Reduction Of Specific Energy Consumption Research Articles

An integrated approach to investigate the energy consumption for manufacturing and surface finishing 3D printed Inconel 718 parts

Current scenarios show the need of making manufacturing more sustainable as it plays a crucial role in global sustainability. For this reason, sustainability should be included among the objectives driving the selection of process parameters. As-built parts manufactured by additive manufacturing techniques always require post-processing to meet industrial quality requirements, and machining is one of the solutions often adopted to improve their surface finishing. However, inevitably an additional manufacturing process requires some supplementary both energy and resource consumption by also impact unavoidably on the environment. This experimental study includes both additive manufacturing and post-process machining to evaluate the global specific energy consumption required to manufacture and then finish Inconel 718 parts. This paper aims at understanding how to obtain Inconel 718 parts manufactured by selective laser melting (SLM) and machined by turning by saving energy without sacrificing roughness and density. The printing process parameters of SLM process have been varied in a wide range: 27 different samples have been produced to evaluate the specific energy consumption (SEC) and to highlight the influence of the process parameters on the energy consumption. Density and roughness measurements have been chosen as measured outputs to prove the effectiveness of the process and to attempt a correlation among process parameters, properties of the printed parts and energy consumption. All the as-built samples were post-treated by turning process under the same conditions to achieve a surface finishing with a Ra value close to 4 μm; the energy consumption of this process has been also recorded and analyzed. Finally, the energy consumption of the whole processing path, including both printing and turning, has been discussed and a correlation between processing parameters and energy consumption has been attempted. Results showed that a proper choice of the process parameters leads up to a 54% reduction in specific energy consumption to obtain SLMelted Inconel 718 parts having low surface roughness and high density.

Extractive distillation of ethyl acetate-ethanol-water ternary system using deep eutectic solvent (DES): A techno economic and energy assessment

The extractive distillation (ED) process has been established as a commercially viable process that can be used to break the azeotropic systems. The present study investigates the performance and feasibility of conventional solvent (glycerol) and choline chloride-glycerol based deep eutectic solvent (DES) as entrainers for the separation of ethyl acetate-ethanol-water ternary mixture through ED. A comprehensive approach is proposed with phase-equilibrium measurements and process simulation through Aspen Plus for different entrainer to feed ratio (E/F). Optimization of the process is based on performance indicators such as Total Annual Cost, CO2 emissions, and Specific Energy Consumption. A sequential iterative algorithm was used to find the optimum E/F in distillation trains. The performance analysis has shown a reduction of 45.89% in global TAC with DES as an entrainer. The combined entrainer requirement for the dehydration was 268.3 kmol/h and 118.86 kmol/h with glycerol and DES respectively. The process sees a 58.21% total energy saving with a 15% and 44.5% reduction in Specific Energy Consumption and CO2 emissions respectively as compared to glycerol as an entrainer. The study provides a comparison and proves that DES is an effective entrainer to break the azeotropic point as a low-cost and eco-friendly alternative to conventional solvents.

Forward osmosis dewatering of seawater and pesticide contaminated effluents using the commercial fertilizers and zinc-nitrate blend draw solutions

Fertilizer driven forward osmosis (FDFO) process would be feasible due to the possible prevention of the drainage of dewatered and concentrated pesticide effluent from agricultural pesticide industries to the environment. Instead, it would be possible to return the concentrated pesticide solution to the processing cycle, and on the other hand, employ directly the obtained diluted fertilizer draw solution for irrigation. This study investigated the performance of zinc-nitrate/amino-acids blends as fertilizer type draw solution, and distilled water, saline water (seawater), and synthetic wastewater containing pesticides as feed. The results indicated that the synergetic effect of blended type fertilizer presented significantly higher osmotic pressure and water flux than the sum of their individual ones, especially when the amount of amino acid increased. Conversely, an ignorable reverse flux of blended fertilizer draw solute was observed. The fertilizer blend with a molar ratio of 1:6 zinc-nitrate/amino-acid achieved the higher average fluxes of 34.7 and 23.92 L/m2h from distilled and saline waters compared to common draw solutions such as metal salts. Furthermore, the FDFO exhibited a high rejection (over 99%) of bentazon and imidacloprid in feed solutions compared to other agricultural pesticides due to their larger molecular weight and molecular size. The applied FDFO represented a significant reduction in specific energy consumption (from 0.17 to 0.049 kWh/m3) in a bench-scale setup as compared to the RO process almost at the same water permeation flux and the rejection of bentazon.

