PROCESS INDUSTRY ENERGY

& MATERIALS MODELLING

Prof. Dr. Eng. Kant Ateenyi Kanyarusoke; DEng.; MSc. Mech. Eng; BSc. Eng. 1st Class Hons;
HDHET cum laude; CIRDAFRICA. M-ASHRAE, M-SASEE, M-UIPE.
kant_kanyarusoke@eng.busitema.ac.ug; kanyarusokek@gmail.com
APE 3106: WEEK 1 - MODELLING PROCESS INDUSTRY ENERGY & MATERIALS FLOWS 1
 PROCESS INDUSTRIES
• Have built structures and environments on pieces of land
• Have people either as employees or as visitors to their industries’ premises
• Take in raw materials and store them temporarily
• Withdraw raw materials from stores, process them to produce both finished company
products and waste
• Temporarily store finished products and some waste, then move these to destinations
outside the premises (to customers or to dumping sites)
• Use both labour and machinery to process the raw materials and pack both the finished
products and some waste materials
• Consume energy and other services (water, ITC, air, etc.) to clean, move, store, process the
raw materials and pack , both the waste and products for more temporary storage
• Consume energy to move the products and waste out of the factory
• Consume energy to keep the working environment clean and safe for both industry assets
and people
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 MATERIAL FLOWS IN A PROCESS INDUSTRY
UN WEIGHED, UNPACKED MATERIAL WASTE/LOSSES
RAW MATERIALS & FUELS

PRODUCTS TO THE MARKET

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1 8
RAW MATERIALS RECEIPT 12 FINISHED
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PRODUCTS
RAW STORAGE
MATERIALS PROCESSING & 11
0 6
AND FUELS 7 PACKING
3 STORAGE MACHINERY 13 16

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2 14 OFFICES
COMPOUND & SECURITY 15
10
Arrows indicate materials flow PACKED, WEIGHED MATERIAL WASTE/LOSS
Numbers indicate operations Figure 1.1: Materials flow in a process industry
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 MATERIALS FLOW CHART: explanation
 • Total Materials, m0 are purchased and loaded onto factory delivery trucks
• Materials m1 are unknowingly lost to the environment or to purchase errors so that m2 are delivered
to the factory:
+ (1.1)
• After receipt, materials are moved (3) to storage, where some (m5) are again unknowingly lost to the
environment to remain with m6 :
(1.2)
• Materials m6 are delivered to the processing and packing machinery (7) where m8 are unknowingly
lost, m9 are known wastages and m11 are the finished products coming out of the production line:
(1.3)
• Finished products m11 are then stored (12) and eventually loaded onto sales delivery truck (13) for
transportation (16) to the market:
(1.4)
• Known waste materials from the factory are moved (9) to waste packing area (10) weighed and
disposed of (10): (1.5)
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Qu. 1.1: List and discuss the possible causes of losses m1 in case of a) Maize grain; b) Mangoes c) Cabbages; d) Milk; e)
Cassava tubers.
Qu 1.2: The materials flow chart assumes no losses in storage of finished products. Is this assumption valid for the crops in
Qu. 1.1? If not, suggest a set of equations (1.3) to (1.5) to describe what you think could be happening in actual processing
factories.
Worked Example 1.1:
A company buys 50 Tonnes of Farmers’ maize grain at UGX 480 per kg, transports it to its premises at UGX 150 000 per trip of
10 Tonnes. On reaching the premises, moisture tests reveal a 17% value instead of the desired 13%. It is therefore decided to
open up and dry the grain before storage. These operations discover 800 kg of foreign matter (maize cobs, soil, stones etc.) in
the produce before drying.
a) Compute the values mo, m1 and m2 in this scenario.
b) If the cleaning operation costs UGX 15 000 per Tonne input, and the drying process costs UGX 50 per kg of moisture
expelled, determine the actual unit cost of stored maize in UGX per kg.
SOLUTION:
c) m0 = 50 000kg; Ans.; Actual maize bought = 50 000 – 800 kg = 49 200 kg at 17% MC, wet basis.
Dry matter bought = 49 200* (100 -17)/100 = 0.83* 49 200 kg = 40 836 kg.
This is (100 – 13)% of the dried maize. => Total dry maize bought = 40 836/0.87 kg = 46 938 kg. So m2 = 46 938 kg Ans.
And m1 = 50 000 – 46 938 kg = 3 062 kg. Ans.
b) Cost of Transport = UGX 150 000* 50 000/10 000 = UGX 750 000; Cost of cleaning = UGX 15 000*50 = UGX 750 000;
Expelled moisture = (49 200 – 46 938) kg. = 2262 kg. Hence, cost of drying = UGX (50*2262) = UGX 113 100. Total maize cost
in storage = UGX (480*50 000 + 750 000 +750 000 + 113 100) = UGX 25 613 100; Hence, unit cost of stored maize = UGX (25
613 100/46 938) UGX/kg = 545.68 UGX/kgAPE Ans. [or 13.7% HIGHER than farmer price]
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 HOMEWORK 1.1
1. The above two photos were taken mid 2020 in Yumbe dstrict, West
Nile. Find out, and report on the progress of this factory, and of all
others processing fruits in the country (Uganda).
2. Watch the video https://www.youtube.com/watch?
v=bhGOTM7Mh9U
3. Then list all the raw materials you see in the unit operations. Which
of them are likely to suffer the greatest unaccountable losses m1, m5
and m8?

