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Exergy Analysis of Energy Consuming Devices at a sugar factory. Just use this document for reference and do not copy the data . **Usage of the document at your own risk** I am not liable.

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0% found this document useful (0 votes)
16 views49 pages

Project Report

Exergy Analysis of Energy Consuming Devices at a sugar factory. Just use this document for reference and do not copy the data . **Usage of the document at your own risk** I am not liable.

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omaseishan4
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A

Project Report

On

“EXERGY ANALYSIS OF ENERGY CONSUMING DEVICES AT


SUGAR INDUSTRY”

Submitted by

1. Raje Dhanshree (19121120)


2. Jadhav Nikita (19121139)
3. Omase Ishan (19121267)
4. Agre Rathin (19121276)
5. Kadganche Sejal (18121183)

B. Tech. (Mechanical Engineering)

Under the guidance of

Prof. K. S. Gharge

Department of Mechanical Engineering

GOVERNMENT COLLEGE OF ENGINEERING, KARAD


(An Autonomous Institute of Govt. of Maharashtra)
(2022-2023)
Government College of Engineering
Karad, Maharashtra, India Phone: 02164-271711, 272414

E-mail: princek@gcek.ren.nic.in

CERTIFICATE

This is to certify that, we

1. Raje Dhanshree (19121120)


2. Jadhav Nikita (19121139)
3. Omase Ishan (19121267)
4. Agre Rathin (19121276)
5. Kadganche Sejal (18121183)

Studying in B. Tech. Mechanical Engineering have successfully completed the project entitled
“Exergy Analysis of Energy Consuming Devices at Sugar Industry” under the guidance
and supervision of Prof. K. S. Gharge during the academic year 2022-23.

Prof. K. S. Gharge Dr. R. K. Shrivastava


Guide Head of the Department
Dept. of Mechanical Engineering Dept. of Mechanical Engineering
Govt. College of Engg., Karad Govt. College of Engg., Karad

Dr. S. J. Wagh External Examiner


Principal

Govt. College of Engg., Karad


ACKNOWLEDGEMENT

It is indeed pleasure for us to express our gratitude and sincere thanks to our project
guide Prof. K. S. Gharge of Mechanical Engineering Department, Govt. College of
Engineering, Karad who have been constant source of inspiration and encouragement. We
are indeed grateful to her for providing helpful suggestions from time to time. Due to her
constant encouragement and inspiration we are able to present this project.

We deeply express our sincere thanks and respect to our Head of Department, Dr.
R. K. Shrivastava for encouraging and allowing us to present the project on the topic
“Exergy Analysis of Energy consuming devices at Sugar Industry” for the partial
fulfillment of the requirements leading to the award of B. Tech degree. We are very much
thankful to Principal, Dr. S. J. Wagh for providing all the necessary facilities to carry out
project work.

We take this opportunity to thank all our lecturers who have directly or indirectly
helped our project. We pay our respects and love to our parents and all other family
members and friends for their love and encouragement throughout our career.

GOVERNMENT COLLEGE OF ENGINEERING, KARAD. Page i


ABSTRACT

This project aims to conduct an exergy analysis of energy consuming devices,


namely a boiler and a pump, at a sugar factory. The purpose of this study is to identify the
sources of energy inefficiencies in these devices and propose possible solutions for energy
saving. The exergy analysis will be based on the input and output data of the devices,
which will be obtained through measurements and data logging. The analysis will include
the calculation of energy and exergy efficiencies, as well as the identification of the
sources of exergy destruction. The results of the analysis will provide insights into the
performance of the devices and the potential for energy savings. The proposed solutions
will involve improvements in the design and operation of the devices, as well as the use of
more efficient components. This study will contribute to the efforts of the sugar factory in
reducing its energy consumption and improving its sustainability.

GOVERNMENT COLLEGE OF ENGINEERING, KARAD. Page ii


TABLE OF CONTENTS

ACKNOWLEDGMENT ...................................................................................................... i
ABSTRACT ......................................................................................................................... ii
LIST OF FIGURES ............................................................................................................ v
LIST OF TABLES ............................................................................................................. vi
LIST OF ABBREVATION AND NOMENCLATURE................................................................ vii
CHAPTER 1 .....................................................................................................................................1
INTRODUCTION ......................................................................................................................1
1.1 BACKGROUND ..................................................................................................................1
1.2 OBJECTIVE.........................................................................................................................2
1.3 EXERGY .............................................................................................................................2
1.3.1 EXERGY ANALYSIS ..................................................................................................3
1.3.2 EXERGY ANALYSIS APPLICATION ........................................................................4
1.4 MAINTENANCE AND ADVANCEMENT IN SYSTEM COMPONENTS ..........................4
1.4.1 MAINTENANCE .........................................................................................................4
1.4.2 .....................................................................................................................................4
CHAPTER 2 .....................................................................................................................................6
LITERATURE REVIEW ...........................................................................................................5
2.1 REVIEW OF LITERATURE ................................................................................................6
2.2 CONCLUDING REMARK ................................................................................................ 10
2.2 METHODOLOGY ............................................................................................................. 10
CHAPTER 3 ................................................................................................................................... 12
PLANT LAYOUT AND COMPONENTS ................................................................................ 12
3.1 THEORY ........................................................................................................................... 12
3.2 PLANT LAYOUT .............................................................................................................. 12
3.3 COMPONENT SPECIFICATIONS .................................................................................... 13
3.4 SOFTWARE DETAIL........................................................................................................ 14
CHAPTER 4 ................................................................................................................................... 15
EXERGY ANALYSIS CALCULATION ................................................................................. 15
4.1 EXERGY ANALYSIS PROCEDURE ............................................................................... 15
4.1.1 EXERGY DESTRUCTION RATE ............................................................................. 15
4.1.2 EFFICIENCY ............................................................................................................. 16
4.2 EXERGY OF FUEL ........................................................................................................... 17
4.3 OBSERVATIONS .............................................................................................................. 17

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4.4 SAMPLE CALCULATION ................................................................................................ 19
4.5 SOFTWARE VALIDATION.............................................................................................. 21
CHAPTER 5 ................................................................................................................................... 22
RESULT AND DISCUSSION .................................................................................................. 22
5.1 RESULT ............................................................................................................................ 22
5.1.1 TOTAL EXERGY FLOW OF BOILER ...................................................................... 22
5.1.2 TOTAL EXERGY FLOW OF PUMP ......................................................................... 23
5.1.2.1 FEED WATER PUMP ................................................................................ 23
5.1.2.2 SULPHITED JUICE PUMP ........................................................................ 23
5.1.2.3 CLEAR JUICE PUMP ................................................................................. 24
5.1.3 EXERGY DESTRUCTION RATE ............................................................................. 25
CHAPTER 6 ................................................................................................................................... 26
CONCLUSION AND SUGGESTIONS .................................................................................... 26
6.1 CONCLUSION .................................................................................................................. 26
6.2 SUGGESTIONS TO REDUCE EXERGY DESTRUCTION RATE .................................... 26
6.3 DISCUSSION .................................................................................................................... 27
REFERENCES .................................................................................................................. 29
APPENDIX ........................................................................................................................ 31

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LIST OF FIGURES

Figure 3.1 Plant Layout ....................................................................................................... 12

Figure 3.2 Water-Tube Boiler .............................................................................................. 13

Figure 4.1 Comparison of Theoretical and Actual Exergy Flow ........................................... 21

Figure 5.1 Total Exergy Flow of Boiler ............................................................................... 22

Figure 5.2 Total Exergy Flow of Feed Water Pump ............................................................. 23

Figure 5.3 Total Exergy Flow of Sulphited Juice Pump ....................................................... 24

Figure 5.4 Total Exergy Flow of Clear Juice Pump ............................................................. 24

Figure 5.5 Exergy Destruction Rate of Energy-Consuming Devices .................................... 25

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LIST OF TABLES

Table 4.1 Observation data of Boiler ................................................................................... 18

Table 4.2 Observation data of Feed Water Pump ................................................................. 18

Table 4.3 Observation data of Sulphited Juice Pump ........................................................... 18

Table 4.4 Observation data of Clear Juice Pump ................................................................. 19

Table 5.1 Total Exergy Flow of Boiler ................................................................................ 22

Table 5.2 Total Exergy Flow of Feed Water Pump .............................................................. 23

Table 5.3 Total Exergy Flow of Sulphited Juice Pump ........................................................ 23

Table 5.4 Total Exergy Flow of Clear Juice Pump .............................................................. 24

Table 5.5 Exergy Destruction Rate of Energy-Consuming Devices...................................... 25

Table 5.6 Percentage Exergy Destruction ........................................................................... 26

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ABBREVIATION AND NOMENCLATURE

Nomenclature:
𝑚̇ Mass flow rate
e Specific exergy rate
Ė Total exergy rate
h Enthalpy
s Entropy
T Temperature
P Pressure
İ Exergy destruction rate
𝑊̇ Work rate
NCV Net calorific value
∅ Mass fraction

Greek symbols:
Ƞ𝑒𝑥 Exergetic efficiency

Subscripts:
o Dead state conditions
b/B Boiler
p/P Pump
f Fuel
fp Feed water pump
sp Sulphited juice pump
cp Clear juice pump

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CHAPTER 1
INTRODUCTION

1.1. Background

The energy crisis of the 1970s and the increasing emphasis on the conservation of fuel
resources (i.e., efficiency) have led to a complete over haul of how power systems are
analyzed and improved thermodynamically. Thermodynamics is a credible method of
performing analysis of technical systems efficiently by finding the most economical solution
within the limits of the technical possibilities. Thus, thermodynamics laws play an important
role in performing the energy and exergy analysis of industrial systems.

