• Energy Research

In the framework of the iWAYS project, a synergy between energy and water reclamation and exploitation is addressed by means of the development and the installation of a wide array of technologies in three different industrial sectors: ceramic tile manufacturing, aluminium fluoride production and steel tubes manufacturer. The aim of the project is the creation of customized and integrated systems to achieve a substantial reduction in the thermal waste and in the freshwater consumption; this is the principal challenge the iWAYS project is solving by developing a set of technologies capable of recovering water and energy from challenging exhaust streams for productive use in the industrial processes. iWAYS systems will then treat steam condensate to meet the water quality requirements of each industrial process, while the recovered heat will be used to reduce primary energy consumption. iWAYS will recover additional materials from flue gas such as valuable acids or particulates, improving the production’s raw material efficiency and reducing detrimental emissions to the environment. The iWAYS technology will provide a reduction in the freshwater consumption greater that the 30% in each industrial case; with regards to the energy recovery, iWAYS will recover 6 GWh/y in the ceramic sector, more than 5 GWh/y in the chemical scenario and approximately 1 GWh/y in the steel sector. The iWAYS solution will have a payback lower than 5 years.

The paper investigates hydraulic wave propagation phenomena through hydraulic circuits of power transmission systems by means of numerical approaches. The actuation circuit of a Dual-Clutch Transmission (DCT) power transmission system supplied by a Gerotor pump is analyzed. A steady state approach is adopted to detect resonance phenomena due to Gerotor design parameters and circuit lengths, while one-dimensional numerical models are implemented to predict the pressure oscillations through the hydraulic ducts for the whole pump operating domain. CFD-1D pipelines are adopted to address the pressure oscillation behavior through the hydraulic pipeline, while spectral maps and order tracking techniques are used to evaluate their fluctuation intensity in function of the pump speed rate. The numerical models are validated with experimental tests performed on an ad hoc test rig for power transmission systems and a good match is found between the numerical and the experimental results. Pump design parameters as well as hydraulic accumulators and resonators are numerically investigated to quantitatively evaluate their improvement on the circuits’ hydro-dynamic behavior. Furthermore, simplified numerical models are implemented to investigate the frequency response behavior of the hydraulic circuits by means of linear analysis. This approach resulted to be particularly effective for the prediction of the resonance frequencies location, and it can be adopted as an optimization tool since significant simulation time can be saved. Finally, the performance of the circuits operating with an eco-friendly fluid is evaluated numerically and the results are compared with the ones obtained with a traditional petroleum-based oil.

Abstract The paper shows the preliminary design of the superheated steam generator to be used in a novel hydrogen production and energy conversion system based on the combustion of aluminum particles with water. The system is aimed at producing hydrogen and pressurized superheated steam, using the heat released by the Al–H2O reaction. The interest on this type of technology arises because of the possibility of obtaining hydrogen with very low pollutant and greenhouse gas emissions, compared to the traditional hydrogen production systems, such as the steam reforming from methane. The analysis of the combustion chamber and the heat recovery system is carried out by means of a lumped and distributed parameter numerical approach. The multi phase and gas mixture theoretical principles are used both to characterize the mass flow rate and the heat release in the combustion chamber and within the heat exchangers in order to relate the steam generator performance to the system operating parameters. Finally, the influence of the steam generator performance on the whole energy conversion system behavior is addressed, with particular care to the evaluation of the total power and efficiency variation with the combustion parameters.

This article investigates the interaction between the resin spray and the wood chips in a vapour stream using a multi-phase multi-component computational fluid dynamics approach. The interaction between the spray and the chips is one of the main issues in the industrial process for manufacturing medium density fibre boards. Thus, the optimization of this process can lead to important benefits, such as the reduction in the emission of formaldehyde-based toxic chemicals, the reduction in energy consumption in the blending process and energy saving in the fibreboard drying process. First step of the study is the numerical analysis of the resin injector in order to extend the experimental measurements carried out with water to the resin spray. The effects of the injector’s geometrical features on the spray formation are highlighted under different injection pressure values and needle displacements. Afterwards, the results obtained in the analysis of the single injector are used for the complete simulation of multi-injector rail where the mixing of the resin spray and wood chips takes place. The influence of the main operating conditions, such as the vapour and the wood chip flow rates, on the resin distribution is addressed in order to optimize the resination process.

The investigation of the flow through the metering section of hydraulic components plays a fundamental role in the design and optimization processes. In this paper the flow through a closed center directional control valve for load –sensing application is studied by means of a multidimensional CFD approach.In the analysis, an open source fluid-dynamics code is used and both cavitation and turbulence are accounted for in the modeling. A cavitation model based on a barotropic equation of state and homogeneous equilibrium assumption, including gas absorption and dissolution in the liquid medium, is adopted and coupled to a two equation turbulence approach.Both direct and inverse flows through the metering section of the control valve are investigated, and the differences in terms of fluid – dynamics behavior are addressed In particular, the discharge coefficient, the recirculating regions, the flow acceleration angle and the pressure and velocity fields are investigated and compared.

Abstract Energy efficiency, which is one of the pillars of the EU's Energy Union strategy, has been proposed as a solution, namely as a highly effective pathway to improve economic competitiveness and sustainability of the European economy, lower emissions, reduce energy dependency and increase security of supply, and job creation. The paper reviews the EU strategies and policies on energy efficiency and argues that further focus should be placed on industrial energy efficiency. Despite a decline in energy consumption in recent years in industry, this sector is one of the largest users of energy in the EU. Therefore, the paper reviews the extent to which the European and national policies in the selected jurisdictions, such as Italy and the UK address energy efficiency in industry and whether there are any measures in place to promote it.

The article investigates the performance of an integrated system for the energy recovery from biomass and waste based on anaerobic digestion, gasification and water treatment. In the proposed system, the organic fraction of waste of the digestible biomass is fed into an anaerobic digester, while a part of the combustible fraction of the municipal solid waste is gasified. Thus, the obtained biogas and syngas are used as a fuel for running a cogeneration system based on an internal combustion engine to produce electric and thermal power. The waste water produced by the integrated plant is recovered by means of both forward and inverse osmosis. The different processes, as well as the main components of the system, are modelled by means of a lumped and distributed parameter approach and the main outputs of the integrated plant such as the electric and thermal power and the amount of purified water are calculated. Finally, the implementation of the proposed system is evaluated for urban areas with a different number of inhabitants and the relating performance is estimated in terms of the main outputs of the system.

The effect of ammoniac deoxidizing agent (Urea) on the reduction of NO x produced in the Diesel engine was investigated numerically. Urea desolved in water was directly injected into the engine cylinder during the expansion stroke. The NOx deoxidizing process was described using a simplified chemical kinetic model coupled with the comprehensive kinetics of Diesel oil surrogate combustion. If the technology of DWI (Direct Water Injection) with the later injection timing is supposed to be used, the deoxidizing reactants could be delivered in a controlled amount directly into the flame plume zones, where NOx are forming. Numerical simulations for the Isotta Fraschini DI Diesel engine are carried out using the KIVA-3V code, modified to account for the "co-fuel" injection and reaction with combustion products. The results showed that the amount of NOx could be substantially reduced up to 80% with the injection timing and the fraction of Urea in the solution optimized. Copyright © 2007 SAE International.