of CO2 released from the system in relation to the amount being recycled between the power plant and the CO2 adsorbed by rice husk. The transportation of rice husk to the power plant has significant on global warming, but not on acidification and photo-oxidant formation. The results showed that the impact potentials from rice husk power plant are lesser than the conventional plants for most of the categories considered; except the photo-oxidant formation potential from CO. The high CO from rice husk power plant may be due to low boiler efficiency and high moisture content in rice husk. The performance of the study site can be enhanced by improving the combustion efficiency.