The sugar industry is a vital sector in the global economy and is a major consumer of
energy. The sugar industry is a big business in India. Sugarcane is planted in India on three
occasions annually, in October, March, and July, depending on the region and the most
effective habitat. India is now a structurally sugar-surplus country and is also exporting sugar
to other countries. India's cooperative local sugar mills are where the majority of the country's
sugar is produced. Around mills produced more than 288 Lakh tonne of sugar in the last
crushing season, which lasted from October 2022 to March 2023. Sugarcane cultivation and
extraction employs about 50 million farmers and thousands of additional industry workers.
The largest consumer of sugar worldwide is India.

During the last sugar season 2021-22, India exported around 110 LMT of sugar. In the
current sugar season 2022-23, the Government of India has allocated a quantity of 60 LMT of
sugar for export to sugar mills across the country.

Sugar production requires numerous energy-intensive processes, including the boiling


of juice, evaporation of water, and crystallization of sugar. The boiler and pump systems used
in a sugar factory are critical components that consume a significant amount of energy for
steam generation as well as the flow of fluid throughout the factory. The method for clearly
distinguishing between energy losses to the environment and internal irreversibilities in the
process is exergetic analysis. The exergy analysis methodology involves assessing the exergy
at various points in a series or process of energy-conversion steps and serves as an aid
forassessingtheperformanceofthedevicesaswellasprocesses.Withthisinformation,efficiencies
can be evaluated, and the steps of a process having the largest losses (i.e. in
turnhavingthegreatestmarginforimprovement)canbeidentified.Forthesereasons,thecontempora
ry approach to procedure analysis uses exergy analysis, which provides a more realistic view
of the process and is a useful tool for engineering evaluation.

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR
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The exergy analysis applied can be obtained to reduce the use of natural resources for
energy generation and, as a result, to decrease the pollution of the environment. Therefore,
analysis of these systems can provide valuable insights into their performance and efficiency.

1.2 Objective:

The aim of this project is to perform exergy analysis of energy consuming devices.

i. Analyze the performance of efficiency of energy consuming devices i.e. Boiler and pumps.

ii. The exergy analysis will be conducted using thermodynamic principles, with a focus on
calculating the exergy of the input and output streams, as well as the exergy destruction
within the systems.

iii. To evaluate the exergy destruction rate and efficiency of these systems.

iv. To identify areas of improvement in these systems.

v. Find feasible solutions for significant energy savings.

1.3 Exergy:

An opportunity for doing work exists whenever two systems at different states are
placed in contact, as work can be developed when the two are allowed to come into
equilibrium. Exergy is the greatest theoretical shaft work or electrical work that can
be obtained as the two systems interact to reach equilibrium, with heat transfer occurring
exclusively with the environment when one of the two systems is a sufficiently
idealized system known as the environment and the other is a system of interest

Exergy, on the other hand, is the minimal amount of theoretical electrical or shaft
labor needed to create a certain amount of material from elements found in the environment
and get it to a specific state. Exergy is typically destroyed rather than conserved. When energy
would be lost, that would be a limiting circumstance. as would happen if a system were to
naturally reach equilibrium with the environment without any means of obtaining work. The
opportunity to develop work that exists initially would be completely wasted in the
spontaneous process. Moreover, since no work needs to be done to effect such a spontaneous
change, we may conclude that the value of exergy (the maximum theoretical work obtainable)
is at least zero and therefore cannot be negative.

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1.3.1 Exergy analysis:

The exergy analysis is based on the first and second laws of thermodynamics and
Exergy is defined as the maximum amount of work potential of a material or an energy
stream concerning the surrounding environment.
In addition, a feature of the exergy concept permits quantitative evaluation of energy
degradation.
The first law of thermodynamics indicates that,
 The energy content of the universe and its masses are constant.

 Neither energy nor matter can be produced, destroyed, or consumed.

 Energy is never lost in quantitative terms; it only gets degraded in quality as the degradation
of quality makes it less useful.

The concept of the destruction of something can be considered useful. But, energy
cannot be considered, however, but there exists another term: exergy.
The second law of thermodynamics indicates that the quality of energy is degraded
every time energy is used in any process. The energy quality has been named the exergy law
or the second law. Exergy can be destroyed or consumed, but not conserved and created.

 Exergy is defined as the maximum amount of work that can be produced by a stream of
matter, heat, or work, as it comes to equilibrium with a reference environment.

 Exergy is the useful work potential of the energy; it can never be recovered.

 The entropy of a system increases when the exergy is lost.

 The kinetic and potential energies of the system contribute their full magnitudes to the exergy
magnitude when measured relative to the environment because each is fully convertible to
work as the system approaches the dead state.

 Exergy can be expressed as the sum of the chemical exergy and the thermo-mechanical
exergy. Thermo-mechanical exergy can be further classified as physical, kinetic, and potential
exergy.

 Energy conservation does not apply to exergy; instead, it is used or destroyed as a result of
irreversibilities in all procedures.

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1.3.2 Exergy analysis application:

Thermal systems are supplied with exergy inputs derived directly or indirectly from
the consumption of resources such as oil, natural gas, coal, and other resources. Accordingly,
avoidable destructions and losses of exergy represent the waste of these resources. By
devising ways to reduce such sources of inefficiency, better use can be made of fuels.
The exergy balance can be used to determine the location, type, and true magnitude of
the waste of energy resources, and thus can play an important part in developing strategies for
more effective fuel use. Exergy analysis can help locate system non-idealities that either are
not identified or misevaluated by energy analysis, for example, the combustion irreversibility.
Accordingly, exergy analysis can be used as a tool to devise better processes or design better
components. Exergy analysis also can be used to assess the real effect of off-design conditions
on individual components or overall plants. Ultimately, exergy analysis can be applied
globally to the industrial sector, the agricultural sector, or an entire nation to develop insights
concerning the location and relative significance of key non-idealities. Such insights can be
used to guide measures for improving the sector's overall conversion efficiency in turn
reducing thereby resource waste attributable to that sector.
1.4 Maintenance and advancement in system components:
1.4.1 Numerous measures related to maintenance and controls are possible to
reduce losses. These include,
i. Minimizing gas, air, steam, and other substance leaks in pipes, valves, couplings, and
equipment.

ii.Utilizing improved and more automated controllers, both to ensure design specifications are
adhered to and to detect parameter variations that may indicate future problems.

iii.Improved maintenance to ensure minor breaks and actual operating parameters match design
specifications, for example, minor modifications to reheat steam rising temperature in the
boiler can be implemented to improve overall efficiency.

iv. Periodic overhauls of devices.

1.4.2 Exergy-related techniques for analyzing energy-consuming devices at sugar


production factory:

To assist in improving the efficiencies of bagasse to electricity technologies, their


thermodynamic performances are usually investigated. Energy analysis is typically used to
analyze energy technology. A more comprehensive thermodynamic viewpoint, which makes
use of the second rule of thermodynamics along with energy analysis via exergy methods,
leads to a better understanding.
Exergy is more freely regarded as a measure of the quality or usefulness (in addition to

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the quantity) of an energy flow or quantity. Exergy analysis is a technique for evaluating the
efficiencies of processes and devices and identifying the locations and causes/sources of
major inefficiencies, where actual performance exhibits the largest deviations from ideal
performance. Unlike energy efficiencies, exergy efficiencies always provide a measure of the
approach to the ideal. Through the better understanding developed with exergy analysis, the
efficiencies of devices and processes can usually be improved, often in a cost-effective
manner.
Exergy analysis is therefore particularly beneficial for
i. Designing better new facilities, and

ii. Modifying existing facilities to improve them.

Exergy approaches may provide important insights that assist in improving


productivity and achieving ideal designs.

