Análise de viabilidade de sistemas de cogeração em plantas de produção do segmento de cerâmica de revestimento
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Data
2022-08-17
Autores
Santos, Vanessa Fonseca dos
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Universidade Estadual Paulista (Unesp)
Resumo
As indústrias têm se preocupado cada vez mais em melhorar seus processos e atualizar a tecnologia de seu parque fabril para reduzir o consumo e custo referente à sua necessidade energética. O fator econômico e ambiental são os principais estímulos para desenvolvimento de projetos de eficiência energética. O segmento sucroalcooleiro tem por tradição o uso de sistemas de cogeração devido ao conveniente aproveitamento do resíduo de bagaço de cana e, em virtude ao expressivo potencial de geração de energia elétrica por cogeração, este segmento é um importante participante na matriz elétrica brasileira. No caso do segmento de cerâmica de revestimento, a aderência desta prática já é bastante consolidada na Europa, enquanto que, no Brasil, não se verifica esta realidade pois grande parte das plantas são pertencentes ao grupo de cerâmica vermelha (telhas e tijolos), que são de fabricação mais simplificada e produto de baixo valor agregado. Baseado em um cenário de estudo de caso hipotético a partir de dados da literatura, este trabalho propôs uma análise de viabilidade técnico-econômica de sistema de cogeração para unidade de secagem de uma planta de cerâmica de revestimento, afim de alcançar melhor aproveitamento energético dos secadores. Através da avaliação termodinâmica de primeira Lei e de indicadores econômicos foi possível determinar quais turbinas a gás puderam ser viáveis ao processo de secagem. A temperatura e vazão mássica de gases quentes disponibilizada pelas turbinas foram fatores determinantes na possibilidade de substituição total ou parcial da fonte quente convencional dos secadores. Dois modelos de turbina a gás, na configuração de dois conjuntos a gás, apresentaram resultados mais satisfatórios, sendo a turbina 2 com TIR de 30% e PB de 2,79 anos, e a turbina 4 com TIR de 22% e PB de 3,71 anos. A análise de sensibilidade mostrou que a turbina 2 foi mais resiliente às variações (para baixo) do preço de venda da energia elétrica excedente, além disso, mesmo dobrando o número de conjuntos a gás e o consumo de combustível do sistema de cogeração, o consumo total de combustível do processo de secagem após a integração do sistema permaneceu o mesmo (0,3 kg/s). Com estes resultados, concluiu-se que a cogeração de fato promove um melhor aproveitamento energético do processo de secagem da indústria cerâmica de revestimento.
Industries are increasingly concerned with their processes of improvement and updating of equipment manufacturing technology to achieve consumption and cost savings for their energies. The economic and environmental factors are the main motivation for the development of energy efficiency projects. The energy is successful in the use of the segment or in the use of generation systems due to the convenience of the electric cogenerator and an important one because of the expressive potential of generation of generation of the segment is a participant in the Brazilian electrical matrix. In the case of the ceramic tile segment, there is no adherence to this practice in Europe, the group is already quite practical while, in Brazil, this reality is verified because most of the plants belong to the red ceramic (tiles and bricks) that are of simplified manufacturing and low added value product. Based on a hypothetical case scenario from a study of feasibility analysis plants from technical literature, this study of technical feasibility analysis plants of coating, in order to optimize the best energy use of spray dryers and vertical plant drying stage. From the first law and possible determination indicators the gas evaluation conditions will be viable to the drying process. The smaller gases are determined in the distribution of flows of larger amount of gases according to the temperature, due to the higher or lower temperature of energy produced in the gases, thus having the highest energy distribution to the gas dryer. This distribution was fundamental to determine the possibility of replacing the total or conventional heat source of the dryers by the partial adjustment gases of the gas turbine. Two turbines, in the configuration of gas sets, had more satisfactory results, being turbine 2 with an TIR of 30% and PB of 2.79 years, and turbine 2 with an TIR of 22% and PB of 3.71 years. The sensitivity analysis showed that turbine 2 was more resilient to variations (downwards) in the selling price of electricity, in addition, even doubling the number of gas sets and the fuel consumption of the cogeneration system, the total consumption of fuel after integration of the processing system or even (0.3 kg/s). With these results, it was concluded that cogeneration actually promotes a better energy use of an industrial process.
Industries are increasingly concerned with their processes of improvement and updating of equipment manufacturing technology to achieve consumption and cost savings for their energies. The economic and environmental factors are the main motivation for the development of energy efficiency projects. The energy is successful in the use of the segment or in the use of generation systems due to the convenience of the electric cogenerator and an important one because of the expressive potential of generation of generation of the segment is a participant in the Brazilian electrical matrix. In the case of the ceramic tile segment, there is no adherence to this practice in Europe, the group is already quite practical while, in Brazil, this reality is verified because most of the plants belong to the red ceramic (tiles and bricks) that are of simplified manufacturing and low added value product. Based on a hypothetical case scenario from a study of feasibility analysis plants from technical literature, this study of technical feasibility analysis plants of coating, in order to optimize the best energy use of spray dryers and vertical plant drying stage. From the first law and possible determination indicators the gas evaluation conditions will be viable to the drying process. The smaller gases are determined in the distribution of flows of larger amount of gases according to the temperature, due to the higher or lower temperature of energy produced in the gases, thus having the highest energy distribution to the gas dryer. This distribution was fundamental to determine the possibility of replacing the total or conventional heat source of the dryers by the partial adjustment gases of the gas turbine. Two turbines, in the configuration of gas sets, had more satisfactory results, being turbine 2 with an TIR of 30% and PB of 2.79 years, and turbine 2 with an TIR of 22% and PB of 3.71 years. The sensitivity analysis showed that turbine 2 was more resilient to variations (downwards) in the selling price of electricity, in addition, even doubling the number of gas sets and the fuel consumption of the cogeneration system, the total consumption of fuel after integration of the processing system or even (0.3 kg/s). With these results, it was concluded that cogeneration actually promotes a better energy use of an industrial process.
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Palavras-chave
Cogeração, Secagem, Gás natural, Cerâmica de revestimento, Eficiência energética, Cogeneration, Drying, Energy efficiency, Natural gas, Ceramic tiles, Energia elétrica e calor - Cogeração, Energia elétrica - Consumo