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Dynamic exergy analysis: From industrial data to exergy flows.

Charalampos Michalakakis1, Jonathan M Cullen1

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Summary
This summary is machine-generated.

This study applied exergy analysis to real industrial data from an ammonia plant, revealing significant energy losses and providing insights for performance improvements in industrial decarbonization efforts.

Keywords:
Sankey diagramsenergy efficiencyexergy analysisindustrial dataindustrial ecologymaterials efficiency

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Area of Science:

  • Chemical Engineering
  • Industrial Ecology
  • Thermodynamics

Background:

  • Industrial emissions are a key focus for decarbonization as power and transport sectors become greener.
  • Exergy analysis offers a comprehensive approach to assess material and energy efficiency in industrial plants.
  • Previous studies relied on simulated data, limiting practical application for plant operators.

Purpose of the Study:

  • To conduct an exergy analysis using real-world operational data from an ammonia production facility.
  • To develop methods for processing and visualizing industrial data for exergy assessment.
  • To identify key areas of exergy loss within the plant for targeted improvements.

Main Methods:

  • Collected 2 years of data from 311 sensors at a real ammonia production site.
  • Developed data processing techniques to handle challenges of real industrial data.
  • Utilized Sankey diagrams to visualize resource flows and estimated exergy indicators for plant components.

Main Results:

  • Evaluated exergy efficiencies for the overall plant and specific units (e.g., primary reformer, combustor).
  • Identified substantial exergy losses, totaling 80 MW, with the primary reformer (35 MW) and combustor (33 MW) being major contributors.
  • Reported average conventional exergy efficiencies for the plant at 71% and transit exergy efficiencies at 15%.

Conclusions:

  • Exergy analysis of real plant data provides actionable insights for industrial decarbonization and performance optimization.
  • The methods developed are applicable to various industrial sites, aiding in targeted improvement projects.
  • Advancements in sensor technology and Industry 4.0 can facilitate real-time performance monitoring for enhanced efficiency.