| Literature DB >> 32715120 |
Chukwuemeka J Okereke1, Olumuyiwa A Lasode1, Idehai O Ohijeagbon1.
Abstract
Exergoeconomic analysis is a tool used to identify hidden costs associated with a machine or a system that cannot be identified using typical cost management techniques applied in the industry. While exergoeconomic analysis finds applications in power system innovations and optimization, it has not yet been harnessed by the manufacturing industry to reduce operating costs. The purpose of this study is to use exergoeconomic analysis to identify hidden costs in manufacturing processes, with a focus on the industrial beverage mixer system. The study proposes a methodology of identifying the hidden financial losses in the system and recommends modifying the systems operation and design as a measure to reduce costs and increase profitability. Thermodynamic and economic data for the study were obtained from manufacturing plants. An exergy cost analysis was performed using thermoeconomic analysis software. Exergoeconomic values and variables were obtained using equations based on extant literature. The results reveal that the mixer possesses a low exergoeconomic factor of 5.50% owing to the high irreversibility of the H2O reservoir, flow-mix reservoir, and carbonator. The total hidden cost of the system equaled 733.04 $/h, of which 99.0% is contributed by the mixer. Improvements to the deaeration technique for the H2O reservoir of the mixer component, as well as the H2O treatment procedure, can reduce the irreversibility of the H2O reservoir and the hidden costs.Entities:
Keywords: Beverage mixer; Cost analysis; Energy; Exergoeconomics; Manufacturing; Mechanical engineering; Thermodynamics
Year: 2020 PMID: 32715120 PMCID: PMC7369611 DOI: 10.1016/j.heliyon.2020.e04402
Source DB: PubMed Journal: Heliyon ISSN: 2405-8440
Figure 1Thermodynamic diagram of material stream flow in the industrial beverage mixer system.
Economic data of equipment in the industrial beverage mixer system.
| Parameters | Mixer | NH3 compressor | Air compressor | Treated H2O pump | Syrup pump |
|---|---|---|---|---|---|
| Total cost of investment ($) | 208,333.33 | 17,267.43 | 12,020.01 | 905.65 | 972.22 |
| Number of years operated | 7.00 | 7.00 | 7.00 | 7.00 | 7.00 |
| Number of hours operated at full load in a year | 6,553.00 | 6,553.00 | 6,553.00 | 6,553.00 | 6,553.00 |
| Electricity tariff ($/kWh) | 0.12 | 0.12 | 0.12 | 0.12 | 0.12 |
Results of system operating-cost analysis.
| S/N | Components/Process | Fuel [kW] | Product [kW] | Irreversibility [kW] | Unit Exergy consumption k (kW) | Unit Exergy cost of fuel- | Unit Exergy cost of product- | Residual cost (kW/kW) |
|---|---|---|---|---|---|---|---|---|
| 1 | Treated H2O pump | 4.74 | 0.03 | 4.71 | 158.00 | 1.00 | 158.00 | 0.00 |
| 2 | H2O reservoir inlet valve | 5,324.42 | 5,323.37 | 1.05 | 1.00 | 1.00 | 1.00 | 0.00 |
| 3 | H2O reservoir | 5,329.04 | 1,392.24 | 3,936.80 | 3.83 | 1.01 | 3.85 | 0.00 |
| 4 | H2O orifice | 1,392.24 | 1,392.24 | 0.00 | 1.00 | 3.85 | 3.85 | 0.00 |
| 5 | Syrup pump | 4.92 | 0.04 | 4.88 | 123.00 | 1.00 | 123.00 | 0.00 |
| 6 | Syrup reservoir inlet valve | 4,791.75 | 4,782.21 | 9.54 | 1.00 | 1.00 | 1.00 | 0.00 |
| 7 | Syrup reservoir | 4,783.73 | 4,782.24 | 1.49 | 1.00 | 1.00 | 1.00 | 0.00 |
| 8 | Syrup orifice | 4,782.24 | 4,782.24 | 0.00 | 1.00 | 1.00 | 1.00 | 0.00 |
| 9 | Flow mix reservoir | 6,176.60 | 5,198.10 | 978.50 | 1.19 | 1.65 | 1.96 | 0.00 |
| 10 | Flow mix pump | 7.18 | 0.29 | 6.89 | 24.76 | 1.00 | 24.76 | 0.00 |
| 11 | Node | 5,210.87 | 5,197.61 | 13.26 | 1.00 | 1.96 | 1.96 | 0.00 |
| 12 | Carbo Trol | 13.93 | 12.48 | 1.45 | 1.12 | 1.50 | 1.68 | 0.00 |
| 13 | Carbonator inlet valve | 5,199.20 | 5,197.74 | 1.46 | 1.00 | 1.96 | 1.96 | 0.00 |
| 14 | NH3 compressor | 85.62 | 44.59 | 41.03 | 1.92 | 1.00 | 1.92 | 0.00 |
| 15 | Carbonator | 5,318.95 | 5,113.49 | 205.46 | 1.04 | 1.95 | 2.03 | 0.00 |
| 16 | Carbonator safety valve | 51.31 | 18.30 | 33.01 | 2.80 | 2.03 | 5.70 | 0.00 |
| 17 | Air compressor | 35.99 | 26.47 | 9.52 | 1.36 | 1.00 | 1.36 | 0.00 |
| 18 | Air receiver tank | 26.47 | 24.44 | 2.03 | 1.08 | 1.36 | 1.47 | 0.00 |
| 19 | Air distribution valve | 13.04 | 9.47 | 3.57 | 1.38 | 1.47 | 2.03 | 0.00 |
| 20 | CO2 distribution valve | 135.90 | 90.55 | 45.35 | 1.50 | 1.00 | 1.50 | 0.00 |
Figure 2Exergy efficiencies of industrial beverage mixer system.
Figure 3Cost flow rate at all locations of the industrial beverage mixer.
Results of exergoeconomic analysis of system equipment.
| Machine/Equipment | Cost rate of exergy destroyed ($/h) | Cost rate of investment and maintenance ($/h) | Cost rate of operation ($/h) | Exergoeconomic factor (%) |
|---|---|---|---|---|
| Treated H2O pump | 0.56 | 0.19 | 0.74 | 24.90 |
| Syrup pump | 0.58 | 0.20 | 0.78 | 25.60 |
| NH3 compressor | 4.85 | 3.52 | 8.37 | 42.10 |
| Air compressor | 1.45 | 2.45 | 3.91 | 62.80 |
| Mixer | 725.61 | 42.52 | 768.13 | 5.50 |
Figure 4Irreversibility and hidden cost from deaeration process of industrial beverage mixer subsystem.
Figure 5Irreversibility and hidden cost without deaeration process of industrial beverage mixer.