From Potential To Cost

Lecture 4
from Potential … to Cost

Content
“Potential“ vs “Driving force”
“Driving force” vs “Speed”
“Driving force” vs “Efficiency”
“Speed” vs “Efficiency”
“Efficiency” vs “Cost”
“Potential” vs “Driving force”
There must be a
POTENTIAL DIFFERENCE
for something to happen
Potential is lost
when something has happened
The driving force is as

“necessary condition”
of a process
Who is going to be hurt ?

How fast a process happens

depends on
how big the driving force is
𝐷𝑖𝑓𝑓𝑢𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 = 2 𝑚𝑜𝑙Τ𝑠𝑒𝑐

Solvent
𝐶 = 4 𝑘𝑚𝑜𝑙 Τ𝑚3 𝐶 = 5 𝑘𝑚𝑜𝑙 Τ𝑚3
𝐷𝑖𝑓𝑓𝑢𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 = 4 𝑚𝑜𝑙Τ𝑠𝑒𝑐

Solvent
𝐶 = 1 𝑘𝑚𝑜𝑙Τ𝑚3 𝐶 = 3 𝑘𝑚𝑜𝑙Τ𝑚3
increase the driving force,

the process happens faster
∆𝐸𝑥 = 1000𝑘𝑊 ∆𝐸𝑥 = 1000𝑘𝑊
𝐸𝑥𝐿 = 200𝑘𝑊
𝜂 = 0.8
Potential
𝐸𝑥𝐿 = 500𝑘𝑊
∆𝐸𝑥 = 800𝑘𝑊
𝜂 = 0.5
∆𝐸𝑥 = 500𝑘𝑊
the bigger driving force,

the lower efficiency process
𝑅𝑖𝑛𝑡
Battery
𝑈
𝐼=
𝑃𝑤𝑎𝑠𝑡𝑒 = 𝐼2 𝑅𝑖𝑛𝑡 𝑅𝑒𝑥𝑡 + 𝑅𝑖𝑛𝑡
𝑅𝑒𝑥𝑡
𝑃𝑢𝑠𝑒𝑓𝑢𝑙 𝑅𝑒𝑥𝑡
𝜂= =
𝑃𝑢𝑠𝑒𝑓𝑢𝑙 = 𝐼2 𝑅𝑒𝑥𝑡 𝑃𝑢𝑠𝑒𝑓𝑢𝑙 + 𝑃𝑤𝑎𝑠𝑡𝑒 𝑅𝑒𝑥𝑡 + 𝑅𝑖𝑛𝑡
𝑅𝑖𝑛𝑡
Battery
𝑈
𝐼=
𝑅𝑒𝑥𝑡
𝐼 𝐼𝑚𝑎𝑥
𝑅𝑒𝑥𝑡 0 𝑃𝑢𝑠𝑒𝑓𝑢𝑙 0 ൝
𝜂 0
𝑃𝑢𝑠𝑒𝑓𝑢𝑙 = 𝐼2 𝑅𝑒𝑥𝑡
𝑅𝑖𝑛𝑡
Battery
𝑈
𝐼=
𝑅𝑒𝑥𝑡
𝐼 0
𝑅𝑒𝑥𝑡 ∞ 𝑃𝑢𝑠𝑒𝑓𝑢𝑙 0 ቊ
𝜂 1
𝑃𝑢𝑠𝑒𝑓𝑢𝑙 = 𝐼2 𝑅𝑒𝑥𝑡
𝑅𝑖𝑛𝑡
Battery
𝑈
𝐼=
𝑅𝑒𝑥𝑡
𝐼
𝑅𝑒𝑥𝑡 𝑅𝑖𝑛𝑡 𝑃𝑢𝑠𝑒𝑓𝑢𝑙 ቊ
2 𝜂 0.5
𝑃𝑢𝑠𝑒𝑓𝑢𝑙 = 𝐼 𝑅𝑒𝑥𝑡
𝑈2
4𝑅𝑖𝑛𝑡
𝑃𝑢𝑠𝑒𝑓𝑢𝑙
𝜂
0 0.5 1
All is waste Maximum useful power Totally resisted process
Maximum speed Acceptable speed Zero speed
“Efficiency”
controls
speed of change
High efficiency processes

