O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina
Autor(a) principal: | |
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Data de Publicação: | 2012 |
Tipo de documento: | Dissertação |
Idioma: | por |
Título da fonte: | Repositório Institucional da UFSCAR |
Texto Completo: | https://repositorio.ufscar.br/handle/ufscar/867 |
Resumo: | The increased need of reducing production costs of commodities raised the importance of reaching higher levels of process efficiency and also the consolidation of financial gains due to larger-scale production capacities. In this scenario, the control and reduction of energy consumption is considered one of the most critical issues due to its impact on the companies economical, environmental and social businesses sustainability. In the primary alumina industry, it is estimated that the calcination process still demands 30% in excess of energy to operate, although there have been major improvements in the current calciners when compared to the former versions disseminated in the 70 s. In parallel, although the production capacity increased significantly, diluting the overall production costs, they also raised the importance of maintaining their operational availabilities at the maximum level to attain the financial viability of the processes. Currently, daily losses are estimated to be close to 1 million dollars per each nonproductive day of a large-capacity calciner. Despite this critical aspect, it is not rare to find literature reports indicating refractory failure as one of the main causes of unexpected production halts, which highlights the need of high performance linings as a pre-requisite for longer campaigns and lower levels of energy consumption. This project evaluated one of these refractory failure detected in three new large-capacity calciners. The root-cause of the refractory s short life was identified and afterwards a novel more suitable material was selected increasing twofold the operational campaign time, which resulted in additional potential revenue of 60 million dollars per year. In order to complement the study, the overall reduction of energy consumption was quantified for different high performance insulating materials. This project was concluded with an economical viability study for the implementation of this novel insulating lining concept for those three calciners. |
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Teider, Bruno HenriquePandolfelli, Victor Carloshttp://lattes.cnpq.br/7369376873984839http://lattes.cnpq.br/07121978690455517328140e-17c9-4ca7-b734-0ac2ab74c4302016-06-02T19:12:20Z2012-09-112016-06-02T19:12:20Z2012-07-25https://repositorio.ufscar.br/handle/ufscar/867The increased need of reducing production costs of commodities raised the importance of reaching higher levels of process efficiency and also the consolidation of financial gains due to larger-scale production capacities. In this scenario, the control and reduction of energy consumption is considered one of the most critical issues due to its impact on the companies economical, environmental and social businesses sustainability. In the primary alumina industry, it is estimated that the calcination process still demands 30% in excess of energy to operate, although there have been major improvements in the current calciners when compared to the former versions disseminated in the 70 s. In parallel, although the production capacity increased significantly, diluting the overall production costs, they also raised the importance of maintaining their operational availabilities at the maximum level to attain the financial viability of the processes. Currently, daily losses are estimated to be close to 1 million dollars per each nonproductive day of a large-capacity calciner. Despite this critical aspect, it is not rare to find literature reports indicating refractory failure as one of the main causes of unexpected production halts, which highlights the need of high performance linings as a pre-requisite for longer campaigns and lower levels of energy consumption. This project evaluated one of these refractory failure detected in three new large-capacity calciners. The root-cause of the refractory s short life was identified and afterwards a novel more suitable material was selected increasing twofold the operational campaign time, which resulted in additional potential revenue of 60 million dollars per year. In order to complement the study, the overall reduction of energy consumption was quantified for different high performance insulating materials. This project was concluded with an economical viability study for the implementation of this novel insulating lining concept for those three calciners.Com a crescente necessidade de diminuição do custo de produção das commodities, aumentou-se também a importância de manter os mais elevados níveis de eficiência dos processos e de se obter ganhos de escala em equipamentos. Neste cenário, o controle e a redução do consumo de energia dos processos produtivos alcançou lugar de destaque pelo seu impacto na sustentabilidade econômica, ambiental e social dos negócios das empresas. Na industria de produção primária de alumina ainda estima-se um excesso no consumo de energia de aproximadamente 30% para o processo de calcinação, ainda que os equipamentos atuais apresentem melhorias signifcativas quando comparados aos primeiros calcinadores de leito fluidizado disseminados na década de 70. Em paralelo, os aumentos de escala destes mesmos equipamentos diluiram os custos de produção por um lado, mas por outro tornaram a manutenção das suas disponiblidades operacionais um ítem crítico para obter os ganhos financeiros desejados. Para se ter idéia, atualmente estima-se um potencial de perdas da ordem de 1 milhão de dólares por dia não produtivo por unidade de calcinação. Apesar desta relevância, não são raros os relatos de literatura indicando falha dos materiais refratários como uma dos principais causas de paradas indesejadas, destacando a necessidade de utilizar revestimentos refratários de alto desempenho como meio fundamental para se obter campanhas mais longas e menores consumos de energia. Este trabalho estudou um destes casos de falha do revestimento refratário em três novos calcinadores de leito fluidizado, identificou o motivo da curta vida útil do refratário e posteriormente selecionou um novo, que duplicou o tempo das campanhas operacionais, gerando um potencial adicional de receita de 60 milhões de dólares por ano. Para complementar o trabalho, foram quantificados os potenciais de redução do consumo energético para diferentes materiais isolantes de alto desempenho. O estudo é finalizado com a análise de