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CHAPTER 2
LITERATURE REVIEW
2.1 Review of literature:

I. Energy and exergy analysis conducted at sugar factory:


 H. M. Sahin et al [2010] - In this paper, the energy and exergy analysis of sugar
production processes were presented using operational system data from a sugar plant in
Turkey. The results showed that the best values of the energy and exergy efficiencies
were obtained in the juice production process and juice concentration process,
respectively. The authors also identified the location of energy degradation and
irreversibility in the sugar production processes, and suggested that improving these rates
could lead to increased energy and exergy efficiencies.
 Sibo Dennis [2019] - In his study, Sibo Dennis observed the energy losses of three
power plants in a sugar refinery and used exergy and energy data to provide a
technological solution for energy cost reduction and stability. The goals included
developing a cutting-edge system for increasing revenue while reducing energy use,
utilizing energy data to develop strategies for managing and reducing energy costs, and
promoting efficient energy management systems.
 Tolga Taner et al [2015] - Sugar manufacturing in the food business uses a significant
amount of energy, primarily from the usage of steam and the strength of the turbine
power plant. Energy and exergy analyses are therefore vital in sugar mills. The input and
output data necessary for energy and exergy analysis of sugar factories were the subject
of a different study. According to the analysis, the plant had an overall energy efficiency
and exergy efficiency of 72.2% and 37.4%, respectively, with an overall energy quality
of 0.64.
II. Exergy analysis of energy-consuming devices (Boiler based):
 Neetu Singh et al [2019] - The paper identifies the reactions having max energy losses.
The heat losses through the boiler and condenser are considered here and the energy
balance and exergy destruction are performed around the different equipment of the
plant. The major source of exergy loss is the boiler where around 77% of the fuel exergy
was destroyed, in the turbine it is 13% of the total fuel exergy was destroyed. It shows
that the boiler is the major source of the irreversibility in the plant. Exergy analyses are
the first step in understanding where the weak points of the processes are. In this case
study, energy and exergy analysis of a power plant is done with a varying reference
temperature.

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 Yusuf Parvez et al [2019] - In the present scenario, the energy crisis and its demand
have become global problems that restrict sustainable development. To overcome this
problem, one needs to develop an advanced technological system that not only improves
the system's performance but also reduces the environmental effects. Yusuf Parvez and
M M Hasan conducted an energy and exergy analysis of a sugarcane bagasse boiler and
found that the energy efficiency of the boiler was high, but the second law efficiency was
relatively low due to significant irreversibility rates associated with the combustion
chamber and heat exchangers. The authors suggested that improving the performance of
the combustion chamber and heat exchangers could lead to improved overall
performance of the plant.
 S. Jayakumar et al [2008] - In this study, the authors performed an exergy analysis of
boilers in the sugar industry, which are used to generate steam for various processes. The
authors found that the combustion chamber had the highest exergy destruction, and
suggested improvements in the combustion process to improve the overall efficiency of
the boilers.
 Hemanta kumar Panda et al [2018] - The primary objective of the work is to analyze
the system components separately to identify the parts responsible for the loss of energy
at large. The conclusion of the research can enable the configuration of suitable
modifications to improve the efficiency of the system components and minimize the
energy loss of the power plant. Based on a study of energy destruction, the boiler system
has a maximum of 64.04% energy loss. The energy efficiency of the power plant is
50.41%, which is low as compared to modern power plants. According to analysis, it is
found that the boiler is the major source of irreversibility in the power plant, but the
energy destruction rate in the boiler can be reduced by introducing a reheating system. It
is an effective method for reducing boiler irreversibility. In this research, the effect of
reheating on enhancing overall performance is contrasted with the actual state of the
power plant. The impact of reheating to reduce energy destruction has also been studied,
with no change in fuel use. It has been discovered that the introduction of the reheating
technology boosted overall plant efficiency and increased power generation, in addition
to minimizing boiler energy destruction.
 PeriyasamyK et al [2018] -The project's goals are to increase boiler efficiency and
eliminate moisture from biogas. Bagasse is a byproduct of the sugar milling process that
is used as a fuel resource. It is a low-density, fibrous material that has a very wide variety
of particle sizes and a high moisture content. Its chemical characteristics are comparable
to those of fiber from hardwoods. The physical characteristics of bagasse particles are
challenging to describe using conventional metrics (such as particle density, size, drag
coefficient, etc.). To use standard design practices, these characteristics are required. As
an illustration, consider pneumatic conveyance, fluidization, drying, burning, etc. The

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gravimetric method is typically used to determine moisture content. After milling, the
moisture content is typically up to 50%.Moisture content has an impact on calorific
value. Therefore, burning bagasse at the proper degree of moisture is crucial for the
efficiency of the furnace. Here, both direct and indirect techniques are used to eliminate
the moisture. the technique for altering the processes of conduction, convection, and
radiation. by using exhaust flue gas as a source to drain bagasse of moisture.
 R. Saidur et al [2010] - This essay analyses and applies the practical idea of energy and
energy utilization to the boiler system. In this study, the energy and exergy flows in a
boiler are illustrated. Additionally, energy and exercise efficiencies have been
established. Energy and exergy efficiencies in a boiler were discovered to be 72.46% and
24.89%, respectively. The energy and energy efficiency of a boiler are also evaluated in
comparison to other works. It has been discovered that a boiler system's heat exchanger
and combustion chamber are the two main contributors to energy destruction.
Additionally, a number of energy-saving techniques are used to lessen a boiler's energy
consumption, such as the use of variable-speed drives in the fan and heat recovery from
flue gas. According to research, the payback period for heat recovery from boiler flue gas
is roughly one year. The payback period for using a 19 kW motor with a VSD was found
to be economically feasible for boiler fan energy reductions.

III. Exergy analysis of various components carried out at sugar industries:


 M. Narayanan et al [2006] - In this study, the authors performed an exergy analysis of a
cogeneration system in a sugar industry, which produces both electricity and steam for
the industry's use. The authors found that the boiler and the steam turbine had the highest
exergy destruction, and suggested improvements in these devices to improve the overall
efficiency of the system.
 N. W. Kimari et al [2017] -The authors performed an exergy analysis of a sugar industry
process that incorporates a partial condensing turbo-generator. The authors found that the
evaporator and the condenser had the highest exergy destruction, and suggested
improvements in the heat transfer process to improve the overall efficiency of the
system.

 Necmettin Sahin et al [2015] - A study was conducted at the Eregli Sugar Factory to
analyze the energy and exergy used in sugar production processes. The study found that
the factory needs to implement energy-saving innovations to prevent energy losses. To
achieve this, the study recommended that the factory's systems be maintained, repaired,
and renovated to save energy. 
 Muhammad Faisal Hasan et al [2018] - Exergy analysis is a valuable tool for
evaluating the performance and efficiency of various systems, including those related to

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solar energy, sugar production, and cogeneration. In the study by Muhammad Faisal
Hasan et al., the authors conducted a thermodynamic analysis on a serpentine-type
thermosyphon flat-plate solar heater using the Second Law of thermodynamics. The
results showed that most exergy destruction occurs due to the high-temperature
difference between the sun and the absorber plate, and utilizing solar energy for water
heating can greatly reduce energy costs.
 Hector Velasquez et al [2010] - In the study by Hector Velasquez et al., the authors
aimed to determine how energy resources are used in the production of unrefined sugar
in Colombia. The results showed that technological improvements can increase energy
efficiency to acceptable levels, but implementing cogeneration systems in large-scale
production processes may be necessary for further improvements in second-law
efficiency. 

IV. Thermal power plant’s analysis:


 Isam H. Aljundi [2009] – It is studied that the energy and exergy analysis of Al-Hussein
power plant (396MW) in Jordan. The performance of the plant was estimated by a
component wise modeling and a detailed break-up of energy and exergy losses for the
considered plant has been presented. It was found that the exergy destruction rate of the
boiler is dominant over all other irreversibility in the cycle. It counts alone for 77% of
losses in the plant, while the exergy destruction rate of the condenser is only 9%. The real
loss is primarily back in the boiler where entropy was produced. Contrary to the first law
analysis, this demonstrates that significant improvements exist in the boiler system rather
than in the condenser.
 Sandhya Hasti et al [2013] - In this study, exergy analysis was performed for ultra super-
critical power plant. The analysis was carried out by means of process simulation using a
computer model developed in Microsoft Excel The model was based on the concepts of
coal combustion, energy balances, enthalpy balances, entropy changes and heat transfer
of the steam power cycle. After development, the validated model was used to simulate
the hypothetical power plant combusting lignite coal with the net output of 422 MW. The
exergy loss indicates that the highest concentration of losses appears to be the furnace
followed by the turbine.
 Mohammadreza BabaeiJamnani et al [2020] - The gas-fired combined-cycle power
station that will be built in Kuantan and Kapar on the Malay Peninsula in 2020 is the
subject of this study's energy-exergy analysis. The main goals of the current study are the
evaluation of the gas turbine unit, condenser, heat recovery steam generator, and triple-
pressure steam turbines as first- and second-law systems. Energy-exergy analysis allows
us to analyze the major or minor effects of changes in environmental conditions on plant
components in addition to determining the precise amount of energy destruction and

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efficiency in each component independently. When the pressure ratio, reference


temperature, HPT and condenser pressure, reheating, and stack temperature change,
performance effects are also identified. With regard to the current analysis, the gas turbine
cycle accounts for approximately 83.79% of all exergy destruction, followed by HRSG
(11.3%), steam turbines (around 2.58%), and condenser (2.54%). The average molar
percentages of nitrogen, oxygen, carbon dioxide, and water vapour are calculated to be
76.42%, 17.57%, 1.37%, and 4.64%, respectively, in the exhaust gas portions from the
gas turbine across the combustor. In light of the findings, various positive prospects for
the growth of CCPP's performance are introduced. Energy-exergy assessment and
optimization advice may be beneficial for this project's construction in 2020 in order to
improve some operating conditions and simultaneously take advantage of the low
destruction rate.

