Project Report
Project Report
Project Report
On
Submitted by
Prof. K. S. Gharge
E-mail: princek@gcek.ren.nic.in
CERTIFICATE
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.
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.
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
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
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.
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.
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.
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.
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 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.
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.
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
CHAPTER 2
LITERATURE REVIEW
2.1 Review of literature:
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
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.
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
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.
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:
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.
thoroughly examined.
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:
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
No. of pump 3
Make KSB
Type HAD-65/12
Capacity 45 m3/hr
Head 650 m
Motor Kiloskar make 225HP –
2900rpm
No. of pump 5
Type GK/00/40B
Head 50 m
Capacity 200 m3/hr
Motor 30 kW – 1460 rpm
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.
CHAPTER 4
EXERGY ANALYSIS CALCULATIONS
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
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
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.
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
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
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.
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
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
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
Ė𝑜𝑢𝑡 = 0.705 𝑀𝑊
𝑊𝑠𝑝 = 53.919 𝑘𝐽/𝑠
İ𝑠𝑝 = 127.239 kJ/s = 0.127 𝑀𝑊
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.
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)
CHAPTER 5
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.
100.7115
80.7115
60.7115
40.7115
20.7115
0.7115
Fuel 1
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.
0.2
0.15
0.1
0.05
0
Inlet Outlet
1.11
1.105
1.1
1.095
1.09
1.085
1.08
Inlet Outlet
50
40
30
20
10
0.2701
0
Boiler Pumps
CHAPTER 6
6.1 Conclusion:
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
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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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
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
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
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
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