Millmerran Power Station ROM coal blockage removal system

[Abstract]: Millmerran Power Station (MPS) consists of two units with each unit producing 420 MW of electricity. The coal is delivered to the plant by off road type trucks and unloaded into a 500 MT hopper. The ROM (run of mine) coal is processed through a series of crushing stations and coal handling (storage/reclaim) systems, and delivered by overland conveyor to the power plant silos. MPS, as a coal fired station, is wholly dependent on a consistent and reliable supply of coal to maintain operating efficiency. MPS has been experiencing inefficiencies in their ROM coal supply because of constant blockage issues at the receiving hopper. This blockage is a direct result of large lumps of coal coming from the mine. The blockages interrupt the supply of coal potentially lowering the fuel supply to the power station. Currently, an excavator is hired to clear up the blockage which could be utilised more effectively elsewhere. This introduces an extra cost to the mine in terms of both money and inefficiency. MPS is seeking an engineering design solution to this problem. The elimination of the blockages through an automatic system without increasing any safety risks is highly desirable as that would result in a cheaper and smoother operation of the mine. A literature review on the current coal handling system of MPS was essential in order to be able to develop a design that is suitable for MPS. In this investigation, five conceptual designs with the most appropriate design, in terms of meeting the specified criteria, was analysed and detailed. It was found that the simpler and more effective the design, the higher its practicality in terms of reaching the desired objectives. This enabled an overall cost estimate budget to be produced, which would be the major deciding factor on the implementation of the design. The results of this investigation will aid in gaining an understanding of the overall general solution for the ROM coal blockage problem at MPS. Both design and engineering solutions have been recommended in this dissertation. This will lead eventually to a more automated, safer, efficient and cost effective operating environment

Development of a CO2e quantification method and of solutions for reducing the greenhouse gas emissions of construction machines

This work focuses on the development of a quantification method for GHG (CO2e) emissions from construction machines. The method considers CO2e reduction potentials in the time past-present–future, through influencing factors from six pillars: Machine efficiency, process efficiency, energy source, operating efficiency, material efficiency and CCS. In addition, transformation solutions are proposed to reduce GHG emissions from construction machines like liquid methane, fuel cell drive or CCS

Suited for spacewalking: A teacher's guide with activities

This publication is an activity guide for teachers on spacesuits and spacewalking. It uses the intensive interest many children have in space exploration as a launching point for hands-on-opportunities. The guide begins with brief discussions of the space environment, the history of space walking, the Space Shuttle spacesuit, and working in space. These are followed by a series of activities that enable children to explore the space environment as well as the science and technology behind the functions of spacesuits. The activities are not rated for specific grade levels because they can be adapted for students of many ages. The guide concludes with a brief glossary as well as references and resources

