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Detailed 3E Exploration of a Sugar Industry Using Its Experimental Data

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Synergy Development in Renewables Assisted Multi-carrier Systems

Part of the book series: Green Energy and Technology ((GREEN))

Abstract

Sugar beet production is low in Iran, and about 50% of sugar demand is imported from other countries. Meanwhile, the factories are old in Iran, and novel technologies are not employed, and consequently, the sugar production unit cost is high. Sugar production is one of the most important industries. An increase in energy usage and cost of sugar production has forced the researchers to concentrate on cost analysis while considering the thermodynamics analysis of sugar production systems. In the present study, using experimental data of Urmia Sugar Factory in northwestern Iran, first, the energetic and exergetic analyses are done on different parts of the plant. Then, the most inefficient parts of the system under study are identified, and a thermo-economic analysis is performed for that unit. The results show that cogeneration, purification, and crystallization units have the highest exergy destruction, respectively. Also, the cogeneration unit with 20.17%, the purification unit with 89.25%, and the condensation unit with 91.31% have the lowest second law efficiency, respectively. The total exergy efficiency of the plant is found to be 56.44%. In the cogeneration unit, the 5th and 3rd economizers have the lowest exergy efficiency, and the 2nd and 3rd combustion chambers have the highest exergy destruction. Also, the 2nd HRSG and 4th combustion chamber have the highest values of the summation of investment cost and exergy destruction, and exergy loss costs.

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Abbreviations

A/F :

Mass-based air-fuel ratio

APTD :

Approach point temperature difference,\((^\circ{\rm C} )\)

\(\dot{C}\) :

Cost rate, ($/h)

C :

Unit cost, ($/GJ)

CRF :

Capital recovery factor

Ex :

Specific exergy, (kJ/kg)

\(\dot{E}\) :

Exergy rate, (kW)

F :

Exergo-economic factor

\(\varphi \) :

Equivalence ratio

H :

Specific enthalpy, (kJ/kg)

HFO :

Heavy Fuel Oil

\(\dot{I}\) :

Irreversibility rate, (kW)

K :

Interest rate, (%)

LHV :

Lower heating value, (kJ/kg)

LMTD :

Logarithmic mean temperature difference,\((^\circ{\rm C} )\)

\(\dot{m}\) :

Mass flow rate, (kg/s)

MW :

Molecular weight, (kg/kmol)

N :

Number of moles

\(\dot{n}\) :

Molar flow rate, (kmol/s)

\({n}_{r}\) :

System lifetime, (Year)

P :

Pressure, (kPa)

PEC :

Purchased equipment cost, ($)

PPTD :

Pinch point temperature difference, \((^\circ{\rm C} )\)

Q :

Quality of juice, (%)

\(\dot{Q}\) :

Heat transfer rate, (kW)

R :

The relative cost difference, (%)

S :

Specific entropy, (kJ/kg.K)

St :

Steam

Sup :

Superheater

T :

Temperature, \((^\circ{\rm C} )\)

\({\tau}\) :

Annual operating hours, (h)

treat :

Treatment unit

\(\dot{W}\) :

Power, (kW)

X :

Mass fraction

Y :

Mole fraction

CC :

Combustion chamber

CI :

Capital investment

Cogen :

Cogeneration

Conc :

Concentration unit

cond :

Condensation unit

crys :

Crystallization unit

Dest :

Destruction

Desup :

Desuperheater

DS :

Dry Substance

eco :

Economizer

eva :

Evaporator

exp :

Expansion of steam

ext :

Extraction unit

F :

Fuel

f :

Formation

Fb :

Fiber

Fr :

Fructose

gen :

Generator

heat :

Heating unit

L :

Liquid

L :

Loss

mix :

Mixer

OM :

Operating and maintenance cost

R :

Reactants

r :

Reference

S :

Sucrose

sto :

Stoichiometric

Turb :

Turbine

w :

Water

W :

Work

water :

Water distribution unit

ƞ :

Efficiency, (%)

\(\varphi \) :

Operating and maintenance factor

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Acknowledgements

The authors acknowledge the support of the Urmia sugar factory for collecting experimental data from several units of the factory. Furthermore, the authors would like to express their specific thanks to “IPSB” for doing accurate measurements in 2016 at the factory. Also, the authors are grateful for the technical support of Mr. Ahmadi at the Naghadeh sugar factory.

Author information

Authors and Affiliations

  1. Faculty of Mechanical Engineering, Sahand University of Technology, Sahand New Town, Tabriz, Iran

    Hamed Ghiasirad & Rahim Khoshbakhti Saray

  2. Department of Mechanical Engineering, Faculty of Engineering, Khoy Branch, Islamic Azad University, Khoy, Iran

    Bahman Abdi

  3. Mechanical Engineering Department, Faculty of Engineering, Girne American University, Via Mersin 10, Girne, N. Cyprus, Turkey

    Keyvan Bahlouli

Authors
  1. Hamed Ghiasirad
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  2. Rahim Khoshbakhti Saray
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  3. Bahman Abdi
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  4. Keyvan Bahlouli
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Corresponding author

Correspondence to Rahim Khoshbakhti Saray .

Editor information

Editors and Affiliations

  1. Faculty of Mechanical Engineering, K. N. Toosi University of Technology, Tehran, Iran

    Majid Amidpour

  2. Faculty of Mechanical Engineering, K. N. Toosi University of Technology, Tehran, Iran

    Mohammad Ebadollahi

  3. Department of Power System Operation and Planning, Niroo Research Institute, Tehran, Iran

    Farkhondeh Jabari

  4. Energy and Environmental Research Center, Niroo Research Institute, Tehran, Iran

    Mohammad-Reza Kolahi

  5. Faculty of Engineering, University of Mohaghegh Ardabili, Ardabil, Iran

    Hadi Ghaebi

Appendix

Appendix

See Tables A.1, A.2 and A.3.

Table A.1 Considered relations for calculation of the PEC (purchase of equipment cost)
Full size table
Table A.2 Thermodynamics and thermo-economic results (* refers to input data)
Full size table
Table A.3 Mass percentages of different materials for composite flows (* refers to input data)
Full size table

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Ghiasirad, H., Saray, R.K., Abdi, B., Bahlouli, K. (2022). Detailed 3E Exploration of a Sugar Industry Using Its Experimental Data. In: Amidpour, M., Ebadollahi, M., Jabari, F., Kolahi, MR., Ghaebi, H. (eds) Synergy Development in Renewables Assisted Multi-carrier Systems. Green Energy and Technology. Springer, Cham. https://doi.org/10.1007/978-3-030-90720-4_15

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  • DOI: https://doi.org/10.1007/978-3-030-90720-4_15

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  • Online ISBN: 978-3-030-90720-4

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