The use of aluminum (Al) alloy substances is analyzed in this paper in order to obtain a lighter and less costly winding design without dimensional changes in electrical machines. The determination of aluminum alloy winding material, which has an electrical conductivity close to that of copper (Cu) but has a lower density, is the basis of this study. In this context, various aluminum alloy substances have been investigated. Windings with these aluminum alloy materials for a 300 kVA synchronous alternator have been modeled with the Ansys Maxwell 2D software program. The performances of tempered and annealed alloy windings have been analyzed with respect to that of a copper winding. The analysis results show that the aluminum winding losses are close to copper winding losses under nominal operating current values. Among the aluminum alloy winding models, aluminum 1350 and aluminum 2041 have the closest loss values. On the other hand, there is very little difference between aluminum alloy windings in terms of winding weight, while the weight of the aluminum winding is 70% lower compared with that of the copper winding. It is suggested to wind turbine manufacturers that windings be formed with the aluminum 1350 and aluminum 2041 series to provide performance comparable with that of copper windings.
Due to today's competitive conditions and rising energy prices, the efficient use of energy consumed by facilities is only possible with the energy savings that can be made by investing in time, updating the technology, optimizing operating conditions and constant controlling. In this direction, The Bar Rolling Mill authorities have started this work to detect possible energy losses on the site and to increase energy efficiency. Measurements and evaluation of the results were made on the surface insulation inspections in annealing furnace, annealing furnace flue gas and annealing furnace cooling water, compressors, compressed air lines, pumps and annealing furnace burning air fan and hydraulic motors in Bar Mill. In the studies of the measurements, each equipment and line were examined separately and necessary calculations were done. Some suggestions were made on determined points which cause energy losses, how much loss is realized through these points and necessary investments to compensate for these energy losses, the price information. In the light of these works carried out in the factory; It is possible to save a total of 1,767,120.04 kWh/year energy and 441,780.01 ₺/year saving of money. Total investment cost is 558,500.85 ₺. The average return on investment (ROI) for all application plans is 1.26 years. After all these improvements, CO2 emission values will be reduced to 1,030.23 tons per year.
Organic Rankine Cycle (ORC) is widely used in electricity generation from low temperature waste heat sources. This study introduces the analysis of the biogas cogeneration plant run by internal combustion engines of different power scales. Taking into consideration the variable exhaust temperatures of the engines of the biogas plant operating at asymmetric power and the thermal capacities of the high temperature and low temperature circuits, analyzes and optimizations were realized by considering different fluids and boundary conditions for different cycle types at variable temperatures. To increase the overall efficiency of the plant and to recover the thermal energy thrown into the atmosphere, different fluids in different cycle types have been examined. To designate the working conditions of the proposed system, the energy production and internal consumption data of a working biogas power plant were investigated. Calculations were executed by taking consideration of the long-term recorded gas production data and the corresponding electrical power, electrical efficiency values, thermal production, waste feeding and preheating needs, and environmental conditions. The effects of different cycles on the total energy and exergy efficiencies of the plant were analyzed.
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