viabilidade econômica da implementação de uma nova concepção de isolamento térmico para estes calcinadores.application/pdfporUniversidade Federal de São CarlosPrograma de Pós-Graduação em Ciência e Engenharia de Materiais - PPGCEMUFSCarBRMateriais refratáriosCalcinadores de leito fluidizadoAluminaEnergiaAnálise de falhaENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICAO revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de aluminaThe Refractory Lining and its Effect on the Life Time and Energy Consumption of Alumina Calcinersinfo:eu-repo/semantics/publishedVersioninfo:eu-repo/semantics/masterThesis-1-1390bd4d1-c505-4015-b043-b075d197c61finfo:eu-repo/semantics/openAccessreponame:Repositório Institucional da UFSCARinstname:Universidade Federal de São Carlos (UFSCAR)instacron:UFSCARORIGINAL4474.pdfapplication/pdf3600461https://repositorio.ufscar.br/bitstream/ufscar/867/1/4474.pdfa575d302d2c8b3ebb8ef2562d8ddad52MD51TEXT4474.pdf.txt4474.pdf.txtExtracted texttext/plain0https://repositorio.ufscar.br/bitstream/ufscar/867/2/4474.pdf.txtd41d8cd98f00b204e9800998ecf8427eMD52THUMBNAIL4474.pdf.jpg4474.pdf.jpgIM Thumbnailimage/jpeg6494https://repositorio.ufscar.br/bitstream/ufscar/867/3/4474.pdf.jpgb6f131a41edbae348f0411f63807cbc1MD53ufscar/8672023-09-18 18:31:28.039oai:repositorio.ufscar.br:ufscar/867Repositório InstitucionalPUBhttps://repositorio.ufscar.br/oai/requestopendoar:43222023-09-18T18:31:28Repositório Institucional da UFSCAR - Universidade Federal de São Carlos (UFSCAR)false |
dc.title.por.fl_str_mv |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
dc.title.alternative.eng.fl_str_mv |
The Refractory Lining and its Effect on the Life Time and Energy Consumption of Alumina Calciners |
title |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
spellingShingle |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina Teider, Bruno Henrique Materiais refratários Calcinadores de leito fluidizado Alumina Energia Análise de falha ENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICA |
title_short |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
title_full |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
title_fullStr |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
title_full_unstemmed |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
title_sort |
O revestimento refratário e seu efeito na vida útil e no consumo energético de calcinadores de alumina |
author |
Teider, Bruno Henrique |
author_facet |
Teider, Bruno Henrique |
author_role |
author |
dc.contributor.authorlattes.por.fl_str_mv |
http://lattes.cnpq.br/0712197869045551 |
dc.contributor.author.fl_str_mv |
Teider, Bruno Henrique |
dc.contributor.advisor1.fl_str_mv |
Pandolfelli, Victor Carlos |
dc.contributor.advisor1Lattes.fl_str_mv |
http://lattes.cnpq.br/7369376873984839 |
dc.contributor.authorID.fl_str_mv |
7328140e-17c9-4ca7-b734-0ac2ab74c430 |
contributor_str_mv |
Pandolfelli, Victor Carlos |
dc.subject.por.fl_str_mv |
Materiais refratários Calcinadores de leito fluidizado Alumina Energia Análise de falha |
topic |
Materiais refratários Calcinadores de leito fluidizado Alumina Energia Análise de falha ENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICA |
dc.subject.cnpq.fl_str_mv |
ENGENHARIAS::ENGENHARIA DE MATERIAIS E METALURGICA |
description |
The increased need of reducing production costs of commodities raised the importance of reaching higher levels of process efficiency and also the consolidation of financial gains due to larger-scale production capacities. In this scenario, the control and reduction of energy consumption is considered one of the most critical issues due to its impact on the companies economical, environmental and social businesses sustainability. In the primary alumina industry, it is estimated that the calcination process still demands 30% in excess of energy to operate, although there have been major improvements in the current calciners when compared to the former versions disseminated in the 70 s. In parallel, although the production capacity increased significantly, diluting the overall production costs, they also raised the importance of maintaining their operational availabilities at the maximum level to attain the financial viability of the processes. Currently, daily losses are estimated to be close to 1 million dollars per each nonproductive day of a large-capacity calciner. Despite this critical aspect, it is not rare to find literature reports indicating refractory failure as one of the main causes of unexpected production halts, which highlights the need of high performance linings as a pre-requisite for longer campaigns and lower levels of energy consumption. This project evaluated one of these refractory failure detected in three new large-capacity calciners. The root-cause of the refractory s short life was identified and afterwards a novel more suitable material was selected increasing twofold the operational campaign time, which resulted in additional potential revenue of 60 million dollars per year. In order to complement the study, the overall reduction of energy consumption was quantified for different high performance insulating materials. This project was concluded with an economical viability study for the implementation of this novel insulating lining concept for those three calciners. |
publishDate |
2012 |
dc.date.available.fl_str_mv |
2012-09-11 2016-06-02T19:12:20Z |
dc.date.issued.fl_str_mv |
2012-07-25 |
dc.date.accessioned.fl_str_mv |
2016-06-02T19:12:20Z |
dc.type.status.fl_str_mv |
info:eu-repo/semantics/publishedVersion |
dc.type.driver.fl_str_mv |
info:eu-repo/semantics/masterThesis |
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masterThesis |
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publishedVersion |
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https://repositorio.ufscar.br/handle/ufscar/867 |
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https://repositorio.ufscar.br/handle/ufscar/867 |
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por |
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info:eu-repo/semantics/openAccess |
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openAccess |
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application/pdf |
dc.publisher.none.fl_str_mv |
Universidade Federal de São Carlos |
dc.publisher.program.fl_str_mv |
Programa de Pós-Graduação em Ciência e Engenharia de Materiais - PPGCEM |
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UFSCar |
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BR |
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Universidade Federal de São Carlos |
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