2.2 Concluding remark:


i. It was found that the exergy destruction rate of the boiler is dominant over all other
irreversibilities in the cycle and followed by the turbine of the plant closely followed by a
condenser.

ii. The cost of exergy destruction in the boiler and turbine is higher in comparison to the
other components' cost.

iii. Through exergy analysis, the most sensitive mechanisms associated with heat loss is the
exergy lost by heat transfer and thermal irreversibilities.

iv. Exergy analysis results can aid efforts to improvement, design, and optimization efforts are
likely to be more rational and comprehensive if exergy is one of the factors considered.

2.3 Methodology:

i. Detailed Literature survey regarding experimental performance of sugar production factory


and performance analyze of it for enhancing performance.

ii. Literature survey gap analysis is carried out and gaps are identified.

iii. Data is collected from the actual workings of the sugar production factory.

iv. Energy-consuming components such as boilers and plant pumps are

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

thoroughly examined.

v. To determine the exergy generated and the exergy destroyed at each


component of the plant
vi. A conclusion is drawn from the discussion, and the scope of the work is
decided.

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

CHAPTER 3
PLANT LAYOUT AND COMPONENTS
3.1 Theory:
The exergy analysis is conducted at Jaywant Sugars Ltd. (JSL) is located in Satara,
Maharashtra, near post Dhawarwadi, Tal. Karad.
Corporation for agriculture and bio-energy, Jaywant Sugars Ltd. JSL is the outcome
of an inspirational business concept and a compelling mission to become the most effective
sugar processor. The company is founded by Dr. Suresh Jaywantrao Bhosale and his son
Dr. Atul Suresh Bhosale in 2006, not just dreamers but doers in their own right.
JSL has installed capacity of 2500 Tonne per Day and 10 MW co-generation. JSL
produce white crystal fine sugar of M & S grade with double sulphation process. Where
clarified sugar cane juice treated and mixed with sulphur di-oxide and outcome is known
as sulphured syrup, which is sent for pan boiling for crystallization process and then final
free flow sugar crystal forms with by products such as bagasse and molasse.
With an added distillery producing Ethanol, rectified spirit, neutral alcohol and
hand sanitizer.
3.2 Plant Layout:

Figure 3.1 Plant Layout

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

Turbine:
The plant uses Triveni Eng. & Ind. Ltd. Multistage impulse type turbine. The turbine has a
capacity of 10MW and temperature up to 510 o C. With generator of 10 MW and voltage-11000V
and 656 A.
3.3 Component specifications:
The following data gives specifications about boiler and pumps used in the sugar factory:
I) Boiler

Figure 3.2 Water-tube boiler


Boiler is used for steam power production. It is fueled by burning bagasse.

Make S. S. Eng. Ltd.


Type Water tube – Bagasse fueled
Design and working 45 kg/cm2
parameter
Hydraulic test pressure 67.5 kg/cm2
Boiler Capacity 70 Ton/hr.
Total heating capacity 3749sq.m.

II) Pump Specifications


All the mentioned pumps used are centrifugal-type pumps.
i. Feed water pump
The feed water pump is used to feed the water to the boiler for heating.

No. of pump 3
Make KSB

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

Type HAD-65/12
Capacity 45 m3/hr
Head 650 m
Motor Kiloskar make 225HP –
2900rpm

ii. Sulphited juice pump


A sulphited juice pump is used to mix the clear juice obtained from the sugarcane with
sulphur dioxide.

Type CPHM – 125/45


Head 70 m
Capacity 200 m3/hr
Motor 75 kW/100 HP –
1470 rpm

iii. Clear juice pump


A clear juice pump is used to pump out the clear juice.

No. of pump 5
Type GK/00/40B
Head 50 m
Capacity 200 m3/hr
Motor 30 kW – 1460 rpm

3.4 Software Detail:

For numerical calculation, data analysis, and visualization, many different fields employ the
high-level programming language and environment known as MATLAB. It offers a variety
of tools and features that make it appropriate for utilization in engineering and scientific
applications.
MATLAB was used for the validation of calculated data total exergy flow and exergy
destruction rate of selected components. For the same MATLAB R2023a was utilized.
Program was generated and ran for the computation of the exergy destruction rate along with
determination of specific entropy, enthalpy and thermodynamical properties required in the
calculations.

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CHAPTER 4
EXERGY ANALYSIS CALCULATIONS

4.1 Exergy analysis procedure:

To carry out exergy analysis the following assumptions are considered:


i. The process is carried out at steady state.
ii. Changes in potential and kinetic energies are neglected
iii. There are no heat losses over the surface of the components.
iv. Cycle and cooling water are treated as pure
v. There are no changes of the specific chemical energies in the cycle.

a. Exergy can be transferred by heat, work and mass flow. The general equation of the
total exergy for the all steps, considered as an open steady state thermodynamics
system or a steady flow process, is calculated as :
Extotal= Exheat + Exwork + Exmass
 The total exergy of a system (E) can be divided into four components: physical
exergy (EPH) kinetic exergy (EKN), potential exergy (EPT), and chemical exergy
(ECH).
Ė = Ė PH + Ė KN + Ė PT + Ė CH
 If the kinetic, potential and chemical exergy are considered to be negligible the
specific exergy is defined as by equation.
e = (h-ho) -To (s-so)
 The total exergy rate of the system is given by the equation.
Ė = 𝑚̇ [(h - ho) - To(s - so)]
Where 'h' and 's' are specific enthalpy and specific entropy at a particular point in a
system a cycle at a particular pressure and temperature. T o and Po are the temperature and
pressure at a or in reference environment considered for the analysis (P =101.325 KPa and
T=298.15 K)
4.1.1 Exergy destruction rate
Irreversibilities such as friction, mixing, chemical reactions, heat transfer through a
finite temperature difference, unrestrained expansion, non quasi-equilibrium compression or
expansion always generate entropy, and anything that generates entropy always destroys
exergy. The exergy destroyed is proportional to the entropy generated.
Note that exergy destroyed is a positive quantity for any actual process and becomes zero for
a reversible process. Exergy destroyed represents the lost work potential and is also called
the irreversibility or lost work. Since any system and its surroundings can be enclosed by a

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sufficiently large arbitrary boundary across which there is no heat, work, or mass transfer,
any system, and its surroundings constitute an isolated system, the decrease of exergy and
the exergy destruction are applicable to any kind of system undergoing any kind of
process. Since no real process is fully reversible, energy is lost as a result of processes. As a
result, the exergy of the universe, which may be thought of as a standalone system, is always
declining. The amount of energy lost during a process increases in proportion to how
irreversible it is.
A reversible process doesn't waste any energy. The decline of the exergy principle
does not necessarily mean that a system's exergy is reduced.
To find out the exergy destruction rate the following equations can be used.
 Boiler,
Exergy destruction rate
İb = Ė𝑓 + Ė𝑖𝑛 − Ė𝑜𝑢𝑡
Where, Efuel is total exergy of fuel, Ein is total exergy at inlet, Eout is total exergy at outlet.

 Pump,
Exergy destruction rate
İpump = Ė𝑖𝑛 − Ė𝑜𝑢𝑡 + 𝑊̇ P
Where, Wp is work rate by pump, Ein is total exergy at inlet, Eout is total exergy at outlet.
Work rate,
𝑄×𝐻×𝜌×𝑔
𝑊= 𝑘𝐽/𝑠
Ƞ × 1000
Where, Q is mass flow rate, H is head, Ƞ is efficiency of pump and 𝜌 is density of
fluid.
4.1.2 Efficiency
The ratio between the exergy used or gained and consumptive exergy is defined as
exergy analysis of the system.
Efficiency of boiler:

Ė𝑜𝑢𝑡 − Ė𝑖𝑛
Ƞ𝑒𝑥𝐵 =
Ė𝑓
Efficiency of pump:
İpump
Ƞ𝑒𝑥𝑃 = 1 −
𝑊̇𝑝

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4.2 Exergy of fuel (sugarcane bagasse)


The ratio of chemical exergy (e) of dry solid fuels to the net calorific value of fuel (NCV),
with mass ratio of oxygen to carbon (O/C) varies from 0.667 to 2.67 in general and in
particular for bagasse is given by Kotas,

1.0438 + 1.0882 (ℎ⁄𝑐 ) − 0.2509[1 + 0.7256(ℎ⁄𝑐) + 0.0383(𝑛⁄𝑐)]


∅𝑑𝑟𝑦 =
1 − 0.3035(𝑜⁄𝑐)
= 1.2744
Where c, h, o and n are the mass fractions of carbon, hydrogen, oxygen and nitrogen
respectively.
 Taking moisture of the fuel into consideration the chemical energy E of the wet
bagasse is given by:
Ė = [𝑁𝐶𝑉 + 𝑊 ∗ ℎ𝑓𝑔 ]∅𝑑𝑟𝑦
From the steam table, at To = 298.15 K the value of hfg = 2442 kJ/kg is found.
W (water content of wet bagasse in percentage) = 0.5
NCV = 7130 kJ/kg c = 22.04 h = 2.72
n = 0.15 S = 0.02 o = 21.07

Ė𝑓𝑢𝑒𝑙 = [7130 + 0.5 ∗ 2442] ∗ 1.2744 = 10642.515 𝐾𝐽⁄𝑘𝑔

Ė𝑓𝑢𝑒𝑙 = 9.37 ∗ 10642.515 = 103551.671 𝑘𝐽⁄𝑠


Ė𝑓 = 103.5517 𝑀𝑊

4.3 Observations

At the sugar factory, it was observed that, automation of most of the components
is done to collect data regularly.

