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Energy Management :: 2007/2008

Class # 8P

Process Input-Output Analysis

Dr. Joo Parente


joao.parente@dem.ist.utl.pt

Energy Management

Process Input-Output Analysis

Basic concepts
Process / Activities

(square matrix)

Product Availability

Activity
Matrix

=
Activity Level

Products

Activity matrix: Defines the amounts of products/energy consumed or produced per unit of final product in each
process. An input to the process (process consumption) is defined as a negative quantity, while the output is
defined as a positive quantity (process production).
Activity level: Defines the production of each process, i. e., the total amount of final product produced in that
process.
Product availability: Defines the amount of final products available at the end of the whole production process.

Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

Basic concepts

A
1
2
3
Ener

A
A11
A21
A31
A41

B
A12
A22
A32
A42

C
A13
A23
A33
A43

Ener
A14
A24
A34
A44

T
T1
T2
T3
T4

a
a1
a2
a3
a4

By definition A14 = A24 = A34 = 0 (no energy consumption in the products), and A44 = A41 + A42 + A43 = 1 (all energy
consumed in the process must equal the delivered to the whole process).
If the final products of process A, B, and C are 1, 2, and 3, respectively. In this case A11 = A22 = A33 = A44 = 1.
So, to determine the activity level required at each process to fulfill a specific final production, we have:
[A]-1 * [a] = [T]
for example, if we wish to determine the activity level required to produce one unit of product 3,
[a] = [ 0 0 1 0]T

Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

EXAMPLE 01 - Sequential connection


Consider a system composed only by an oven, selection of products without deficiencies and storage. The specific
energy consumption of the oven is 200 kJ/kg, the selection of the products is characterized by a specific energy
consumption of 5 kJ/kg, and 20 kJ/kg for the storage. The raw materials embrace an energy consumption of 50 kJ/kg in
transformation process. The heating process promotes the volatilization of some components of the raw material,
around 5% of the original material. The selection process disposes around 10% of the oven production and the storage
losses are around 1%. Determine the specific energy consumption of the final product.
EXAMPLE 02 - Convergent connection
A company in the biological oil production imports 60% of the raw material, while the remaining raw material is from
national production. The imported oil is transported by boat with a travel distance ~ 1000 km, while the national oil is
transported by truck with a travel distance ~ 200 km. The oil refinery process presents a specific energy consumption of
100 kJ/kg. The mass rejection in the oil refinery process is ~ 90%. The specific consumption associated to the transport
is 0.025 kJ/kg*km by truck and 0.010 kJ/kg*km by boat. The oil losses in the transport are 1% by truck and 0.1% by
boat. Determine the specific energy consumption associated to the refined oil.
EXAMPLE 03 - Divergent connection
A glass oven presents a mass loss by volatilization ~7%. From the glass produced in the oven, 40% is employed in the
production of 0.33 cl bottles, and the rest to the production of 0.75 cl bottles. The conformation of the 0.33 cl bottles has
a rupture ratio of 2%, while the 0.75 cl bottles has a rupture ratio of 3%. The sand used in the glass production has an
energy value of 10kJ/kg. The specific consumption are, 200 kJ/kg in the oven , in the conformation 20 kJ/kg for the 0.33
cl bottle and 25 kJ/kg for the 0.75 cl bottles. Determine the specific energy consumption for each type of bottle.

Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

SOLUTION EXAMPLE 01 - Sequential connection


Specific energy consumption of the final product: c4 = cST + SST*(cS + SS*(cO + SO*c1)
SST = 1 / (1 0.01) = 1.01 kg3/kg4
SS = 1 / (1 0.10) = 1.11 kg2/kg3
SO = 1 / (1 0.05) = 1.05 kg1/kg2

Losses

Losses

cST = 20 kJ/kg4
cS = 5 kJ/kg3

1 Raw materials

cO = 200 kJ/kg2

Oven

(2)

Selection

(3)