operate with small driving forces
and move slowly
𝑇 = 1000𝐾
𝑄 = 1000𝑘𝑊
𝑄 = 500𝑘𝑊
𝑄 = 1000𝑘𝑊
𝑇 = 700𝐾
𝐴𝑟𝑒𝑎 = 𝐴 𝐴𝑟𝑒𝑎 = 2𝐴
𝑇 = 400𝐾
𝐴𝑟𝑒𝑎 = 𝐴
𝑊 = 4000𝑘𝑊
ቐ 𝜂 = 0.25
1 𝑐𝑜𝑠𝑡 = 1.25
1
𝑊 = 1250𝑘𝑊
ቐ 𝜂 = 0.8
3 𝑐𝑜𝑠𝑡 = 2.5
𝑊 = 2000𝑘𝑊
ቐ 𝜂 = 0.5
2 𝑐𝑜𝑠𝑡 = 1.0
Cost
1
Equilibrium process
No driving force
Zero speed
2
𝜂
0 0.5 1
in continuous processes, if
rates slow down as a result of
improved efficiency, we have
to buy bigger equipment
Cost
optimum design
𝜂
0.5 1
Why is Exergy ?
Exergy always reflects potential
Potential of Entropy of Exergy of
working medium working medium working medium
?
Entropy is not Exergy
worth money (work) is !
Why is Exergy ?
Exergy as well as
Entropy
Why is Exergy ?
‒ Exergy is ideal work

‒ There is always an exergy
loss in practical processes
Lecture 5
Process Improvement
Content
Avoidable and inevitable
Unit operations
Flowsheet
Methodology to Targets
‒ No exergy lost in ideal process

‒ The ideal process can never be
achieved, but it sets limitation on
the performance of all processes
The ideal targets is not

realistic, but we can only
hope to achieve the
BEST PRACTICAL
to use exergy losses as design

targets, we must know which
losses are inevitable
Cost
0
optimum region
1 Useful output
𝜂
“Avoidable” and “Inevitable”
No lost
No happen
Zero speed
Cost
Infinite cost
INEVITABLE
A little bit lost
For happen
LOSSES
Very slow speed
Very expensive cost
TARGET
More lost
For acceptable speed
High cost
Much more lost
For acceptable cost
0.5
𝜂
0 1
𝐸𝑥𝐿 = 𝐸𝑥𝐿𝑖𝑛𝑣 + 𝐸𝑥𝐿𝑎𝑣𝑑
𝐸𝑥𝐿𝑎𝑣𝑑 0
𝐸𝑥𝐿 𝐸𝑥𝐿𝑖𝑛𝑣
rough experience:
for 2–year payback projects
𝜂 ≈ 60%
Heat exchanger Improvement
ideal case
𝑇
 equal 𝑚𝑐𝑝
 zero speed
 no driving force 𝐸𝑥𝐿 = 0
 infinite area
𝐻
ideal case
𝑇
 acceptable speed
 a little bit driving force
 infinite area 𝐸𝑥𝐿 > 0
𝐻
real case
𝑇
 acceptable speed
 more driving force
 finite area 𝐸𝑥𝐿 > 0
 acceptable cost
𝐻
real case 𝑇, 𝑃
𝑇
∆𝑇𝑚𝑖𝑛
 ∆𝑇𝑚𝑖𝑛 bigger
 𝜂 lower, 𝐸𝑥𝐿 higher
 higher speed 𝐸𝑥𝐿 > 0
 smaller area
 lower capital cost 𝐻
 𝑇, 𝑃 higher
 higher operation cost “∆𝑇𝑚𝑖𝑛 is key variable”
example 𝑇, 𝑃
𝑇
Product
Feed 1 B reactor
Feed 2 A
𝐻
example 𝑇, 𝑃
𝑇
Feed 1 B reactor
Feed 2 A
𝐻
Product
Which one is better ?

Compressor Improvement
ideal case
𝑇
𝐸𝑥𝐿 = 0
𝑆
real case
𝑇
𝐸𝑥𝐿 > 0
𝑆
real case
𝑇
𝐸𝑥𝐿 > 0
𝑆
 lower capital cost
 but higher operation cost
Turbine Improvement
ideal case
𝑇
𝐸𝑥𝐿 = 0
𝑆
Turbine Improvement
real case
𝑇
𝐸𝑥𝐿 > 0
𝑆
Turbine Improvement
real case
𝑇
𝐸𝑥𝐿 > 0
𝑆
 lower capital cost
 but less work
Throttling valve Improvement
𝑇𝑜𝑢𝑡
𝑇1
𝑇𝑜𝑢𝑡 𝐻1
𝐻2
𝐸𝑥𝐿 > 0
𝑆
Throttling valve Improvement
Which one is better ?

