Technical Analysis Based on Exergoeconomic, Advanced Exergetic Evaluation of An In-Service Cement Production Plant With Instantaneous Process Data

Abstract

An all-inclusive advanced exergy and exergoeconomic, analysis of a dry process, 5 million MTPA cement plant with real-time operational data located in Mfamosing, Cross River State, Nigeria was performed. The analysis was based on component-wise modelling by separating the exergy destruction (ED) rates into endogenous, exogenous, avoidable and unavoidable portions for the two production lines, which makes the study novel as available studies in a cement plant was based on conventional applications. The result shows an exergy efficiency (EE) of 55.58 % for L1 and 58.22 % for L2. The exergoeconomic analysis revealed that the cost of exergy destruction (COED) was higher in L2 at $14,786.40/hr with L1 calculated at $12,977.34/hr. The preheaters (PH) and Clinker Coolers (CC) contributed about 72.39 % and 59.67% for L1 and 11.09 % and 18.20 % for L2, respectively, to the overall COED. The advanced exergy analysis showed that the mainstream of the ED rates in the plant is endogenous and unavoidable. Components with high potential for improvement were identified and possible system design and optimization suggestions.