The use of cogenerators (CHP units) in the industrial sector can give remarkable advantages of different kinds and its most important benefits can be both economical and environmental. Cogenerators allows both energy and economic saving on electricity bills. Consequently the producers are able to decrease the unit price of the final product and offer more competitive prices on the market. Furthermore the use of CHP units contributes to reducing the emissions of pollutants, which results in a less significant environmental impact. The aim of this project is to investigate the installation of a cogenerator in thermal treatment factory in order to power the entire production line and the furnaces in particular. Some sections of the furnaces, in which originally the heat was provided by means of electrical resistances, have been rearranged in order to use the gas-fired flow generated by the CHP unit as thermal power. In order to exploit the thermal power of the cogenerator cooling water an absorption system has been installed, and its chilled power can be useful to the washing units operation. The quenched products need to be washed, this operation requires both thermal power and chilled power. The first one is exploited through the cogenerator exhaust gases, the second comes from the absorption system; consequently energy and money savings are expected. After several and accurate measurements on site, a feasibility study has been developed, in order to understand whether CHP is suitable and what benefits can be expected from it. A sensitivity analysis has been performed changing the productivity of the factory and stretching the electricity and gas price. In addition a comprehensive exhaust gasses recovery system analysis has been performed with the heat exchangers needed to supply the right thermal amount. A path for the gas circuit has been designed in order to minimize the pressure losses and ensure the correct operation of the CHP unit, taking into account the maximum allowable back pressure.
L’ utilizzo della cogenerazione in campo industriale può produrre notevoli vantaggi di diversa natura e i principali benefici sono riconducibili alla sfera economica ed ambientale. I cogeneratori consentono un risparmio energetico e un risparmio economico sui costi in bolletta, grazie a ciò il produttore è in grado di ridurre il prezzo unitario del prodotto finito e diventare più competitivo sul mercato. Inoltre l’utilizzo del cogeneratore favorisce la riduzione delle emissioni di sostanze inquinanti, con conseguente minor impatto ambientale. Lo scopo di questo lavoro è lo studio dell’installazione di un cogeneratore in un’industria di trattamenti termici al fine di alimentare l’intera linea di produzione, in particolar modo i forni. Determinate sezioni di quest’ultimi, nelle quali originariamente l’apporto di calore avveniva attraverso resistenze elettriche, sono state riadattate utilizzando come potenza termica il flusso di fumi uscente dal cogeneratore. Per sfruttare inoltre la potenza termica del circuito acqua uscente del cogeneratore, si è provveduto ad installare una macchina frigorifera ad assorbimento, la quale produce potenza frigo utile per il funzionamento delle lavatrici. I pezzi temprati in bagno di sale necessitano di successivo lavaggio, questa operazione, necessita sia di una potenza termica, fornita attraverso i gas uscenti dal cogeneratore, sia di una potenza frigo, proveniente dal sistema ad assorbimento, con conseguente risparmio energetico ed economico. Si è così provveduto a sviluppare lo studio di fattibilità, dopo attente misure sul campo e uno studio di sensibilità per verificare se l’investimento rimane vantaggioso a seguito di variazioni riguardanti il prezzo unitario del gas, dell’elettricità e della produzione dell’impianto. Si è inoltre analizzato il sistema di recupero termico dei fumi con i relativi scambiatori necessari per fornire il giusto apporto di calore. Si è scelto un percorso per il circuito fumi che minimizzasse le perdite di carico e che garantisse il corretto funzionamento del cogeneratore, rispettando il valore di contropressione massima.
An application of a cogeneration unit in a thermal treatment factory
MENEGAZZO, ANNA
2018/2019
Abstract
The use of cogenerators (CHP units) in the industrial sector can give remarkable advantages of different kinds and its most important benefits can be both economical and environmental. Cogenerators allows both energy and economic saving on electricity bills. Consequently the producers are able to decrease the unit price of the final product and offer more competitive prices on the market. Furthermore the use of CHP units contributes to reducing the emissions of pollutants, which results in a less significant environmental impact. The aim of this project is to investigate the installation of a cogenerator in thermal treatment factory in order to power the entire production line and the furnaces in particular. Some sections of the furnaces, in which originally the heat was provided by means of electrical resistances, have been rearranged in order to use the gas-fired flow generated by the CHP unit as thermal power. In order to exploit the thermal power of the cogenerator cooling water an absorption system has been installed, and its chilled power can be useful to the washing units operation. The quenched products need to be washed, this operation requires both thermal power and chilled power. The first one is exploited through the cogenerator exhaust gases, the second comes from the absorption system; consequently energy and money savings are expected. After several and accurate measurements on site, a feasibility study has been developed, in order to understand whether CHP is suitable and what benefits can be expected from it. A sensitivity analysis has been performed changing the productivity of the factory and stretching the electricity and gas price. In addition a comprehensive exhaust gasses recovery system analysis has been performed with the heat exchangers needed to supply the right thermal amount. A path for the gas circuit has been designed in order to minimize the pressure losses and ensure the correct operation of the CHP unit, taking into account the maximum allowable back pressure.File | Dimensione | Formato | |
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https://hdl.handle.net/10589/148855