𝑊 = 𝐻1 − 𝐻2
𝑇ሖ 𝑜𝑢𝑡 𝑇
𝑇1
“Capital cost” 𝑇𝑜𝑢𝑡 𝐻1
𝑇ሖ 𝑜𝑢𝑡 𝐻2
vs 𝐸𝑥𝐿 > 0
“Operation cost” 𝑆
Mixer Improvement
𝑇1 , 𝑃1
𝑇3 , 𝑃3
𝑇1 ≈ 𝑇2 ≈ 𝑇3
𝑇2 , 𝑃2 𝑃1 ≈ 𝑃2 ≈ 𝑃3
Distillation column Improvement
ideal case
Feed
𝑅𝑒𝑓𝑙𝑢𝑥 𝑚𝑖𝑛
𝜂𝐸𝑥 1
𝐻𝑒𝑖𝑔ℎ𝑡 ∞ 𝑅𝑒𝑓𝑙𝑢𝑥 𝑇𝑜𝑡𝑎𝑙
𝜂𝐸𝑥 0
𝐷𝑖𝑎𝑚𝑒𝑡𝑒𝑟 ∞
Column size
0
0.5
optimum region
1
Useful output
𝜂
𝑄𝐶
• Check heat sink
• Check operating pressure
Tops
𝑃
Feed • Check reflux /
plate trade off
• Position
• Condition Bottoms
𝑄𝑅
• Check heat source
Unit operations
• Unit operations – trade off

• Must always be aware of the
rest of flowsheet
• Biggest savings by improving
networks
Flowsheet
Don’t just go for the largest loss

Flowsheet
Ancilliaries
Changes made to the “inner
Heat exchanger systems” affect “outer systems”
network
Expansion -
compression
Separation
Reaction Don’t go from feeds

to products, go from
inner to outer level
Flowsheet
Quality of
product
Exergy
lost
Accept the loss
Flowsheet
Exergy
lost
Income
(work, steam)
Avoid the loss

Flowsheet
Mix and split at wrong place
Avoid the loss

Flowsheet
Network sensitivities
Loss of
plant
Loss of unit
operation
Flowsheet
Loss of Reduce
plant here
Increase
there
Loss of unit
Accept the loss operation
Flowsheet
Total
consumption
Loss of unit
Avoid the loss operation
Flowsheet
Load or level
Level is too low
Accept the loss

Flowsheet
Efficiency
𝑊 = 100𝑘𝑊 𝑊 = 500𝑘𝑊
𝜂 = 0.5 𝜂 = 0.9
𝐸𝑥𝐿 = 50𝑘𝑊 𝐸𝑥𝐿 = 50𝑘𝑊
Avoid the loss Accept the loss

Flowsheet
Cross the boundary
Accept the loss in circulation

Must cross the boundary to reduce the loss
Flowsheet
Only savings by reducing

consumption or switching sinks
(emission – power / steam)
Flowsheet
Economy
10 years for payback 1 year for payback
Accept the loss Avoid the loss

Flowsheet
Minimum the driving forces

Flowsheet
How to approach
— Rough data (T, P, H, n)
— Set up source / sink models
— Calculate 𝐸𝑥𝐿 and 𝜂
— Decide avoidable and inevitable losses
— How could unit operations be improved?
— Consider the flowsheet interactions
— Compile a list of questions and suggestions
— Ignore the project manager’s justified scepticism
(he’s just a peasant!) and become an entropy buff

From Potential To Cost

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From Potential To Cost

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Lecture 4

from Potential … to Cost

“Driving force” vs “Speed”

“Driving force” vs “Efficiency”

The driving force is as

Who is going to be hurt ?

How fast a process happens

𝐷𝑖𝑓𝑓𝑢𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 = 2 𝑚𝑜𝑙Τ𝑠𝑒𝑐

𝐷𝑖𝑓𝑓𝑢𝑠𝑖𝑜𝑛 𝑟𝑎𝑡𝑒 = 4 𝑚𝑜𝑙Τ𝑠𝑒𝑐

increase the driving force,

the bigger driving force,

High efficiency processes

‒ Exergy is ideal work

Avoidable and inevitable

‒ No exergy lost in ideal process

The ideal targets is not

to use exergy losses as design

𝐸𝑥𝐿 = 𝐸𝑥𝐿𝑖𝑛𝑣 + 𝐸𝑥𝐿𝑎𝑣𝑑

Which one is better ?

Which one is better ?

• Unit operations – trade off

Don’t just go for the largest loss

Reaction Don’t go from feeds

Avoid the loss

Mix and split at wrong place

Avoid the loss

Level is too low

Accept the loss

Avoid the loss Accept the loss

Accept the loss in circulation

Only savings by reducing

10 years for payback 1 year for payback

Accept the loss Avoid the loss

Minimum the driving forces

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