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Abstract(s)
A presente dissertação tem como objetivo fundamental a realização de uma auditoria
energética ao processo de misturação na empresa Continental Mabor – Indústria de Pneus,
S.A, sita em Lousado, concelho de Vila Nova de Famalicão.
Iniciou-se o estudo com o levantamento energético total, para o ano de 2022, tendo se determinado um consumo específico de energia igual a 269,8 kgep/ton. Na globalidade,
o custo relacionado com o consumo de energia ascendeu a cerca de 65 milhões de euros.
Posteriormente efetuou-se o levantamento energético do setor da misturação, tendo se concluído que este setor é o maior consumidor de energia contabilizando 45% em
relação ao consumo total da fábrica. A quantificação do consumo de energia total neste
setor revelou que a energia elétrica representa 97,8% e o consumo de vapor os restantes
2,23%. No setor da misturação, as misturadoras representam o maior consumo de energia
elétrica (77,5%) sendo seguidas pela ventilação (6,12%) e pelos quadros de usos gerais
(3,25%). O consumo de vapor destina-se apenas para aplicação de AVAC, sendo utilizado
nas baterias de aquecimento das unidades de tratamento de ar e em termoventiladores.
Determinou-se igualmente um consumo específico médio anual neste setor igual a 0,093
tep/ton.
Relativamente ao desenvolvimento de medidas de otimização energética, a proposta
de aumento da produção em One-Step Mixing (OSM) em detrimento da produção Master
Batch+Final Mix (MB+FM) para compostos de sílica permitirá poupar anulamente entre
163 € e 2291 € em custos relacionados com o consumo de energia elétrica nas
misturadoras. A otimização de transformadores através da desativação parcial ou através
da sua substituição permitirá poupar cerca de 9720 € anualmente e 37 000 € ao longo do
tempo de vida médio dos transformadores, respetivamente. A desativação do consumo de
vapor utilizado para descongelar borracha permitirá poupar cerca 37 000 € anuais,
implementando-se por sua vez um sistema de recuperação de calor da corrente de
condensados sujos através de um permutador de calor em espiral.
The primary objective of this dissertation is to conduct an energy audit of the mixing process at Continental Mabor - Indústria de Pneus, S.A., located in Lousado, Vila Nova de Famalicão. The study began with a comprehensive energy survey for the year 2022, which determined a specific energy consumption of 269.8 kgoe/ton. Overall, the cost associated with energy consumption amounted to approximately 65 million euros. Subsequently, an energy survey of the mixing sector was conducted, revealing that this sector is the largest energy consumer, accounting for 45% of the total factory consumption. The quantification of total energy consumption in this sector showed that electrical energy represents 97.8%, while the remaining 2.23% is attributed to steam consumption. Within the mixing sector, mixers account for the highest electricity consumption (77.5%), followed by ventilation (6.12%) and general-purpose panels (3.25%). Steam consumption is solely used for HVAC applications, such as heating the air treatment units and thermofans. Additionally, the average specific annual consumption in this sector was determined to be 0.093 toe/ton. Regarding the development of energy optimization measures, the proposal to increase production through the One-Step Mixing (OSM) method, instead of the Master Batch+Final Mix (MB+FM) method for silica compounds, would result in annual savings ranging from 163 € to 2,291 € in electricity consumption costs for the mixers. Optimizing transformers through partial deactivation or replacement would save approximately 9,720 € annually and 37,000 € over the average lifespan of the transformers, respectively. Discontinuing the use of steam for rubber thawing would save approximately 37,000 € per year, while implementing a heat recovery system from the dirty condensate stream through a spiral heat exchanger.
The primary objective of this dissertation is to conduct an energy audit of the mixing process at Continental Mabor - Indústria de Pneus, S.A., located in Lousado, Vila Nova de Famalicão. The study began with a comprehensive energy survey for the year 2022, which determined a specific energy consumption of 269.8 kgoe/ton. Overall, the cost associated with energy consumption amounted to approximately 65 million euros. Subsequently, an energy survey of the mixing sector was conducted, revealing that this sector is the largest energy consumer, accounting for 45% of the total factory consumption. The quantification of total energy consumption in this sector showed that electrical energy represents 97.8%, while the remaining 2.23% is attributed to steam consumption. Within the mixing sector, mixers account for the highest electricity consumption (77.5%), followed by ventilation (6.12%) and general-purpose panels (3.25%). Steam consumption is solely used for HVAC applications, such as heating the air treatment units and thermofans. Additionally, the average specific annual consumption in this sector was determined to be 0.093 toe/ton. Regarding the development of energy optimization measures, the proposal to increase production through the One-Step Mixing (OSM) method, instead of the Master Batch+Final Mix (MB+FM) method for silica compounds, would result in annual savings ranging from 163 € to 2,291 € in electricity consumption costs for the mixers. Optimizing transformers through partial deactivation or replacement would save approximately 9,720 € annually and 37,000 € over the average lifespan of the transformers, respectively. Discontinuing the use of steam for rubber thawing would save approximately 37,000 € per year, while implementing a heat recovery system from the dirty condensate stream through a spiral heat exchanger.
Description
Keywords
Energy Audit Mixing Process Energy Optimization MB+FM vs OSM Transformers Spiral Heat Exchanger