(4) Final Product


STorage

Boundary

c4 = 20 + 1.01*(5 + 1.11*(200 + 1.05*50) = 308 kJ / kg4

Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

SOLUTION EXAMPLE 01 - Sequential connection

A*T

RM
1 1.1814
2
0
3
0
4
0
Ener -59.07

O
-1.181
1.122
0
0
-224.5

A
-1.053
1
0
0
-200

1
2
3
4
Ener
A-1
RM
A
B
C
Ener

RM
1
0
0
0
-50
1
1
4E-17
2E-17
0
50

Class # 8P :: Input-Output Analysis

S
0
-1.122
1.010
0
-5.051
B
0
-1.111
1
0
-5

ST

Ener
0
0
0
0
-1.01
0
1
0
-20 308.59
C

Ener

0
0
-1.01
1
-20

2
3
4
1.0526 1.1696 1.1814
1 1.1111 1.1223
0
1 1.0101
0
0
1
252.63 285.7 308.59

*
0
0
0
0
1

Ener

*
0
0
0
0
1

T
=
1.181
1.122
1.010
1
308.6
a

=
0
0
0
1
0

a
0
0
0
1
0
T
1.181
1.122
1.010
1
308.6

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Energy Management

Process Input-Output Analysis

SOLUTION EXAMPLE 02 - Convergent connection


Specific energy consumption of the final product: c5 = cR + SR*(f2*(cB + SB*c1) + f4*(cT + ST*c3))
SR = 1 / (1 0.90) = 10 (kg2 + kg4) /kg5
SB = 1 / (1 0.001) = 1.001 kg1/kg2
ST = 1 / (1 0.01) = 1.01 kg3/kg4

Losses
(1) Imported oil

cR = 100 kJ/kg5

Transport
Boat

2
Refinery

cB = 0.010 kJ/(kg*km) * 1000 km = 10 kJ/kg2


cT = 0.025 kJ/(kg*km) * 200 km = 5 kJ/kg4
c1 = c3 = 0 kJ/kg

(3) National oil

Transport
Truck

(5) Refined oil

4
Boundary

c5 = 100 + 10*(0.6*10 + 0.4*5) = 180 kJ/kg5

Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

SOLUTION EXAMPLE 02 - Convergent connection

A*T
1
2
3
4
5
Ener

RMi
6.061
0
0
0
0
0

RMi

1
2
3
4
5
Ener
A-1
RMi
B
RMn
T
R
Ener

B
-6.061
6
0
0
0
-60

RMn

RMn

1
0
0
0
0
0

B
-1.01
1
0
0
0
-10

1
0
0
0
0
0

2
1.0101
1
-2E-17
-2E-17
-6E-18
10

Class # 8P :: Input-Output Analysis

0
0
4.040
0
0
0

0
0
1
0
0
0
3
0
0
1
0
0
0

0
0
-4.040
4
0
-20

R
0
-6
0
-4
1
-100

0
0
-1.01
1
0
-5

0
-6
0
-4
1
-100

4
5
-9E-17 6.0606
-9E-17
6
1.0101 4.0404
1
4
-3E-18
1
5
180

Ener
0
0
0
0
0
180
Ener

*
0
0
0
0
0
1

Ener

*
0
0
0
0
0
1

T
=
6.061
6
4.040
4
1
180
a

=
0
0
0
0
1
0

a
0
0
0
0
1
0
T
6.061
6
4.040
4
1
180

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Energy Management

Process Input-Output Analysis

SOLUTION EXAMPLE 03 - Divergent connection


Specific energy consumption of the final product: c3 = cA + SA*c2 ; c5 = cB + SB*c4 ;

c2 = c4 = cO + SO*c1

SA = 1 / (1 0.02) = 1.020 kg2/kg3


SB = 1 / (1 0.03) = 1.031 kg4/kg5

SO = 1 / (1 0.07) = 1.075 kg1/(kg2 + kg4)


(1) Sand

c2 = c4 =200 + 1.075*10 = 210.75 kJ/kg2 ou 4


c3 = 20 + 1.02*210.75 = 235 kJ / kg3
c5 = 25 + 1.031*210.75 = 242.3 kJ / kg5

Class # 8P :: Input-Output Analysis

Conf.
A_0.33cl

(3) 0.33cl bottles

Conf.
B_0.33cl

(5) 0.75cl bottles

Glass Oven
4

Boundary

Slide 9 of 53

Energy Management

Process Input-Output Analysis

SOLUTION EXAMPLE 03 - Divergent connection

A*T
1
2
3
4
Ener
A
1
2
3
4
Ener
A-1
RM
O
A
B
Ener

RM
2.206
0
0
0
-22.06

O
-2.206
2.051
0
0
-410.3

RM

O
-1.075
1
0
0
-200

1
0
0
0
-10
1
1
0
6E-18
0
10

Class # 8P :: Input-Output Analysis

A
0
-1.02
1
0
-20
A
0
-1.02
1
0
-20

Ener
0
0
-1.031
0
0
0
1
0
-25 477.32
B

Ener

0
-1.031
0
1
-25

2
3
4
1.075 1.097 1.109
1 1.020 1.031
0
1 2E-16
1E-16 2E-16
1
210.75 235.05 242.27

*
0
0
0
0
1

Ener

*
0
0
0
0
1

T
=
2.206
2.051
1
1
477.3
a

=
0
0
1
0
0

a
0
0
1
1
0
T

1.097
1.020
1
2.15E-16
235.1

=
0
0
0
1
0

T
1.109
1.031
1.99E-16
1
242.3

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Energy Management

Process Input-Output Analysis

PROBLEM 01 - Treatment
Consider the following system and data:

Treatment

m1 = 1 kg; Energy associated to 1 ~ 1kJ/kg;


losses in A ~ 20%; energy consumption in A 1,25 kJ/kg;
losses in B ~ 0%; energy consumption in B 1,25 kJ/kg;
losses in C ~ 0%; energy consumption in C 5 kJ/kg;
Determine C3.