Research in biomass production and utilization: systems simulation and analysis

There is considerable public interest in developing a sustainable biobased economy that favors support of family farms and rural communities and also promotes the development of biorenewable energy resources. This study focuses on a number of questions related to the development and exploration of new pathways that can potentially move us toward a more sustainable biobased economy. These include issues related to biomass fuels for drying grain, economies-of-scale, new biomass harvest systems, sugar-to-ethanol crop alternatives for the Upper Midwest U.S., biomass transportation, post-harvest biomass processing and double cropping production scenarios designed to maximize biomass feedstock production. For each question of interest, specific examples were identified and detailed models developed in MS Excel\u3c®\u3e. Techno-economic analysis and Monte Carlo simulation techniques were used to challenge each model and evaluate viability. The first section of this study considers post-harvest drying of shelled corn grain both at farm-scale and at larger community-scaled installations. Currently, drying of shelled corn requires large amounts of fossil fuel energy. To address future energy concerns, this study evaluates the potential use of combined heat and power systems that use the combustion of corn stover to produce steam for drying and to generate electricity for fans, augers, and control components. Techno-economic analysis suggests that there are significant economies of scale with community-based dryers, e.g. grain elevators, which show a much faster return on investment over farm-scaled systems. Because of the large capital requirements for solid fuel boilers and steam turbines/engines, both farm-scale and larger grain elevator-scaled systems benefit by sharing boiler and power infrastructure with other processes. The second and third sections evaluate sweet sorghum as a possible sugarcane-like crop that can be grown in the Upper Midwest. Various harvest systems are considered including a prototype mobile juice harvester, a hypothetical one-pass unit that separates grain heads from chopped stalks and traditional forage/silage harvesters. Also evaluated were post-harvest transportation, storage and processing costs and their influence on the possible use of sweet sorghum as a supplemental feedstock for existing dry-grind ethanol plants located in the Upper Midwest. Results show that the concept of a mobile juice harvester is not economically viable due to low sugar recovery. However, traditional forage/silage harvest systems provide an economically viable harvest solution as long as chopped forage can be quickly processed in a nearby, centralized facility. The transportation of low bulk density, fresh harvested or ensiled sweet sorghum was found to significantly contribute to overall costs. However, at the scales evaluated in this study, those costs did not adversely affect the viability of sweet sorghum as a supplemental feed for existing dry-grind ethanol plant. The addition of front-end stalk processing/pressing equipment into existing ethanol facilities was also found to be economically viable when combined with the plants\u27 use of residuals as a natural gas fuel replacement. Because of high loss of fermentable carbohydrates during ensilage, storage of sweet sorghum in bunkers was not found to be economically viable. The forth section looks at double cropping winter triticale with late-planted summer corn and compares these scenarios to traditional single cropped corn. Double cropping systems show particular promise for co-production of grain and biomass feedstocks and potentially can allow for greater utilization of grain crop residues. However, additional costs and risks associated with producing two crops instead of one could make biomass-double crops less attractive for producers despite productivity advantages. Detailed evaluation and comparisons show double cropped triticale-corn to be at a significant economic disadvantage relative to single crop corn. The cost benefits associated with using less equipment combined with availability of risk mitigating crop insurance and government subsidies will likely limit farmer interest and clearly indicate that traditional single-crop corn will provide greater financial returns to management. To evaluate the various sweet sorghum, single crop corn and double cropped triticale-corn production scenarios, a detailed but generic model was developed. The primary goal of this generic approach was to develop a modeling foundation that can be rapidly adapted, by an experienced user, to describe new and existing biomass and crop production scenarios that may be of interest to researchers. To facilitate ease-of-use, the techno-economic model was developed in MS Excel\u3c®\u3e. It also incorporates the Excel add-on, Crystal Ball\u3c®\u3e, which provides Monte Carlo simulation and sensitivity analysis capabilities. The foundation model allows input of management practices, crop production characteristics and utilizes standardized machinery performance and cost information, including farm-owned machinery and implements, and machinery and farm production operations provided by custom operators. Several of the studies reported in this dissertation take advantage of the flexibility of the foundation model. Many specific models of unique production scenarios (in excess of 100) were developed and tested. Twenty of these models are actually presented in this work. More important to the success and value of this modeling approach is the now readily available Monte Carlo simulation tools, which allows researchers to describe uncertainty around key model variable in a more realistic manner. It is opinion of the author that all future crop related techno-economic studies should incorporate Monte Carlo simulations as standard practice

IMPROVED AUTOMOTIVE SAFETY THROUGH INSTRUCTIONAL MODULES AND AUTOMOTIVE DRIVING SIMULATOR BASED SKILLS TRAINING WITH ASSESSMENT