From such regular data collection, the following material was collected over a
period of a month.

i. Boiler

The water tube boiler with a capacity of 70 TPH undergoes maintenance every six
months during the off season of the sugar cane crop. With the average turbine load
being 9400 kW.

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Some of the observations are given below,

Sr. Temperature Pressure 𝐦̇


No. (°C) (bar) (kg/s)
1 104 47 20.572
2 500 45 18.628
3 102.35 47 20.209
4 495.75 45 18.637

Table 4.1 Observation data of Boiler


ii. Feed Water Pump

Average pressure in feed water pump is about 1.5 kg/cm2.

Some of the observations are given below,

Sr. Temperature 𝐦̇
No. (°C) (kg/s)
1 65.1 21
2 65.1 19.04
3 65.1 23.8
4 65.1 18.76

Table 4.2 Observation data of Feed water pump


iii. Sulphited Juice Pump

The pressure head is 70 m. Average pressure in sulphited juice pump is about 1


kg/cm2 at inlet and at outlet 3.2 kg/cm2.

Some of the observations are given below,

Sr. Temperature 𝐦̇
No. (°C) (kg/s)
1 65.1 62.1355
2 65.3 61.2885
3 65.4 61.3
4 65.7 64.46

Table 4.3 Observation data of Sulphited juice pump

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iv. Clear Juice Pump

The pressure head is 40 m. Average pressure in clear juice pump is about 0.5
kg/cm2 at inlet and at outlet 0.7 kg/cm2.

Some of the observations are given below,

Sr. Temperature 𝐦̇
No. (°C) (kg/s)
1 65.1 21
2 65.1 19.04
3 65.1 23.8
4 65.1 18.76

Table 4.4 Observation data of clear juice pump

4.4 Sample Calculation


For boiler,
I. At inlet,
𝑇𝑖𝑛 = 104𝑜 𝐶 = 377.15𝐾 ṁ𝑎𝑖 = 74 𝑇𝑃𝐻 = 20.572 𝑘𝑔⁄𝑠
ℎ𝑖𝑛 = 436.04 𝑠𝑖𝑛 = 1.352
The specific exergy
e = (436.04 − 104.89) – [298.15 (1.352 − 0.3674)] = 37.592
The total exergy rate
Ė𝑖𝑛 = 20.572 ∗ 37.592 = 423.207 𝑘𝐽⁄𝑠
Ė𝑖𝑛 = 0.423 𝑀𝑊

At outlet,
𝑇𝑜𝑢𝑡 = 500𝑜 𝐶 = 778.15𝐾 ṁ𝑎𝑜 = 767 𝑇𝑃𝐻 = 18.628 𝑘𝑔⁄𝑠
ℎ𝑜𝑢𝑡 = 3440.01 𝑠𝑜𝑢𝑡 = 2.312
The specific exergy
e = (3440.01 − 104.89) – [298.15 (2.312 − 0.3674)] = 2755.338
The total exergy rate
Ė𝑜𝑢𝑡 = 18.628 ∗ 2755.338 = 51326.436 𝑘𝐽⁄𝑠
Ė𝑜𝑢𝑡 = 51.326 𝑀𝑊
Exergy destruction rate
İ𝑏 = 103.5517 + 0.423 − 51.326
İ𝑏 = 52.64 𝑀𝑊

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Efficiency:
Ė𝑜𝑢𝑡 − Ė𝑖𝑛
Ƞ𝑒𝑥𝐵 =
Ė𝑓
49725.94−700.2914
= 103.5517
= 0.47344

For pump,
II. Feed water pump,
At inlet,
𝑇𝑖𝑛 = 65.1𝑜 𝐶 = 338.25𝐾 ṁ𝑎𝑖 = 75 𝑇𝑃𝐻 = 21 𝑘𝑔⁄𝑠
ℎ𝑖𝑛 = 272.42 𝑠𝑖𝑛 = 0.895
The specific exergy
e = (272.42 − 104.89) – [298.15 (0.895 − 0.3674)] = 10.0968
The total exergy rate
Ė𝑖𝑛 = 212.0328 𝑘𝐽⁄𝑠
Ė𝑖𝑛 = 0.212 𝑀𝑊

At outlet,
𝑇𝑜𝑢𝑡 = 59.6𝑜 𝐶 = 332.75𝐾 ṁ𝑎𝑜 = 75 𝑇𝑃𝐻
ℎ𝑜𝑢𝑡 = 249.42 𝑠𝑜𝑢𝑡 = 0.8260
The specific exergy
e = (249.42 − 104.89) – [298.15 (0.8260− 0.3674)] = 7.66915
The total exergy rate
Ė𝑜𝑢𝑡 = 21 ∗ 7.669 = 161.05215 𝑘𝐽⁄𝑠
Ė𝑜𝑢𝑡 = 0.161 𝑀𝑊
Work done,
𝑊𝑓𝑝 = 93.772 𝑘𝐽/𝑠
Exergy destruction rate
İ𝑓𝑝 = 212.033 − 161.052 + 93.772
İ𝑓𝑝 = 144.753 kJ/s
= 0.145 𝑀𝑊

III. Sulphited juice pump


 Ė𝑖𝑛 = 631.918 𝑘𝐽⁄𝑠
Ė𝑖𝑛 = 0.632 𝑀𝑊
 Ė𝑜𝑢𝑡 = 705.2379 𝑘𝐽⁄𝑠

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Ė𝑜𝑢𝑡 = 0.705 𝑀𝑊
 𝑊𝑠𝑝 = 53.919 𝑘𝐽/𝑠
 İ𝑠𝑝 = 127.239 kJ/s = 0.127 𝑀𝑊

IV. Clear juice pump


 Ė𝑖𝑛 = 1017.60 𝑘𝐽⁄𝑠
Ė𝑖𝑛 = 1.018 𝑀𝑊
 Ė𝑜𝑢𝑡 = 779.229 𝑘𝐽⁄𝑠
Ė𝑜𝑢𝑡 = 0.779 𝑀𝑊
 𝑊𝑐𝑝 = 37.932 𝑘𝐽/𝑠
 İ𝑐𝑝 = 276.303 kJ/s = 0.276 𝑀𝑊

4.5 Software validation

MATLAB software is used for validation or comparison of derived data. The total exergy
rate is computed with MATLAB values of specific enthalpy, specific entropy, and specific
entropy. The graph in fig. 4.1 depicts a comparison of total exergy rate values generated with
MATLAB and utilizing the exergy analysis process. The graph shows that there is no
significant difference between actual and theoretical values (calculated using MATLAB);
these two values are remarkably similar to each other.

Comparison of theoretical and actual exergy flow


60
Exergy Flow Rate(MW)

50

40

30

20 E(Theory)

10 E(Actual)

0
500

500
499.625

499.583

497.833
495.75
498.688
499.438
504.917
501.667
499.375
500.54

488.125
501.416
499.042
500.125
497.375
500.2916
498.71

499.041
499.08
497.79
480.166
478.916
498.2916
497.833
497.0833

500.125

Temperature(°C)

Figure 4.1 Comparison of theoretical and actual exergy flow

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CHAPTER 5

RESULT AND DISCUSSION


5.1 Result
5.1.1 Total exergy flow of boiler:

The total exergy flow rate in boiler is depicted in the following graph. The total
exergy rate is shown in MW on the ordinate. The graph contrasts how much exergy is
provided by the fuel and how much of this exergy is used by the boiler to produce steam out
of the water. Only a portion of the exergy produced by burning fuel is used by a boiler.
Significant quantities of exergy are destroyed in boilers, as shown by the significant
distinction between these two things. This is primarily because of the irreversibility a boiler
produces. The primary cause of irreversibility is a chemical process that takes place during
fuel burning. This is known as uncontrolled combustion.

Total Exergy Flow in Boiler (MW)


Fuel 103.5517
Boiler 49.725

Table 5.1 Total Exergy flow in Boiler

Total Exergy Flow in Boiler


120.7115
Total Exergy (MW)

100.7115

80.7115

60.7115

40.7115

20.7115

0.7115
Fuel 1

Figure 5.1 Total Exergy Flow in Boiler

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5.1.2 Total exergy flow of pump

The irreversibility that occur throughout the pumping process, such as frictional
losses, mechanical losses, and thermodynamic losses, are mostly accountable for the exergy
destroyed in a pump.
The following graphs represent the flow of exergy from pump inlet to pump outlet.