PROBLEM 02 - Recycling
Consider the following system and data:
m1 = 1 kg; Energy associated to 1 ~ 0.01kJ/kg;
losses in A ~ 0.1 kg; energy consumption in A 0.714 kJ/kg;
losses in B ~ 0%; energy consumption in B 1,25 kJ/kg;
losses in C ~ 0.1kg; energy consumption in C 2 kJ/kg;
m5 = 0.5 kg
Determine C3.

Class # 8P :: Input-Output Analysis

Recycling
5

C
4

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Energy Management

Process Input-Output Analysis

SOLUTION PROBLEM 01 - Treatment


C1 = 1 kJ / kg;
CA = 1.25 kJ / kg;
CB = 1.25 kJ / kg;
Cc = 5 kJ / kg;

Treatment
4

C3 = CB + SB*C2 = 5 kJ / kg

C2 = CA + SA*C1 + SAC*Ct4 = 3.75 kJ / kg


Ct4 = CC = 5 kJ/kg

SB = 1
SA = 1 / (1-0.2) = 1.25
SAC = 0.2 / 1.25 = 0.16

Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

SOLUTION PROBLEM 01 - Treatment

A*T

RM

1
2
3
4
Ener
A

Class # 8P :: Input-Output Analysis

-1
0.8
0
-0.2
-1

1
0
0
0
-1

A
-1.25
1
0
-0.25
-1.25

1
0
0
0
1

2
1.25
1
1E-16
0.25
3.75

RM

1
2
3
4
Ener
A-1
RM
A
B
C
Ener

A
1
0
0
0
-1

B
0
-0.8
0.8
0
-1
B
0
-1
1
0
-1.25

Ener

0
0
0
0.2
-1
C

0
0
0
0
4
Ener

0
0
0
1
-5

3
4
1.25 -4E-16
1 -4E-16
1 -3E-16
0.25
1
5
5

Ener

*
0
0
0
0
1

=
1.0
0.8
0.8
0.2
4

0
0
0
0
1
a

0
0
0.8
0
0
=

0
0
1
0
0

T
1.25
1
1
0.25
5

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Energy Management

Process Input-Output Analysis

SOLUTION PROBLEM 02 - Recycling

C1 = 0.01 kJ / kg;
CA = 0.714 kJ / kg;
CB = 1.25 kJ / kg;
Cc = 2 kJ / kg;

Recycling
5

C3 = CB + SB*C2 = 3.763 kJ / kg
C2 = CA + SA*(f1*C1 + f5*C5) = 1.436 kJ / kg
C5 = Cc + Sc*C4 = 2 kJ/kg;

C
4

C4 = 0 kJ/kg;
SB = 1.4 / (1.4 0.6) = 1.750
SA = (1 + 0.5) / (1.5 - 0.1) = 1.071
SC = (0.5 + 0.1) / 0.5 = 1.2
f1 = 66.7%
f2 = 33.3%
Class # 8P :: Input-Output Analysis

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Energy Management

Process Input-Output Analysis

SOLUTION PROBLEM 02 - Recycling

A*T

RM

1
2
3
4
5
Ener

1
0
0
0
0
-0.01

RM

1
2
3
4
5
Ener

1
0
0
0
0
-0.01

A-1
RM
A
B
C
RC
Ener

A
-1
1.4
0
0
-0.5
-1

B
0
-1.4
0.8
0
0
-1

RC

0
0
0
-0.6
0.5
-1

A
-0.714
1
0
0
-0.357
-0.714

0
-1.75
1
0
0
-1.25

0
0
0
-1.2
1
-2

2
1 0.7143
1E-18
1
7E-19 9E-17
3E-19 0.357
4E-19 0.429
0.01 1.436

3
1.25
1.75
1
0.625
0.75
3.763

Class # 8P :: Input-Output Analysis

Ener

0
0
0
0.6
0
0
RC

Ener
0
0
0
1
0
0

5
0
0
0
0
1
0

0
0
0
0
0
3.01
*

*
0
0
0
0
0
1

=
1
1.40
0.8
0.5
0.6
3.01

0
0
0
0
0
1
Ener

0
0
0
1
1.2
2

0
0
0.8
0
0
0
=

0
0
1
0
0
0

T
1.25
1.75
1
0.625
0.75
3.763

Slide 15 of 53

Energy Management

Energy Management :: 2007/2008


Class # 8P

Process Input-Output Analysis

Dr. Joo Parente


joao.parente@dem.ist.utl.pt

Class # 8P :: Input-Output Analysis

Slide 16 of 53

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