Estudo de melhoria da eficiência energética de uma planta de resinas
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Citações na Scopus
Tipo de produção
Trabalho de Conclusão de Curso
Data
2022-12-07
Autores
Barbeta, Ana Carolina Silva
Perossi, Beatriz de Oliveira
Sorbile, Gabriela Reche
Stelmasuk, Guilherme Fernandez
Perossi, Beatriz de Oliveira
Sorbile, Gabriela Reche
Stelmasuk, Guilherme Fernandez
Orientador
Novazzi, Luís Fernando
Periódico
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Texto completo (DOI)
Palavras-chave
eficiência energética,melhoria de processo,otimização,análise térmica,energy efficiency,process improvement,optimization,thermal analysis
Resumo
Na indústria química, o consumo energético se traduz, em grande parte, na forma de energia térmica, especialmente no aquecimento e resfriamento de equipamentos e produtos. Por conta disso, este trabalho visa reduzir o gasto de energia em uma fábrica de resinas através da otimização e reaproveitamento das fontes de calor existentes. Por ser uma fábrica antiga, a planta estudada possui muito espaço para melhorias que gerem aumento da eficiência do processo. O ponto focal escolhido para o presente estudo foi um reator de mistura multipropósito e seu trocador de calor do tipo casco e tubos, onde foram estudadas três propostas de reaproveitamento do calor dissipado pelo óleo. A primeira delas consiste em alternar a corrente de água de resfriamento do trocador já existente com água de diluição do processo que deve ser aquecida, conforme necessidade; já a segunda ideia considera um desvio na corrente de óleo com a inclusão de um novo trocador de calor, em prol de aquecer exclusivamente a água de diluição e garantir sua pureza; por fim, a terceira proposta leva em conta a substituição do vapor utilizado no sistema de aquecimento do armazenamento da resina fabricada pelo próprio óleo recirculado no sistema do reator. Optou-se por seguir com as duas últimas alternativas após a realização da análise de viabilidade técnica do processo, para a qual foi preciso estimar algumas variáveis e propriedades, como a vazão de escoamento de óleo no sistema, avaliada entre 45 e 78 m³/h. A partir dos dados encontrados, foi feita uma estimativa de custo de aquisição e instalação do novo trocador de calor, que possibilitou estipular um tempo de retorno médio de 20 meses para este investimento, comprovando sua viabilidade econômica. Para o trocador proposto, obteve-se um intervalo de custos para diferentes condições de operação do processo, as quais deverão ser apresentadas à empresa em estudo como um conjunto de soluções para futura discussão e decisão. Por fim, a partir do estudo dos pontos de economia no processo, foi estimada uma redução anual de R$ 1,5 M na geração de vapor na caldeira, considerando o gás natural, a água desmineralizada e a implementação das duas propostas viáveis, representando 27,3% de redução nos gastos gás natural para a empresa.
In the chemical industry, energy consumption largely translates into the form of thermal energy, especially in the heating and cooling of equipment and products. Therefore, this work aims to reduce the energy expenditure in a resin factory through the optimization and reuse of existing heat sources. Being an old factory, the studied plant has greats opportunities for improvements that generate increased process efficiency. The focal point chosen for the present study was a multipurpose mixing reactor and its shell and tube heat exchanger, where three proposals for the reuse of heat dissipated by the oil were studied. The first is to alternate the cooling water current of the already existing exchanger with dilution water of the process that must be heated as needed; the second idea considers a deviation in the oil stream with the inclusion of a new heat exchanger, in order to heat only the dilution water and ensure its purity; finally, the third proposal takes into account the replacement of steam used in the heating system of the resin storage manufactured by the oil itself recirculated in the reactor system. It was decided to follow the last two alternatives after the technical feasibility analysis of the process, for which it was necessary to estimate some variables and properties, such as the flow of oil in the system, evaluated between 45 and 78 m³/h. From the data found, an estimate of the cost of acquisition and installation of the new heat exchanger was made, which allowed to stipulate an average return time of 20 months for this investment, proving its economic viability. For the proposed exchanger, a range of costs was obtained for different process operating conditions, which should be presented to the company under study as a set of solutions for future discussion and decision. Finally, from the study of the points of economy in the process, an annual reduction of R$ 1.5 M in steam generation in the boiler was estimated, considering natural gas, demineralized water, and the implementation of the two viable proposals, representing 27.3% reduction in natural gas expenses for the company.
In the chemical industry, energy consumption largely translates into the form of thermal energy, especially in the heating and cooling of equipment and products. Therefore, this work aims to reduce the energy expenditure in a resin factory through the optimization and reuse of existing heat sources. Being an old factory, the studied plant has greats opportunities for improvements that generate increased process efficiency. The focal point chosen for the present study was a multipurpose mixing reactor and its shell and tube heat exchanger, where three proposals for the reuse of heat dissipated by the oil were studied. The first is to alternate the cooling water current of the already existing exchanger with dilution water of the process that must be heated as needed; the second idea considers a deviation in the oil stream with the inclusion of a new heat exchanger, in order to heat only the dilution water and ensure its purity; finally, the third proposal takes into account the replacement of steam used in the heating system of the resin storage manufactured by the oil itself recirculated in the reactor system. It was decided to follow the last two alternatives after the technical feasibility analysis of the process, for which it was necessary to estimate some variables and properties, such as the flow of oil in the system, evaluated between 45 and 78 m³/h. From the data found, an estimate of the cost of acquisition and installation of the new heat exchanger was made, which allowed to stipulate an average return time of 20 months for this investment, proving its economic viability. For the proposed exchanger, a range of costs was obtained for different process operating conditions, which should be presented to the company under study as a set of solutions for future discussion and decision. Finally, from the study of the points of economy in the process, an annual reduction of R$ 1.5 M in steam generation in the boiler was estimated, considering natural gas, demineralized water, and the implementation of the two viable proposals, representing 27.3% reduction in natural gas expenses for the company.