5.1.2.1 Feed Water Pump:

Total Exergy Flow in Feed water pump (MW)


Inlet 0.228
Outlet 0.1654

Table 5.2 Total Exergy flow in Feed Water Pump

Total Exergy Flow in Feed Water Pump


0.25
Total Exergy (MW)

0.2

0.15

0.1

0.05
0
Inlet Outlet

Figure 5.2 Total Exergy Flow in Feed Water Pump

5.1.2.2 Sulphited Juice Pump:

Total Exergy Flow in Sulphited Juice pump (MW)


Inlet 0.7123
Outlet 0.7118

Table 5.3 Total Exergy flow in Sulphited Juice Pump

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Total Exergy Flow in Sulphited Juice Pump


0.7124
Total Exergy (MW) 0.7123
0.7122
0.7121
0.712
0.7119
0.7118
0.7117
0.7116
0.7115
Inlet Outlet

Figure 5.3 Total Exergy Flow in Sulphited Juice Pump

5.1.2.3 Clear Juice Pump:

Total Exergy Flow in Clear Juice pump (MW)


Inlet 1.113
Outlet 1.094

Table 5.4 Total Exergy flow in Clear Juice Pump

Total Exergy Flow in Clear Juice Pump


1.115
Total Exergy (MW)

1.11
1.105
1.1
1.095
1.09
1.085
1.08
Inlet Outlet

Figure 5.4 Total Exergy flow in Clear Juice Pump

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5.1.3 Exergy Destruction Rate of Energy-consuming devices:


The following graph depicts the rate of exergy destruction of energy-consuming
devices. The X-axis displays some of the components of a sugar factory, including the boiler,
and pumps. The graph shows that the boiler consumes a significant amount of exergy. In
comparison to the boiler, the exergy destruction rate of the pumps is low. The destruction of
exergy is mostly caused by irreversibilities in the process.

Exergy Destruction Rate


Sr. No. Components Exergy Destruction Rate (MW)
1 Boiler 54.524
2 Feed Water Pump 0.1565
Sulphited Juice Pump 0.054
Clear Juice Pump 0.0596
Pumps = 0.2701

Table 5.5 Exergy Destruction Rate of Energy-consuming devices

Exergy Destruction Rate


60 54.524
Total Exergy Flow (MW)

50

40

30

20

10
0.2701
0
Boiler Pumps

Figure 5.5 Exergy Destruction Rate of Energy-consuming devices

CHAPTER 6

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CONCLUSION AND SUGGESTIONS

6.1 Conclusion:

In this study, an exergy analysis of energy-consuming devices in sugar industry has


been presented. In terms of exergy destruction, the major loss was found in the boiler
system.Theexergyanalysisrevealedthatthelostexergyinthepumpisthermodynamicallyin
significant. The exergy destruction rate in boilers is about 54.524 MW. As for the
pumps 0.2701 MW of exergy was destroyed. Where, the exergy destruction rate for
the feed water pump, sulphited juice pump, and clear juice pump is 0.1565 MW,
0.054 MW, and 0.0596 MW, respectively.

6.2 Suggestions to reduce exergy destruction rate:

i. As concluded, boiler is a major source of exergy destruction. The most


popular method for decreasing their reversibility of the boiler is to reheat
steam. Reheating often involves using the boiler's combustion by-product.
Combustible gas warms the steam after performing its primary heating
function and before venting into the atmosphere.

ii. In a combustion chamber, the major source of exergy destruction is chemical


reactions. Exergy destruction in the combustion chamber is primarily
influenced by the excess air proportions and the inlet air temperature. By
providing the needed air-fuel ratio, the thermodynamic inefficiencies of
combustion can be decreased. To reduce unwanted exergy destruction, it is
recommended that the combustion chamber be analyzed for varied air and
bagasse mass fractions.

iii. An efficient technique to conserve exergy in a boiler is the method of heat


recovery from flue gas.

iv. Reduction of moisture content of bagasse can reduce exergy destruction


occurred due to chemical reactions. Moisture content of the bagasse can be
reduced from 50 % to30-40%. The use of dryers helps to lower the moisture
content before burning it. The waste heat from the boiler flue gases can also be
used by this bagasse drying system to meet its partial heat needs.

v. The transport of heat across a limited temperature difference is one of the

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crucial variables in plants for the destruction of exergy. Losses increase as


heat is carried far from a boiler, and the opposite is also true. Therefore,
transferring heat over a short distance is effective. For minimum heat loss, the
optimal distance for energy transfer optimal distance should be found.

vi. Minimize friction losses in the pump system by carefully selecting pipe
materials, using smooth and corrosion-resistant surfaces, and employing
proper pipe sizing to avoid excessive pressure drop. Additionally, ensure that
the system is free from leaks and unnecessary fittings.

vii. Improving pump design can aid in reducing internal losses and increasing
overall efficiency. Consider the shape, size, and material of the impeller, as
well as optimize the volute or casing design. Simulations of Computational
Fluid Dynamics (CFD) can help in evaluating various design possibilities.

6.3 Discussion:
The selected energy consuming devices was analyzed using the above relations noting
that the environment reference temperature and pressure are 298.15 K and 1013 kPa,
respectively. Exergy-based efficiencies and losses provide measurements of proximity to or
deviation from ideality. Specific exergy and total exergy rate are summarized in appendix A
for boiler, feed water pump, sulphited juice pump, and clear juice pump. It was found that the
exergy destruction rate of the boiler dominant compared other components' irreversibilities.
According to the second law analyze the values demonstrates that significant improvements
exist in the boiler system rather than in the pump. However, due to physical, technological,
and economic constraints, some of this irreversibility cannot be prevented.
To quantify a system's exergy, we must characterize both the system and its surroundings.
It is assumed that no process alters the intense features of the environment appreciably. A
system's dead state is one in which it is in balance with its surroundings. When a system is at
the same temperature, pressure, elevation, velocity, and chemical composition as its
surroundings, there are no potential differences that would allow usable work to be extracted.
The reference environment state is irrelevant for calculating a change in a thermodynamic
property (first law analysis) However, it is expected that the dead state will have some effects
on the results of exergy (second law) analysis Although, some researchers assumed that small
and reasonable changes in dead-state properties have little effect on the performance of a
given system.
For evaluating a change in a thermodynamic characteristic (first law analysis), the
reference environment state is unimportant. However, the dead condition is predicted to have

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

some impact on the outcomes of the exergy (second law) analysis. However, other
researchers assumed that tiny and reasonable changes in dead-state features have little effect
on system performance.

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14. Velasquez, H., Gudelo, A., & Chejne, F. "Energy use in the production of unrefined sugar
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APPENDIX

Result table 1:
This result table represents the values of specific exergy, total exergy flow, enthalpy, entropy,
at specific temperature and pressure for boiler. These values are calculated by following
exergy analysis procedure.
Sr. Temperature Pressure 𝐦̇ h s e 𝑬̇
No. (°C) (bar) (kg/s) (kJ/kg) (kJ/kg°C) (kJ/kg) (MW)
1 104 47 20.572 436.04 1.352 37.592 0.423
2 500 45 18.628 3440.01 2.312 2755.338 51.326
3 102.35 47 20.209 429.111 1.334 36.028 0.728
4 495.75 45 18.637 3430.19 2.313 2745.219 51.163
5 103.375 47 18.626 433.415 1.345 37.059 0.69
6 498.688 45 20.294 3435.99 2.3158 275.125 55.811
7 103.625 47 20.213 432.465 1.348 37.214 0.752
8 499.438 45 18.684 3437.72 2.316 2751.855 51.416
9 103.938 47 19.726 435.78 1.3514 37.332 0.736
10 504.917 45 18.418 3450.41 2.3138 2765.141 50.928
11 102.667 47 19.495 430.422 1.337 36.464 0.7109
12 501.667 45 17.978 3442.88 2.3148 2757.313 49.571
13 103 47 19.32 431.84 1.34 36.84 0.711
14 499.375 45 18.08 3438.57 2.3168 2752.337 49.762
15 103.41 47 19.519 433.545 1.3455 36.905 0.72
16 500.54 45 18.048 3441.26 2.311 2429.72 43.852
17 103.29 47 19.565 433.048 1.344 36.84 0.72127
18 499.625 45 18.08 3439.15 2.3116 2754.46 49.8
19 102.95 47 19.46 431.63 1.34 36.69 0.71398
20 488.125 45 18.25 341.54 2.3157 2726.623 49.76
21 102.65 47 19.5066 430.7 1.3369 36.624 0.7144
22 501.416 45 18.025 3443.29 2.31106 3338.39 49.7268
23 101.9583 47 19.3783 427.378 1.329 35.5929 0.6897
24 499.042 45 17.325 3437.8 2.31178 2574.1738 44.5975
25 101.5 47 19.506 425.423 1.3239 35.2232 0.687
26 500.125 45 18.1533 3440.3 2.31145 2755.62 50.504
27 103 47 19.565 431.512 1.361 30.2509 0.5918
28 497.375 45 18.165 3433.95 2.312 2749.148 49.938
29 103.375 47 19.616 433.4149 1.3408 38.1645 0.7484
30 500.2916 45 18.305 3440.69 2.3113 2756.067 54.05
31 102.66 47 19.79 430.412 1.3372 36.25487 0.7174
32 498.71 45 18.22 3437.22 2.3118 2752.459 50.1498
33 103.375 47 19.5 434.94 1.3493 37.1672 0.7247
34 500 45 18.14 3440.01 2.3114 2755.36 49.982
35 103.08 47 19.67 432.1 1.341 36.8019 0.72389
36 499.583 45 18.13 3439.05 2.31161 2754.364 49.936