РАЗРАБОТКА КОМБИНИРОВАННОГО РАБОЧЕГО ОРГАНА ДЛЯ ВВОДА ЗАЛЕЖНЫХ ЗЕМЕЛЬ В СЕВООБОРОТ

Constantly increasing requirements to reduce the energy efficiency of technological processes in crop production call for designing new mechanization means capable of cutting and performing surface tillage in one pass of a unit. The study of modern scientific and patent literature has revealed that the existing individual models of such machines are not used in agricultural production. The work aims to theoretically justify a new hybrid unit designed for simultaneous cutting and soil rotatilling based on the system approach. Theoretical studies showed that the initial requirements for removing low-value and weedy vegetation with simultaneous soil surface rotatilling. The authors considered a model of combining these technological processes, taking into account the requirements for fodder harvesting technology. A provision was made that during soil preparation it is necessary to undercut the vegetation completely with the least energy inputs without reducing its quality for further impacts. In mathematical designing of the working unit, rheological properties of cultivation objects – soil layer and vegetative material – were taken into account. Based on these research outcomes, the authors developed the effective design of a working unit combining cutting with soil rotatilling. Comparative analyses of the agro-energy intensity of the combined operation showed a reduction of specific energy consumption by 10…12% on average.

Reduction of specific heat consumption by modification of reversal cycle period of coke oven battery

In this research, we were able to reduce this time to 18 min while maintaining the coke quality required by blast furnaces. In the batteries, we were able to reduce the specific heat consumption of coke oven gas from 660 kcal/kg to 640 kcal/kg of coal. The adoption of this concept in coke oven batteries, which will produce coke in a more energy-efficient manner while incurring no additional costs. Steel industry plays an important role in India's long-term economic growth, which may be further increased by developing and demonstrating innovative energy-efficient technology, as well as adopting world-class energy-efficient practices. Energy consumption and economic growth are inextricably intertwined, and the degree of energy intensity always indicates energy growth. The Coke oven department is critical to the production of steel. Coke is used as a reducing agent and for burden management in blast furnaces. Also Coke oven department plays a very vital role in the energy aspect in integrated steel plants where coke oven gas is recovered during the carbonization process which is used as fuel in coke making as well as in other departments. The Coke oven department is a very energy intensive department. Therefore, reduction in specific energy consumption at coke ovens will reduce manufacturing cost of steel. The areas were identified where some energy conservation study can be done. It was found that the heating reversal period is 20 min; the regenerator is not utilizing the entire heat of the combustion product for 20 min, as it is reaching its maximum temperature before. So different studies were conducted and the cycle period can be reduced. So different studies were conducted and the cycle period can be reduced.

ANALYSIS OF VIBRATION TECHNICAL DEVICES FOR DRYING PUMPKIN SEEDS

A significant obstacle to the expansion of pumpkin production is the lack of quality seed. In connection with the imperfection of existing means for post-harvest seed treatment, it becomes necessary to develop new drying methods that would ensure high quality of the finished product, create conditions for complete and timely processing of the harvested crop, reduce losses, automate, mechanize and significantly intensify this process, as well as reduction of specific energy consumption. When analyzing the latest studies on drying seed products, it was noted that most of the work relates specifically to post-harvest processing of wheat grains, slightly less to drying corn and legumes, and a very insignificant share concerns vegetables and melons. A fundamental requirement of the drying process for pumpkin seeds as seed and food is to ensure standard quality endpoints. In installations where pumpkin seeds are dried in a fixed bed, the upper layer of the seed embankment dries up last, the quality of the lower layer deteriorates due to overdrying below the optimum value. This causes significant heterogeneity in the moisture content of the seed mass. Considering the large range of moisture removal when drying high-moisture pumpkin seeds, when the available moisture reduction in one pass is 6%, the use of drum dryers due to the need to organize multiple passes, as well as the tendency of the seed mass, is technically and economically impractical. Conveyor dryers are difficult to maintain, expensive and have low productivity. It is difficult to use differentiated modes of seed drying in them, and also in the design it is necessary to take into account the increased cohesive-adhesive properties of the seed layer. The drying process, taking into account the necessary requirements associated with the characteristics of pumpkin seeds, it is advisable to carry out in dryers with vibration layer loosening. To improve the flowability of a layer of seeds prone to sticking, sticking, channeling, agglomeration, at the initial stage of vibration drying, along with vibration and aeration mixing, it is advisable to use additional mechanical stirrers.