Motor vehicle crashes involving novice drivers are significantly higher than matured drivers\u27 incidents as reported by the National Highway Traffic Safety Administration Fatality Analysis Reporting System (NHTSA-FARS). There is ongoing research on how to decrease the number of crashes for this driver demographic group in the Unites States and Europe. Novice drivers usually complete driver education classes as a pre-requisite for full licensure to improve overall knowledge and safety. However, compiled statistics still indicate a need for more in-depth training after full licensure. This thesis introduces classroom and virtual training modules to improve the driving skills, attitudes, knowledge, and behavior of \u27high-risk\u27 young adult participants. The approach was to design two training modules for classroom instruction and establish a framework for a Public Service Announcement (PSA) seminar. In addition, a case study was performed using three automotive simulators exploring their potential use as a driver training resource. One of the driving simulators was subsequently used to complete a feasibility study examining the use of simulators as a driver training tool. The instructional modules covered vehicle maintenance, vehicle safety systems, and general automotive operations. The vehicle maintenance material included topics such as operating fluids, tires, brakes, windshield wipers, light bulbs, batteries, and warning lights. The second module focused on the basic operation of the vehicle and several key safety features (e.g., anti-lock braking system, electronic stability control, traction control system, seatbelts, and airbags). The PSA seminar introduced driving strategies such as avoiding driver distractions, seatbelt usage, and speed management using video campaigns produced by national and international organizations. Three simulators (DriveSafety Simulator, STISIM Drive Simulator, CU-Steering Simulator) were evaluated at North Carolina A&T University and Clemson University for their possible use in driver education programs. The overall performance was considered in nine general areas: ease of use, user-interface, motion/vision agreement, vehicle dynamics, haptic feedback, traffic scenarios, realism, mobility, and programmability. The DriveSafety simulator was determined the best option, since it provided the greatest number of characteristics ideally required for a training simulator. Based on the favorable results of this study, the opportunity to improve the driving skills of novice drivers using a DriveSafety automotive simulator was examined. Training test scripts for \u27Following Etiquette\u27 and \u27Situational Awareness\u27 were developed to introduce these key driving techniques. The training modules were administered in a pilot study using Clemson University students (ages 18-25). Students received little verbal instruction from the examiner; the majority of information was delivered by custom training videos and embedded driving simulator instructions. The \u27Following Etiquette\u27 module taught a basic timing method that allowed drivers to maintain a recommended following distance: 58% passed and 42% failed. The \u27Situational Awareness\u27 module allowed students to practice obstacle avoidance techniques and emergency maneuvers: 25% passed out right, 58% conditionally passed, and 17% failed. The classroom and virtual training modules were developed for possible implementation in a safe driving program. The automotive driving simulator proved to be a feasible option for facilitating automotive safety lessons, followed immediately by driving exercises to practice and reinforce the educational concept. Recommendations for additional classroom modules and virtual training modules are put forth for future study

An assessment of the use of antimisting fuel in turbofan engines

The effects of antimisting kerosene on the performance of the components from the fuel system and the combustor of a JT8D aircraft engine were evaluated. The problems associated with antimisting kerosene were identified and the extent of shearing or degradation required to allow the engine components to achieve satisfactory operation were determined. The performance of the combustor was assessed in a high pressure facility and in an altitude relight/cold ignition facility. The performance of the fuel pump and control system was evaluated in an open loop simulation

Investigating blast fume propagation, concentration and clearance in underground mines using computational fluid dynamics (CFD)

Blasting activities using standard industry explosives is an essential component of underground hard rock mining operations. Blasting operations result in the release of noxious gases, presenting both safety and productivity threats. Overestimation of post-blast re-entry time results in production losses, while underestimation leads to injuries and fatalities. Research shows that most underground mines simply standardize post-blast re-entry times based on experiences and observations. Few underground mines use theoretical methods for calculating post-blast re-entry time. These theoretical methods, however, are unable to account for the variations in the blasting conditions. Literature review shows that: (i) there is currently no means of estimating safe blast distance (i.e., blast exclusion zone); and (ii) there is a lack of a comprehensive relationship for calculating optimal post-blast re-entry time and optimal air quantity in underground mines. An important factor associated with blast fume dilution and clearance, the fan duct discharge location, needs to be studied in details. To achieve the above goals, the computational fluid dynamics (CFD) method is used to simulate blast fume dispersion and clearance in the underground mine. An experiment has been successfully conducted at the Missouri S&T Experimental Mine to acquire blast data to validate the proposed CFD model. Computational fluid dynamics simulation results compare favorably with blast data from Missouri S&T Experimental Mine with a coefficient of determination (R2) of 0.97. Based on the verified CFD model, various blasting and ventilation conditions were studied. A linear relationship has been developed and validated for estimating safe blast distances. Four equations have been generated and validated to conservatively calculate optimal air quantity and post-blast re-entry time based on commonly used blasting and ventilation conditions --Abstract, page iii