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37 103.666 47 19.3325 434.6397 1.9783 3729 0.72


38 499.041 45 17.3168 3436.8 2.3156 2751.1126 47.64
39 103.16 47 19.52 432.512 298.15 36.866 0.71962
40 499.08 45 18.11 3436.86 2.3156 2751.144 49.823
41 103.2 47 19.561 432.68 1.343 36.915 0.722
42 497.79 45 18.1973 3434.91 2.312 2750.238 50.047
43 103.75 47 21.069 434.99 1.349 37.436 0.788
44 480.166 45 18.116 3394.1 2.19 2707.34 49.046
45 103.45 47 19.599 433.73 1.346 37.07 0.727
46 478.916 45 18.209 3391.2 2.319 2704.44 49.245
47 104.04 47 19.564 436.21 1.353 37.463 0.733
48 498.2916 45 18.255 3436.06 2.312 2751.43 50.227
49 101.125 47 19.492 423.79 1.319 35.18046 0.6858
50 497.833 45 18.185 3435 2.312 2750.32 50.0147
51 101.66 47 19.5758 426.12 1.326 35.4234 0.6934
52 497.0833 45 17.34 3433.27 2.313 2750.5975 47.695
53 101.0833 47 18.255 423.611 1.319 35.001 0.6389
54 497.833 45 16.6568 3435 2.312 2750.3275 45.8116
55 101.5 47 19.506 425.423 1.3239 35.2232 0.687
56 500.125 45 18.1533 3440.3 2.31145 2755.62 50.504

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Result table 2:
This result table represents the values of specific exergy, total exergy flow, enthalpy, entropy,
at specific temperature and pressure for boiler. These values are calculated by MATLAB
program.
Sr. Temperature Pressure 𝐦̇ h s e 𝑬̇
No (°C) (bar) (kg/s) (kJ/kg) (kJ/kg°C) (kJ/kg) (MW)
1 500 45 18.628 3440.01 2.312 2755.34 51.33
2 495.75 45 18.637 3430.19 2.313 2745.22 51.16
3 498.688 45 20.294 3435.99 2.3158 2750.18 51.38
4 499.438 45 18.684 3437.72 2.316 2751.85 51.42
5 504.917 45 18.418 3450.41 2.3138 2765.2 50.93
6 501.667 45 17.978 3442.88 2.3148 2757.37 49.57
7 499.375 45 18.08 3438.57 2.3168 2752.47 49.76
8 500.54 45 18.048 3441.26 2.311 2756.93 49.76
9 499.625 45 18.08 3439.15 2.3116 2754.48 49.8
10 488.125 45 18.25 3441.54 2.3157 2755.76 50.29
11 501.416 45 18.025 3443.29 2.31106 2759.03 49.73
12 499.042 45 17.325 3437.8 2.31178 2753.19 47.7
13 500.125 45 18.1533 3440.3 2.31145 2755.79 50.03
14 497.375 45 18.165 3433.95 2.312 2749.28 49.94
15 500.2916 45 18.305 3440.69 2.3113 2756.23 50.45
16 498.71 45 18.22 3437.22 2.3118 2752.61 50.15
17 500 45 18.14 3440.01 2.3114 2755.52 49.99
18 499.583 45 18.13 3439.05 2.31161 2754.49 49.94
19 499.041 45 17.3168 3436.8 2.3156 2751.05 47.64
20 499.08 45 18.11 3436.86 2.3156 2751.11 49.82
21 497.79 45 18.1973 3434.91 2.312 2750.24 50.05
22 480.166 45 18.116 3394.1 2.19 2745.8 49.74
23 478.916 45 18.209 3391.2 2.319 2704.44 49.25
24 498.2916 45 18.255 3436.06 2.312 2751.39 50.23
25 497.833 45 18.185 3435 2.312 2750.33 50.01
26 497.0833 45 17.34 3433.27 2.313 2748.3 47.66
27 497.833 45 16.6568 3435 2.312 2750.33 45.81
28 500.125 45 18.1533 3440.3 2.31145 2755.79 50.03

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Result table 3:
This result table represents the values of specific exergy, total exergy flow, enthalpy, entropy,
at specific temperature for clear juice pump. These values are calculated by following exergy
analysis procedure.
Sr. Temperature 𝐦̇ h s e 𝑬̇
No. (°C) (kg/s) (kJ/kg) (kJ/kg°C) (kJ/kg) (MW)
1 79.9 50.93 334.48 1.07 19.9805 1.0176
2 81.8 57.44 342.4 1.0966 19.96 1.1465
3 79.53 58.81 332.92 1.0693 18.62 1.09504
4 81.83 58.7 342.586 1.0969 20.067 1.177932
5 78.69 59.32 329.394 1.0592 18.11 1.07428
6 77.2 59.55 323.14 1.0413 17.19 1.023665
7 79.32 60.82 332.004 1.0668 18.45 1.12213
8 81.15 60.76 339.73 1.088 20.28 1.232213
9 77.5 61.52 330.741 1.045 17.35 1.067372
10 81.7 61.67 342.04 1.095 20.08 1.238333
11 80.85 61.94 338.469 1.0851 19.467 1.205785
12 78.2 60.74 327.34 1.0534 17.789 1.0805
13 80.9 60.149 338.68 1.0858 19.468 1.170807
14 77.39 59.95 323.938 1.0436 17.38 1.041931
15 78.28 50.33 327.676 1.0548 20.33 1.023089
16 80.54 57.44 337.168 1.0814 19.26 1.10694
17 77.13 58.5 322.84 1.04 17.28 1.01088
18 78.26 57.02 327.5 1.054 17.77 1.013454
19 80.73 59.29 337.93 1.088 18.06 1.07774
20 81.18 59.65 339.86 1.089 19.697 1.17492
21 80.9 59.81 338.68 1.0858 19.469 1.1644
22 77.08 62.93 322.63 1.039 17.3732 1.09295
23 78.89 62.28 330.23 1.06 18.712 1.16538
24 80.62 58.62 337.504 1.082 19.426 1.13879
25 77.99 60.15 326.457 1.05 17.92 1.07788
26 78.7 61.85 329.42 1.059 18.2 1.12567
27 80.68 61.06 337.75 1.083 19.354 1.18155
28 77.2 63.03 323.14 1.04 17.58 1.10867
29 78.28 59.55 327.67 1.054 17.94 1.06827
30 81.83 57.44 342.58 1.096 20.32 1.16718
31 80.7 50.93 310.54 1.0054 15.3 0.77929
32 76.35 57.44 342.29 1.09612 20 1.1488
33 74.18 58.81 310.457 1.00516 15.28 0.896168
34 82.41 58.7 345.02 1.1039 20.41 1.19867
35 75.26 59.32 314.99 1.1018 15.99 0.948268
36 81.38 59.55 340.68 1.09156 19.75 1.17125
37 75.88 60.82 317.59 1.0225 16.35 0.99407
38 80.15 60.76 335.53 1.0767 19.03 1.156628

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39 79.01 61.52 330.741 1.0631 18.29 1.12008


40 76.34 61.67 319.52 1.031 16.648 1.02682
41 79.83 61.94 334.86 1.0729 18.82 1.16508
42 76.67 60.74 320.914 1.035 16.84 1.022616
43 81.2 60.149 339.94 1.083 19.77 1.189457
44 77.66 59.95 325.07 1.046 17.726 1.066737
45 80.77 50.33 338.134 1.084 19.46 0.979422
46 77.36 57.44 323.812 1.043 17.36 0.99784
47 75.11 58.5 314.33 1.016 17.28 1.0188
48 78.5 57.02 328.6 1.057 17.97 1.02464
49 74.11 59.29 310.16 1 16.53 0.980637
50 78.15 59.65 327.13 1.05 18.593 1.109245
51 79.56 59.81 333.05 1.0667 18.639 1.1149
52 77.58 62.93 324.736 1.045 17.69 1.1135
53 79.87 62.28 334.35 1.073 18.956 1.18065
54 80.7 58.62 337.84 1.083 19.9696 1.14114
55 80.7 60.15 337.84 1.0834 19.345 1.16317
56 76.35 61.85 319.57 1.0312 16.638 1.0293
57 80.01 61.06 339.949 1.075 18.75 1.15787
58 74.25 63.03 310.75 1.006 15.33 1.6987
59 81.87 59.55 342.75 1.097 20.2 1.20291
60 75.52 57.44 316.08 1.02 16.48 0.94661

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EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

Result table 4:
This result table represents the values of specific exergy, total exergy flow, enthalpy, entropy,
at specific temperature for sulphited juice pump. These values are calculated by following
exergy analysis procedure.