Impact of different pretreatments on drying kinetics and quality of button mushroom slices dried by hot-air or electrohydrodynamic drying

The effects of three pretreatments (pulsed electric field (PEF), ultrasound (US), and conventional blanching (CB) pretreatments) prior to drying were evaluated on drying kinetics and quality of button mushroom slices that were dehydrated in either electrohydrodynamic (EHD) drying or by hot-air (HA) drying. Results showed that the US and PEF pretreatments prior to the drying process significantly reduced the drying time and energy consumption of button mushroom slices and also improved drying rate and effective moisture diffusivity. However, the antioxidant activity of dried mushroom slices pretreated by US or PEF was significantly lower than that of the CB pretreated samples. In general, US pretreatment was more effective on drying kinetics and had a greater effect on the reduction of specific energy consumption than PEF pretreatment. Results also showed that hot air drying was much faster than EHD drying and EHD had detrimental effects on the total phenolic compounds and antioxidant activity of button mushrooms than HA drying. These data demonstrated that selecting the appropriate set of control variables in US and PEF pretreatments and EHD drying techniques are necessary to ensure high-quality dried foods as well as low energy consumption.

ENERGY EFFICIENT ELECTROMECHANICAL SOIL TREATMENT SYSTEM BASED ON ELECTRIC MOTORBLOCK

In Ukraine, the number of farms, private land users and protected soil structures has increased significantly in recent years. To increase the efficiency of vegetable production, small-sized mobile units in the form of motoblocks with internal combustion engines of domestic and foreign production have been widely used. However, during the operation of mobile units with internal combustion engines in greenhouses and hotbeds, the noise level and air pollution increase, which negatively affect not only people but also plants. The disadvantages of motoblocks with internal combustion engines should also include a fairly high specific consumption of liquid fuel, which has a high cost, difficulties in starting and stopping the unit, as well as the relatively low reliability of the internal combustion engine. More promising for work in protected soil structures are mobile units with traction motors, called electric motors, as environmentally friendly units that do not have these shortcomings. The main technical characteristics of the experimental sample of a small-sized electrified soil-cultivating motoblock are given in the work. The structural scheme of the power energy channel of the electric motor unit is substantiated, which clearly demonstrates the processes of energy conversion in it. The equation of energy balance of the electric motor unit and the main energy ratios that determine the properties of the traction motor in the drive of the electric motor unit are obtained. The algorithm of optimal control of a direct current traction motor by the maximum efficiency for direct current motors of serial and mixed excitation is substantiated. The results of field tests of the prototype of the electric motor unit are presented. The analysis of the obtained results of experimental researches of the electrified tillage motor-drive driven by the direct current motor of sequential excitation testifies to the reduction of specific energy consumption for the main types of tillage by 12-15%.

МАТЕМАТИЧЕСКОЕ ОПИСАНИЕ ДВИЖЕНИЯ ДВУХФАЗНОГО ПОТОКА НА ВЫХОДЕ ИЗ ВЕРТИКАЛЬНОЙ РАЗГОННОЙ ТРУБКИ СТРУЙНОЙ МЕЛЬНИЦЫ С ПЛОСКОЙ ПОМОЛЬНОЙ КАМЕРОЙ ТОРООБРАЗНОЙ ФОРМЫ

Nowadays building material industry as well as other industry branches exercise bigger demand to use powders with high dispersion. Jet mills are used to produce such powders that is why development of new jet mill designs, increase of grind efficiency, reduction of specific energy consumption is an important objective. This article provides a mathematic description of the two-phase flow motion at the outlet of the vertical acceleration tube of a jet mill with a plane grinding chamber of torus shape. The part of the acceleration tube above the impact plate is essential for grinding, as the initial particle grind occurs at this very section, in the grind chamber. Moreover, the initial grind defines the size of particles, that are further reground at the mill chamber. As a result of theoretical calculations, a formula is obtained that allows to determine the height of the acceleration tube from the bump element at the specified speed parameters of the two-phase flow. The article also contains the graph, that shows how particle velocity depends on the current (specific) height point (value) of the acceleration tube. This graph demonstrates that particle size strongly affects the way they move in the grind chamber. The formula allows to calculate the effective propulsion range of particles, depending on theirs' size, by presuming they have the maximum velocity