Mango Juice Bottling line from China

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ENERGY FLOWS IN A PROCESS INDUSTRY
FUELS FACTORY THERMODYNAMIC
BOUNDARY

5
1 8
RAW MATERIALS RECEIPT 12 FINISHED
4
PRODUCTS
RAW STORAGE
MATERIALS PROCESSING & 11
0 6
AND FUELS 7 PACKING
3 STORAGE MACHINERY 13 16

9
2 14 OFFICES
COMPOUND & SECURITY 15
10

Thermal Energy going out of factory thermodynamic boundary ELECTRICITY

APE 3106: WEEK 1 - MODELLING PROCESS INDUSTRY ENERGY
Figure 1.2: Materials & Energy flows in a process industry FLOWS
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 ENERGY FLOW CHART: explanation
 • Every activity in a factory, including sitting in offices or keeping the premises safe and secure needs ENERGY. So, all unit
operations 0 to 16 in Figure 1.1 CONSUME ENERGY (even though some do not handle raw materials and finished
products)
• ENERGY enters the premises principally in TWO forms: ELECTRICITY and FUELS. Then each unit operation draws its
requirements from these sources
• Each unit operation consumes MORE ENERGY than it actually needs to do a job. Some of the consumed energy gets
converted to THERMAL form (a little becomes SOUND)
• The THERMAL wasted form, escapes out of the premises to the environment, sometimes even after causing problems in
the premises.
• For each unit operation we can write: (1.6)
• For the whole factory thermodynamic system: The sub systems which receive energy (fuels and electricity supplies) to the
premises can also waste some - so that we have:
(1.7)
• As Engineers, our problem(s) is/are to:
 Minimise losses represented by each of the last two terms of equation (1.7) when energy sources are just delivering
the energy to the premises or factory thermodynamic system.
 Design individual unit operations so that first of all, they need less of Euseful, to do a job, but even after that, they
demand less excess from the supply which they definitely waste as Ewaste.
 Design factories so that the Ewaste does not cause problems within the thermodynamic boundary or even outside, in the
environment.
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 Qu. 1.3: A starch making plant (from Maize grain) draws a balanced 510 Amp line current of 3 phase electricity (415 V)
from UMEME at a power factor of 0.825. Its operations also consume 810 L furnace fuel, 200 L diesel and 150 L petrol a
day. The processing plant runs 10 hours a day. When it closes, a 20 kW lighting load at almost unity power factor remains
till the next day. Compute the daily Eelec and Efuels for this plant in kWh.. Also compute the kVA peak demand of the plant. The
heat values of the various fuels are: Furnace fuel 38.9 MJ/L; Diesel 37.4 MJ/L; Petrol 32.4 MJ/L.
Qu 1.4: One of two identical Maize Hulling machines in the plant is noticed to consume 30 kW at a pf of 85% when steadily
hulling 500 kg maize grain per hour although it draws twice this load at start up. What is the peak demand load (kWpeak) of
this machine? Hence, explain why starting of these machines should be staggered.
Worked Example 1.2:
Consider the plant of Qu. 1.3 and 1.4. Given that the processing machinery does not consume petrol or diesel and that the lighting energy has
nothing to do with the functionalities of the machinery (only required by people to see properly), compute:
a) The daily electricity energy usage ratio of the machinery in kWh/Tonne input and in kVA/Tonne input.
b) The daily fuel energy ratio in L/Tonne input and in kWh/Tonne input
c) The daily total energy demand (i.e. for electricity use kVA not kWh) ratio in kWh/Tonne input
SOLUTION:
a) Power drawn for 3 Φ supply = √3*IVcosФ = 1.732*510*415*0.825 W = 302.427 kW
Power used in lighting = 20 kW (from Qu 1.3). So, Power consumed by Processing machinery = 282.427 kW.
Hourly Kg maize processed = 2 hullers* 500 kg/huller.hr = 1 000. i.e. Tonnes processed per hour =1.
Hence, daily electricity energy usage ratio = 282.427/1 = 282.427 kWh/Tonne. Ans.
In kVA/Tonne, this becomes 282.427/cosФmachine where Фmachine is the phase angle of the machinery alone without lighting (which latter has a zero
phase angle). This angle is computed as in Figure Ex 1.2 on next slide. It is 36.25°. Hence, kVA usage ratio is 350.2 kVA/Tonne. Ans.
b) Daily Furnace fuel consumed = 810 L; => Fuel usage ratio = 810 L/10 Tonne = 81 L/Tonne Ans. This translates to:
38.9MJ/L*[81L/Tonne]/[3.6MJ/kWh] = 875.25 kWh/Tonne Ans.
c) Total energy demand = Eelec + Efuel = 350.2+875.3 = 1 225.5 kWh/Tonne input. Ans.
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 VA A = 00
y k k V 10
c h iner To tal 415/
Ma 51 0*
32*