Sr. Temperature 𝐦̇ h s e 𝑬̇
No. (°C) (kg/s) (kJ/kg) (kJ/kg°C) (KJ/kg) (MW)
1 65.1 62.1355 272.419 0.8947 10.17 0.631918
2 65.3 61.2885 273.2 0.897 10.2 0.625143
3 65.4 61.3 273.68 0.8985 10.31 0.632
4 65.7 64.46 274.93 0.9022 10.46 0.674251
5 69.1 64.603 289.22 0.9437 12.37 0.799578
6 69.04 64.043 288.96 0.943 12.333 0.78988
7 66.72 64.544 283.42 0.9264 11.667 0.753035
8 67.32 64.051 281.74 0.9218 11.418 0.731334
9 66.32 61.209 277.54 0.9098 10.8 0.661057
10 68.24 63.88 285.6 0.933 12.18 0.778584
11 66.4 49.449 277.88 0.9108 10.84 0.536027
12 69.4 60.16 290.52 0.9476 12.51 0.7526
13 68.8 61.32 287.96 0.94 9.22 0.565456
14 66.19 60.49 276.99 0.9082 10.739 0.649602
15 69.65 61.743 299.5311 0.95 12.8 0.790314
16 67.2 60.82 281.14 0.92 10.8 0.657072
17 66.76 65.84 287.79 0.9394 12.22 0.804565
18 65.07 63.8 272.29 0.849 15.06 0.960828
19 67.52 62.983 282.58 0.924 11.61 0.731233
20 65.52 60.358 274.09 0.9 10.27 0.619877
21 69.82 64.475 292.24 0.9527 12.71 0.81948
22 70.28 65.7 294.16 0.95836 12.94 0.850158
23 65.64 62.28 274.68 0.901 10.57 0.6583
24 66.23 62.57 287.79 0.908 10.96 0.68576
25 67.32 55.87 281.71 0.9218 11.3 0.631331
26 69.68 50.19 291.65 0.951 12.63 0.63389
27 67.82 63.518 283.84 0.9278 11.73 0.745066
28 68.88 65.127 288.29 0.941 12.25 0.797805
29 69.35 61.739 290.14 0.9464 12.495 0.771429
30 65.1 62.135 272.41 0.894 10.17 0.631918
31 68.43 62.1355 286.406 0.9377 11.35 0.705238
32 67.74 61.2885 283.58 0.9268 11.67 0.715237
33 68.84 61.3 288.12 0.9405 12.32 0.755261
34 69.49 64.46 290.15 0.9486 12.59 0.808838
35 70.31 64.603 294.28 0.9587 12.97 0.838
36 69.83 64.043 292.28 0.9528 12.72 0.815248

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37 70.51 64.544 295.11 0.9611 13.05 0.843539


38 69.5 64.051 281.74 0.9487 12.55 0.80384
39 67.59 61.209 282.87 0.92502 11.61 0.710636
40 67.82 63.88 283.84 0.9278 11.73 0.749312
41 62.9 49.449 263.23 0.8676 9.2 0.454931
42 66.74 60.16 279.308 0.9148 11.08 0.666572
43 67.99 61.32 284.55 0.9298 11.85 0.726572
44 65.31 60.49 273.3 0.89 12.46 0.75424
45 66.62 61.743 278.84 0.9134 11.11 0.685968
46 65.98 60.82 276.11 0.905 11.46 0.697226
47 66.64 65.84 278.88 0.9136 11.01 0.724898
48 68.78 63.8 287.8 0.9397 12.14 0.774532
49 66.96 62.983 280.23 0.917 11.36 0.715487
50 65.86 60.358 275.612 0.907 10.6 0.639798
51 69.43 64.475 290.6 0.9478 12.54 0.808537
52 67.6 65.7 286.28 0.93 13.52 0.888264
53 70.28 62.28 284.97 9311 11.89 0.740509
54 68.09 62.57 287.79 0.9311 6.355 0.397633
55 68.76 55.87 268.97 0.8845 9.78 0.54648
56 64.28 50.19 267.36 0.8997 9.62 0.482828
57 63.89 63.518 290.22 0.9407 14.27 0.906402
58 69.34 65.127 294.66 0.9598 13.01 0.847302
59 70.4 61.739 286.95 0.937 12.1 0.447491
60 68.56 62.135 286.406 0.9377 11.35 0.705238

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Result table 5:
This result table represents the values of specific exergy, total exergy flow, enthalpy, entropy,
at specific temperature for feed water pump. These values are calculated by following exergy
analysis procedure.
Sr. Temperature 𝐦̇ h s e 𝑬̇
No. (°C) (kg/s) (kJ/kg) (kJ/kg°C) (kJ/kg) (MW)
1 65.1 21 272.42 0.895 10.0968 0.212328
2 65.1 19.04 272.42 0.895 10.0968 0.192243
3 65.1 23.8 272.42 0.895 10.0968 0.243038
4 65.1 18.76 272.42 0.895 10.0968 0.189415
5 65.1 23.52 272.42 0.895 10.0968 0.553902
6 65.1 19.18 272.42 0.895 10.0968 0.193566
7 65.1 22.4 272.42 0.895 10.0968 0.226683
8 65.1 19.32 272.42 0.895 10.0968 0.1957017
9 65.1 22.68 272.42 0.895 10.0968 0.228422
10 65.1 19.88 272.42 0.895 10.0968 0.20072438
11 65.1 22.96 272.42 0.895 10.0968 0.231225
12 65.1 20.44 272.42 0.895 10.0968 0.206378
13 65.1 23.24 272.42 0.895 10.0968 0.234494
14 65.1 23.8 272.42 0.895 10.0968 0.2400384
15 65.1 21.56 272.42 0.895 10.0968 0.217687
16 65.1 22.12 272.42 0.895 10.0968 0.22334
17 65.1 22.12 272.42 0.895 10.0968 0.22341216
18 65.1 23.66 272.42 0.895 10.0968 0.2390288
19 65.1 23.1 272.42 0.895 10.0968 0.2333608
20 65.1 19.544 272.42 0.895 10.0968 0.1973185
21 65.1 20.02 272.42 0.895 10.0968 0.202936
22 65.1 20.72 272.42 0.895 10.0968 0.2092
23 65.1 20.24 272.42 0.895 10.0968 0.20492
24 65.1 22.82 272.42 0.895 10.0968 0.234089
25 65.1 20.328 272.42 0.895 10.0968 0.2024775
26 65.1 22.4 272.42 0.895 10.0968 0.226832
27 65.1 18.76 272.42 0.895 10.0968 0.189159
28 65.1 23.8 272.42 0.895 10.0968 0.2403033
29 65.1 22.96 272.42 0.895 10.0968 0.231225
30 65.1 22.4 272.42 0.895 10.0968 0.22668
31 59.6 21 272.42 0.826 7.66915 0.1615215
32 56.6 19.04 238.24 0.7885 7.669775 0.146325
33 62.6 23.8 261.99 0.8635 9.058525 0.215529
34 55.7 18.76 233.14 0.7771 5.968685 0.1119725
35 62 23.52 259.95 0.856 8.80465 0.2070853
36 57 19.18 238.55 0.7985 4.9983 0.09566
37 61 22.4 255.33 0.84349 8.3345065 0.1866929
38 57.5 19.32 243.99 0.7997 10.0894 0.194929

GOVERNMENT COLLEGE OF ENGINEERING, KARAD. Page 38


EXERGY ANALYSIS OF ENERGY-CONSUMING DEVICES AT SUGAR INDUSTRY

39 61.3 22.68 256.56 0.84725 8.47346 0.192178


40 59 19.88 246.89 0.8185 7.384275 0.146799
41 61.9 22.96 259.08 0.854749 8.75 0.2009
42 59.5 20.44 249 0.82475 7.621 0.15577
43 62 23.24 261.99 0.8635 9.05588 0.210263
44 62.6 23.8 256.99 0.8485 8.52 0.202776
45 60 21.56 251.1 0.831 7.48584 0.169427104
46 59.5 22.12 249 0.82475 7.62 0.1685544
47 60.1 22.12 251.52 0.832249 7.98 0.1765176
48 62.8 23.66 262.82 0.86599 9.1461 0.2163967
49 61 23.1 255.3 0.84349 10.0968 0.092526
50 58 19.54 242.7 0.806 6.91 0.13504904
51 59.2 20.02 247.74 0.821 7.4799 0.15109398
52 60 20.72 251.1 0.831 7.8584 0.16282604
53 59.8 20.24 250.26 0.8284 7.764 0.15714336
54 61.6 22.82 257.82 0.851 8.6154 0.196603
55 60 20.32 251.1 0.831 7.8584 0.197455
56 61 22.4 255.3 0.84349 8.3345 0.1866928
57 55.7 18.76 233.14 0.7771 5.9686 0.1119709
58 62.6 23.8 256.98 0.8484 8.52 0.202776
59 61.9 22.96 259.08 0.85749 8.75 0.2009
60 61 22.4 255.3 0.84349 8.3345 0.1866928

GOVERNMENT COLLEGE OF ENGINEERING, KARAD. Page 39


GOVERNMENT COLLEGE OF ENGINEERING, KARAD. Page 1

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