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Análise e otimização de sistemas de climatização em instalações industriais
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Advisor(s)
Abstract(s)
O presente trabalho analisa a eficiência dos sistemas de climatização e produção de
energia térmica de uma unidade industrial, enquadrando o seu desempenho numa
perspetiva integrada de racionalização energética e alinhamento com os objetivos de
descarbonização. O estudo inicia-se com a contextualização do consumo energético
industrial, evidenciando a importância dos sistemas AVAC e a necessidade da sua
otimização para a redução da absorção de energia elétrica e das emissões de gases
com efeito de estufa.
O objetivo central consistiu na avaliação e otimização dos sistemas de aquecimento,
com especial enfoque no regime de funcionamento das bombas de calor, através
da identificação das temperaturas de produção de água quente mais eficientes e
da análise comparativa dos regimes de bombeamento. A metodologia contemplou o
levantamento técnico detalhado dos sistemas, a recolha e tratamento extensivo dos
dados operacionais e a análise quantitativa dos consumos e perdas energéticas.
A abordagem permitiu correlacionar as condições climáticas exteriores com as
necessidades em climatização e o consumo energético, tendo sido implementados
modelos para avaliar o impacto da temperatura exterior no desempenho do sistema.
Das análises entre diferentes regimes de bombeamento resultou a recomendação de
um novo regime de caudal constante, com produção de água quente a 45°C e uma
temperatura mínima de entrada no condensador de 35°C, permitindo estimar reduções
médias mensais de custos relativos à energia elétrica absorvida pelas bombas de
calor de cerca de 35%, sem comprometer o conforto ambiental e a segurança operacional.
Foram identificadas limitações na medição, monitorização e documentação
técnica, sendo propostas soluções para colmatar estas lacunas.
Com base nos resultados, recomenda-se manter o regime de bombeamento constante
no circuito primário das bombas de calor para otimização operacional, implementar
procedimentos de medição sistemática, calibração regular dos sensores,
modernizar o sistema de gestão técnica, valorizar a recuperação de calor das unidades
de produção de água fria e eliminar um permutador de calor redundante na
distribuição de água aquecida à fábrica. A integração destas medidas potenciará
ganhos energéticos e económicos, o cumprimento das metas ambientais e a competitividade
da empresa. O trabalho comprova que, mesmo em contextos industriais
complexos, a melhoria sustentada da eficiência energética e a adoção de soluções
mais sustentáveis são tecnicamente exequíveis e economicamente vantajosas.
This work analyzes the efficiency of the climate control and thermal energy production systems in an industrial facility, adopting an integrated perspective of energy rationalization and alignment with decarbonization objectives. The study begins by contextualizing the energy consumption of the industrial sector, highlighting the significant proportion represented by HVAC systems and the importance of their optimization in reducing both electricity demand and greenhouse gas emissions. The central goal was to assess and optimize heating systems, with particular focus on the operating regime of heat pumps, seeking to determine the most advantageous one, especially through the identification of the most efficient hot water production temperature and the analysis of pumping regimes. The methodology followed a staged approach, including the detailed technical survey and characterization of the relevant systems, comprehensive collection and processing of operational data, and the quantitative analysis of energy consumption and losses. This approach enabled the establishment of clear links between outdoor climatic conditions, indoor climatization requirements, and eletrical energy consumption, with the implementation of models to assess the impact of outdoor temperature on system performance. Comparative analyses were conducted between different pumping regimes, leading to the recommendation of a new constant-flow pumping regime with a hot water production temperature of 45°C and a minimum condenser water inlet temperature of 35°C. It is estimated that this new regime will yield average monthly savings of approximately 35% in costs associated with the absorbed electrical energy by the evaluated heat pumps, achieved without compromising environmental comfort or operational safety. Key limitations were identified, particularly regarding measurement, monitoring, and technical documentation of the installation, and solutions were proposed to address these gaps. Based on the results, it was recommended to maintain the constant-flow pumping configuration in the heat pump feed circuit for operational simplification and optimization, as well as to implement systematic measurement procedures, regular sensor calibration, modernization of the building management system, future utilization of heat recovery functions from the chilled water production units, and removal of a redundant heat exchanger in the factory’s hot water distribution circuit. The integrated application of these measures will enable the company to enhance energy and economic gains, comply with environmental targets, and strengthen its competitive position. This work demonstrates that, even in complex industrial systems, sustained improvement in energy efficiency and the transition towards more sustainable practices are both technically feasible and economically advantageous.
This work analyzes the efficiency of the climate control and thermal energy production systems in an industrial facility, adopting an integrated perspective of energy rationalization and alignment with decarbonization objectives. The study begins by contextualizing the energy consumption of the industrial sector, highlighting the significant proportion represented by HVAC systems and the importance of their optimization in reducing both electricity demand and greenhouse gas emissions. The central goal was to assess and optimize heating systems, with particular focus on the operating regime of heat pumps, seeking to determine the most advantageous one, especially through the identification of the most efficient hot water production temperature and the analysis of pumping regimes. The methodology followed a staged approach, including the detailed technical survey and characterization of the relevant systems, comprehensive collection and processing of operational data, and the quantitative analysis of energy consumption and losses. This approach enabled the establishment of clear links between outdoor climatic conditions, indoor climatization requirements, and eletrical energy consumption, with the implementation of models to assess the impact of outdoor temperature on system performance. Comparative analyses were conducted between different pumping regimes, leading to the recommendation of a new constant-flow pumping regime with a hot water production temperature of 45°C and a minimum condenser water inlet temperature of 35°C. It is estimated that this new regime will yield average monthly savings of approximately 35% in costs associated with the absorbed electrical energy by the evaluated heat pumps, achieved without compromising environmental comfort or operational safety. Key limitations were identified, particularly regarding measurement, monitoring, and technical documentation of the installation, and solutions were proposed to address these gaps. Based on the results, it was recommended to maintain the constant-flow pumping configuration in the heat pump feed circuit for operational simplification and optimization, as well as to implement systematic measurement procedures, regular sensor calibration, modernization of the building management system, future utilization of heat recovery functions from the chilled water production units, and removal of a redundant heat exchanger in the factory’s hot water distribution circuit. The integrated application of these measures will enable the company to enhance energy and economic gains, comply with environmental targets, and strengthen its competitive position. This work demonstrates that, even in complex industrial systems, sustained improvement in energy efficiency and the transition towards more sustainable practices are both technically feasible and economically advantageous.
Description
Keywords
Air Handling Unit (AHU) Carnot Chillers Coils Energy Energy Efficiency Environment Heat Exchanger Heat Pumps Heat Recovery HVAC Industry Operational optimization Bombas de calor - Chillers Climatização industrial Bombas de circulação Eficiência energética Otimização operacional Recuperação de calor