Classification of Impulse Rotators with Kinematic Excitation of Oscillations

The kinematic torsional vibration exciters ensure that the material to be processed is required in the specified parameters. The structure of the Assur groups involved successive manufacture and testing of a device for practical assessment of motion possibilities, nature of change in process forces, structural reliability and maximum useful application of the supplied energy for destruction of the processed material. Analysis of operation results of laboratory and industrial samples showed their advantage in comparison with existing drives due to expansion of application field, reduction of specific energy consumption of a production unit, quality improvement of technological processes and operation time. The varied influence of torsional oscillations on properties variety of the processed materials has led to the development of an impulse rotators (IR) class of required technical characteristics. In order to increase rotators consistency parameters with materials properties, individual property IR designs are currently being developed.

Real-time neuro-fuzzy controller for pressure adjustment in water distribution systems

Abstract This work applied a neuro-fuzzy technique for real-time pressure control in water distribution systems with variable demand. The technique acted to control the rotation speed of the pumping system, aiming mainly at increasing energy efficiency. Fuzzy, neural and neuro-fuzzy controllers were tested in an experimental setup to compare their performances in a transient regime, a permanent regime, and with respect to disturbances applied to the system. To evaluate the efficiency of the system, a demand variation curve was emulated for different operating conditions. The results demonstrate that the neuro-fuzzy controller (NFC) presented a significant increase in pumping system efficiency and a reduction in specific energy consumption of up to 79.7% when compared to the other controllers. Target pressures were kept close to the set-point values with low hydraulic transients and maintained satisfactory stability (error <8%) under severe situations of demand variation. It is concluded that the NFC presented superior results when compared with the other analyzed controllers.

Vacuum drying characteristics of LiNi0.5Co0.2Mn0.3O2 battery powder

LiNi0.5Co0.2Mn0.3O2 (NCM523) has been extensively used in the commercial lithium-ion batteries due to the excellent electrochemical performance and outstanding thermal stability. NCM523 powder is usually dried in vacuum before the slurry preparation, for the moisture greatly affects its electrochemical performance. In this paper, drying experiment of NCM523 powder is performed and the effects of different drying conditions are investigated. Moreover, the experiment data are fitted to eight mathematical models and Modified Page model is selected to describe the drying behavior. The effective diffusivities range from 9.7212 × 10−8 to 3.2642 × 10−7m2·s-1 and the activation energy is 8.300kJ·mol-1. The total energy consumption and specific energy consumption are discussed at the end of paper. The results reveal that raising drying temperature is beneficial to improve drying performance and cut the energy use. Decreasing the thickness is conducive to shorten drying time, but it isinvalid for the reduction of specific energy consumption. These results can provide valuable information for the scientists and technicians when they design the drying process of NCM523 powder.

A comprehensive approach to evaluate feed stream composition effect on natural gas processing unit energy consumption

Natural gas processing unit consume a high amount of energy. Any attempt to achieve lower energy consumption subjected to evaluation criteria would lead to a remarkable enhancement in the process efficiency. In the present study, an optimization was carried out by minimizing the specific energy consumption [kWh/kg of Sales Gas - SG] including the restriction of a minimum limit of 90% C3+ recovery by manipulation of some operational parameters such as temperature and pressure. Three natural gas C3+ molar compositions were analyzed: 11.2%, 8.9% and 5.5%. The results were submitted to six evaluation criteria: energy, economic, recovery, production, safety and quality performance. There was a reduction in specific energy consumption of 21.1% for 5.5% composition and an increase in the economic margin [US$/h] in 0.35% with a reduction of the recovery performance in about 3.8% and of the adopted safety criterion. In all cases the quality criteria was met.