302.427 tan 34.4°

Reactive power =
1.7
25 =

= 207.1 kVAr
-1 0.8
= cos 34.4°
Ф to
tal

Фmachine

Lighting Machinery real power

power 282.427 kW
20 kW

Фmachine = tan-1 (207.1/282.427) = 36.25°

Figure Ex. 1.2: Finding electrical phase angles of machinery

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Worked Example 1.3:
The plant discussed in example 1.2 is the same as that in Example 1.1. When the maize is fed into the huller, 60% comes out as
broken maize for milling and 35% as maize bran to be used in animal feeds. From research, actual breaking of maize grain at
13% moisture content requires about 275 kJ per kg.
a) Determine the electrical energy wasted by each huller
b) Determine the value of m8 in Figure 1.1 for the day’s input.
c) If electricity costs UGX 611 pu compute the electricity cost per kg output of these hullers.
SOLUTION:
d) In 1 hour, Useful energy = 275 kJ/kg * 500 kg/hr = 137 500 kJ/hr = 38.19 kWh
Active energy used = 50 kWh; So, Energy waste per hour = 11.81 kWh Ans. or 23.6% of active energy consumed from UMEME.
b) m8 = unaccountable loss in processing = (100 – 60 – 35)% of input = 5% of 10 Tonnes/day = 500 kg/day Ans.
c) For each huller, output kg per hour = 500*0.95 = 475. Electricity power consumed per hour = 50 kWh; Cost of electricity per hour = 611*50 =
30 550 => cost per kg out = 30 550/475 UGX/kg = 64.32 UGX/kg. Ans.
Worked Example 1.4:
Dry saturated steam generated from an oil fired 1 tonne per hour 10 bar boiler is used in parts of the above plant to extract
Starch from the milled maize. The starch content of the crashed maize is 75%, and of this, only up to 98.5% is extractable.
a) Compute the thermal efficiency of the boiler if municipal water is available at 10 bar, 25°C.
b) Compute the unit fuel energy cost of the starch from this plant if furnace fuel costs UGX 2800 per litre.
SOLUTION:
c) Properties of steam: hg at 10 bar = 2777.7 kJ/kg; Water at 10 bar, 25°C; hin = 105.7 kJ/kg; Hence energy supplied by boiler = 2777.7 – 105.7 =
2672.0 kJ/kg. For 1 tonne per hour, this is 2672 MJ/hour. But Furnace fuel burnt is 810L/10 hrs = 81 L. This has 81* 38.9 = 3150.9 MJ of
energy. Hence, Boiler efficiency = 2672/3150.9 = 84.8% Ans.
d) Broken maize per hour = 0.6*1000 kg = 600 kg; Starch yield per hour = 0.985*0.75*600 = 443.25 kg; unit cost = 81*2800/443.25 = 511.68
UGX /kg starch. Ans. APE 3106: WEEK 1 - MODELLING PROCESS INDUSTRY ENERGY
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