Automotive Stirling Engine Development Project

The development and verification of automotive Stirling engine (ASE) component and system technology is described as it evolved through two experimental engine designs: the Mod 1 and the Mod 2. Engine operation and performance and endurance test results for the Mod 1 are summarized. Mod 2 engine and component development progress is traced from the original design through hardware development, laboratory test, and vehicle installation. More than 21,000 hr of testing were accomplished, including 4800 hr with vehicles that were driven more dm 59,000 miles. Mod 2 engine dynamometer tests demonstrated that the engine system configuration had accomplished its performance goals for power (60 kW) and efficiency (38.5%) to within a few percent. Tests with the Mod 2 engine installed in a delivery van demonstrated combined metro-highway fuel economy improvements consistent with engine performance goals and the potential for low emission levels. A modified version of the Mod 2 has been identified as a manufacturable design for an ASE. As part of the ASE project, the Industry Test and Evaluation Program (ITEP), NASA Technology Utilization (TU) project, and the industry-funded Stirling Natural Gas Engine program were undertaken to transfer ASE technology to end users. The results of these technology transfer efforts are also summarized

Development of heat recovery solution for heavy duty truck cabs to improve energy efficiency

The recent climate actions to reduce greenhouse gas (GHG) emissions have set the stage for decarbonizing the transportation sector through electrification, which has led to a surge in the deployment of battery electric Trucks (BET). While tail-pipe emissions are reduced drastically, certain aspects of BET prevent its widespread deployment, prominent of which is the range anxiety. BET range is heavily impacted in cold weather as energy from traction batteries is also used to warm the battery pack and cabin. The thesis mainly focuses on the cabin exhaust air ventilation, which accounts 7-42% of the heat losses. In this study, three heat recovery techniques were investigated to harness the waste heat from evacuating cabin air to reduce the heating energy consumption in a BET. One proposed technique employed an air-to-air heat recovery system (AAHRS). Baseline experiments were conducted on a Scania R20H test truck to analyse the performance of the installed Heat Ventilation and Air Conditioning (HVAC) system, which aided the design and prototyping of the AAHRS system. Validation experiments evaluated the energy savings from the prototype in a climate chamber under different ambient temperatures and HVAC fan speed settings. The study found a 20-53% reduction in heating load with the implementation of AAHRS. In contrast, the electrical power consumption increased 1.7-3.3 times higher than the baseline cases because of the additional power-consuming components and the changed system resistances. Overall, 19-47% energy saving was observed from integrating the AAHRS prototype with the existing HVAC system. Two other presented techniques operate on air-to-liquid heat recovery systems (ALHRS), which were coupled separately to a heat pump-assisted integrated thermal management system (ITMS). The two schemes were evaluated via vapour compression system performance analysis to see the potential to increase the coefficient of performance (COP), which is beneficial in terms of available heat that can be dissipated into the battery cold plates and cab heater core. To assess the energy-saving potential of proposed ALHRS solutions, a simulation model of an adopted baseline ITMS concept was developed using Engineering Equation Solver (EES) software. It was then validated against internal bench test results for a mock-up ITMS model. The results of the initial validation test indicated an absolute error between the simulation outputs and bench test results of 8-14% for condensation heat, while it was below 7% for all the other relevant performance parameters