Operational strategies for brackish water desalination plants in island regions of South Korea

Based on the operational data from the Korea Water Resources Corporation (K-water), this study aimed to reduce the operation and maintenance (O&M) costs for 20 brackish water desalination plants in the island regions of South Korea. In addition, brackish water reverse osmosis (BWRO) and low-pressure reverse osmosis (LPRO) membranes were compared and evaluated in terms of reduction in specific energy consumption (SEC) for an island brackish water desalination plant. The high labor costs and plant breakdown accounted for most of the operating losses with low operation rates (less than 60% in 19 plants) and low water flow rates (less than 90% in 15 plants). Thus, in order to reduce the O&M costs of island region desalination plants, it was essential to optimize the plant design while increasing the operation and water flow rates. In particular, installation of the LPRO membrane has shown potential for SEC improvement (approximately 16%) due to high pressure pump optimization and high recovery. These operational strategies for island region desalination plants are applicable alternatives in terms of reduction in O&M costs and SEC.

The Role of Nanofluids and Renewable Energy in the Development of Sustainable Desalination Systems: A Review

Desalination accounts for 1% of the total global water consumption and is an energy-intensive process, with the majority of operational expenses attributed to energy consumption. Moreover, at present, a significant portion of the power comes from traditional fossil-fuel-fired power plants and the greenhouse gas emissions associated with power production along with concentrated brine discharge from the process, pose a severe threat to the environment. Due to the dramatic impact of climate change, there is a major opportunity to develop sustainable desalination processes to combat the issues of brine discharge, greenhouse gas emissions along with a reduction in energy consumption per unit of freshwater produced. Nanotechnology can play a vital role to achieve specific energy consumption reduction as nanofluids application increases the overall heat transfer coefficient enabling the production of more water for the same size desalination plant. Furthermore, concentrated brine discharge harms the marine ecosystems, and hence, this problem must also be solved to support the objective of sustainable desalination. Several studies have been carried out in the past several years in the field of nanotechnology applications for desalination, brine treatment and the role of renewable energy in desalination. This paper aims to review the major advances in this field of nanotechnology for desalination. Furthermore, a hypothesis for developing an integrated solar thermal and nanofluid sustainable desalination system, based on the cyclic economy model, is proposed.

Energy Efficiency of the Russian Regional Economy (a case study of the Sverdlovsk Region)

Today, Russia has the second highest value of GDP energy intensity in the world. Among many factors that determine this indicator, special mention can be made of low use efficiency of the fuel and energy resources. This leads to a decreased competitiveness of the national economy. The aim of this paper is to identify practical challenges that serve as a barrier to the reduction of specific energy consumption and to respond with optimal solutions at the level of a territorial entity of Russia (the Sverdlovsk region). The analysis of the fuel and energy balances and the gross regional product between 2015 and 2018 enabled us to identify the changes in the pattern of fuel and energy resources consumption in individual sectors of economy, as well as influencing factors. Special attention is given to the dynamics of average specific energy consumption indicators and to the status of communal infrastructure in the housing and community amenities sector. The study revealed that reduction of technical and commercial losses due to modernization of communal systems and implementation of energy-saving technologies can be achieved through efficient management via further development of public private partnership.

Применение систем автоматического и параллельного вождения в сельскохозяйственном производстве республики Казахстан и эффективность их использования

Abstract. Precision farming systems are being intensively introduced into the agricultural production of the Republic of Kazakhstan. Based on the data of development firms and dealerships centers, precision farming allows the cost of fertilizing, seeds, plant protection products and fuels and lubricants to be reduced by an average of 20 %. In doing so, the possibilities of obtaining efficiency from the use of precision farming systems under certain conditions of their use have not been fully studied. The aim of the work was to determine the impact of parallel and automatic driving systems on the technical and operational as well as economic indices during comparative tests in the North Kazakhstan region of the Republic of Kazakhstan. Research methods. During process of conducting comparative tests, the test conditions, agrotechnical, energy, operational and technological as well as economic indices of aggregates equipped with parallel and automatic driving systems and without systems were determined. All indices were determined in accordance with the requirements of current state standards. Results. In the article are presented the results of comparative tests of a self-moving sprayer on chemical weeding of wheat and flax crops, as well as a combine harvester for wheat harvesting in the conditions of Northern Kazakhstan. The use of GPS navigation and automatic control on the chemical weeding of grain and oilseeds crops contributes to an increase in productivity by 14.6 %, reduction in specific energy consumption by 8 %, fuel consumption by 17.0 %, and working fluid consumption by 14.5 %. In doing so, the total cost of money is reduced by 9 %, the annual savings of the total cost of money is 6562.6 thousand tenge (1093.7 thousand rubles). Using a parallel driving system (GPS-navigation with a course indicator) for harvesting wheat leads to an increase productivity by 2.1 %, reduction of total cost of money by 3 %, labor costs and specific fuel consumption by 1.4 %, while the annual savings of total cost of money is 233.4 thousand tenge (38.9 thousand rubles). The scientific novelty. In the conditions of the Northern region of the Republic of Kazakhstan, the influence of parallel and automatic driving systems on the technical, operational and economic performance of machine-tractor units was studied for the first time.

Enhanced performance of direct contact membrane distillation via selected electrothermal heating of membrane surface

Membrane distillation (MD) is a thermally driven separation process with great potential, but is currently limited by low energy efficiency. Heating of the entire circulating feed represents a major source of energy consumption in MD. Here, we present electrically conductive carbon nanostructure (CNS-) coated polypropylene (PP) membranes as a possible candidate to mitigate energy consumption through selected electrothermal heating of the membrane surface. A membrane for MD was coated with CNS using a tape casting technique. The resulting CNS-PP membrane is hydrophobic, and its smaller pore size and narrow pore size distribution resulted in a higher liquid entry pressure compared to the uncoated PP membrane. An increase in surface temperature was observed when a current was passed through the conductive CNS layer. The CNS layer on the PP membrane acts as an electrothermal heater when an AC potential is applied, and the rate of heating is proportional to the amplitude of applied AC potential. We applied electrothermal heating of these membranes to desalination by direct contact membrane distillation, in conjunction with heating of the circulating feed, and compared the performance with and without application of AC bias at three feed temperatures viz. 40, 50 and 60 °C. Applying a potential across the CNS layer increased permeate flux by 75, 76 and 61% at feed temperatures of 40, 50 and 60 °C respectively, while maintaining a salt rejection of >99%. This increase in flux is accompanied by a reduction in specific energy consumption of greater than 50% for all three feed temperatures. By combining electrothermal surface heating with MD, this study paves the way for smart, low-energy MD systems.

Improving energy efficiency of Bacillus velezensis broth microfiltration in tubular ceramic membrane by air sparging and turbulence promoter

AbstractBACKGROUNDPopularity of biocontrol has increased due to the growing environmental concerns and the demand for organic products. It is considered as a sustainable practice for efficient agricultural production. Microbial biopesticides offer environment‐friendly biotechnological alternative to chemical control of plant diseases and pests. Due to its advantages in cell separation cross‐flow microfiltration has emerged as a powerful alternative to the conventional separation methods. However, the flux enhancement remains to be addressed. This study has estimated the use of flux improvement techniques for biomass harvesting by microfiltration using tubular ceramic membranes. Investigated methods for flux enhancement were turbulence promoter, i.e. Kenics static mixer, two‐phase flow (air sparging) and the combination of these two methods.RESULTSSignificant flux improvement coincides with a reduction in specific energy consumption, while at the same time Bacillus velezensis cells have retained viability and antibacterial activity. The highest values of flux and corresponding improvement, compared to the microfiltration without enhancement techniques, are obtained in the case of combining Kenics static mixer and two‐phase flow (133.4 L m−2 h−1 and 502%). Flux improvement for air sparging was 134%, for turbulence promoter alone flux increase was 434%.CONCLUSIONThe methods proposed herein have achieved effective flux enhancement for cell harvesting. The obtained results also suggest encouraging basis to promote large‐scale economical production of biomass for biocontrol application. © 2019 Society of Chemical Industry

Conserve to conquer

That the accelerated consumption resulting in exponential depletion of fossil fuels, it is imperative to conserve energy at every possible avenue not only to ensure availability of fuels for use in the days to come but also to ably tackle the climate change which is order of the day. While many initiatives for optimum energy use emanate in various manufacturing companies and also are put into practice, emphasis on reduction of specific energy consumption has become mandatory for high power intensive industrial units. Plethora of micro level energy saving activities at various spheres of life can yield phenomenal results to benefit the country to conserve reserves as well as consequent economic growth. Well buttressed by technical efforts, certain administrative measures too are vital to achieve the said goal. Hence the need for presentation of energy conservation in industry and beyond.