Mass and Energy balance for the different components reference Temperature for

1. Washer and Mixer, heat exchanger

given Masses Amount Einheit given Temperature Amount Einheit

m_Boxes_wett= 10000 kg/h T_ref= 0 °C
m_Boxes_dry 9700 kg/h T_fw80= 80 °C
m_w box= 300 kg/h T_w_in_box_20 20 °C
m_w box= 0.0833333 kg/s T_w_out box_70 70 °C
T_w100 100 °C
T_fw11 11 °C

Q_box = Q_fw80
m_box * cp_b * (70-20) = m_fw80 * cp_w *(80-70)
m_fw80= 22619.048 kg/h 6.2830688 kg/s fresh water with temperature 80°

m_fw80 = m_w100 + m_fw11

Q_fw80 = Qw_100 + Q_fw11

Q_fw80 = m_fw80 * cp_w * (80-0)

Q_fw80= 7600000 kJ/h 2111.1111 kW

Q_fw80 = m_w100*cp_w*100+m_fw11*cp_w*11
Q_fw80 = (m_fw80-m_fw11)*cp_w*100 + m_fw11*cp_w*11
m_fw80*80 = m_fw80*100-m_fw11*100 + m_fw11*11
m_fw11= 5082.932 kg/h 1.4119256 kg/s mass flow fresh water 11°

m_w100 = 17536.116 kg/h 4.8711432 kg/s mass flow water 100°

m_ww = m_fw11 - m_w box

m_ww= 1.3285922 kg/s mass flow waste water

Q_HX_washer = m_w100 * cp_w*(100-70)

Q_HX_washer= 2209551 kJ/h 613.76404 kW energy heat exchanger bevore entering mixer an

Q_HW_washer = m_w110 * cp_w * (110-105) 105° own astimation -> at least 5° temperature difference
m_w105= 105216.69 kg/h 29.226859 kg/s
reference Temperature for all calculations: T_ref = 0°C

given numbAmount Einheit

cp_w 4.2 kJ/kgK
cp_b 1.9 kJ/kgK

erature 80°

r bevore entering mixer and washer

ure difference
Mass and Energy balance for the different components reference Temperature for

1. Dryer and heat exchanger

given Masses Amount Einheit given Temperature Amount Einheit

m_w_return= 13212 kg/h T_ref= 0 °C
m_w_return= 3.67 kg/s T_evap= 70 °C
m_w box= 300 kg/h T_A180= 180 °C
m_w box= 0.0833333 kg/s T_w110= 110 °C
T_A11= 11 °C

Q_A_dry = Q_A70 + Q_evaporate

m_A_180 * cp_A * 180 = m_A_70 * cp_A * 70 + dHv * m_w box
m_A = 6368.1818 kg/h mass air for drying
m_A = 1.7689394 kg/s

Q_HX = m_A * cp_A * (180-11)

Q_HX = 298.95076 kW make up water

Q_dryer = m_w box * dHv / 3600

Q_dryer = 194.58333 kW

Q_HX = m_w_return * cp_w * (110 - T_w_return)

T_w_return = 90.605245 °C Temperature of return water from air-heater

2. Mixing point
m_w105 = 29.226859 kg/s
m_w_return = 3.67 kg/s

Q1 = -Q2
m1 * cp_w * (T_f - T_i1) = - m2 * cp_w * (T_f - T_i2)
m_w105 * cp_w * (T_f - 105) = m_w_return *cp_w * (T_f - 90)
T_f = 103.32659 °C temperature after mixing point

3. general cleaning wather 3rd heat exchanger

t= 2h
m_w= 10000 kg/2h
m_w= 5000 kg/h

Q = m_w *cp_w * (55 - 11)

Q= 256.66667 kW energy need for 3rd heat exchanger
reference Temperature for all calculations: T_ref = 0°C

given numbAmount Einheit

cp_w 4.2 kJ/kgK
cp_A 1 kJ/kgK

dHv_70°= 2335 kJ/kg

overall energy balance

V_gas = 189 m³/h natural gas need for boiler

Hu = 10.1 kWh/m³
De_methan= 0.656 kg/m³ density for methane

Q_gas = 1908.9 kJ/s 1720 kJ/s 1720-> number comes from "boiler efficiency excel
Q_gas = 6872040 kJ/h

m_gas= 123.984 kg/h mass flow natural gas need for boiler
m_gas= 0.03444 kg/s

1kg fuel / sec = 21.074 kg(FG)/s for 1kg fuel (natural gas) we get 21.047 kg flue gas /exhaust gas (FG) -> numbe

m_FG= 0.72578856 kg/s

Q_FG= 120.5 kw amount of energy getting lost flue gas

Q = Q_processes + Q_FG + Q_losses

Q_processes = Q_washer + Q_dryer + Q_cleaning water + Q_make up water

Q_cleaning water= 256.666667 kW

Q_make up water= 298.950758 kW
Q_dryer= 194.583333 kW
Q_washer= 613.764045 kW

Q_losses= 235.535197 kW
m "boiler efficiency excel"

haust gas (FG) -> number comes from "boiler efficiency excel"
renewable energy sources - calculation
we have 2 options for using biogas: 1st is to use
1. Biogas 2nd is to use the biogas in a CHP-plant - we can
m_ww= 1.32859224 kg/s m³/s when density of (waste) water is 1g/cm³
CSB= 4.78 kg/m³
efficiency= 0.8 80% of produced metahne can be used for ener
production= 0.28 m³/kg_CSB 0.28m³ Methane can be produced per kg CSB
Hu = 10.1 kWh/m³

V_methane= 0.00142255 m³/s

Q_methane= 51.7239281 kW amount of energy (heat) can be supplied by biogas

Electicity ? other option is to use the biogas for producing electricity and
Heat ?

2. Solar

available solar radiation: 1279.425 kWh/m²a

available area at the company: 3000 m²

theoretical available energy: 3838275 kWh/a

the efficiency of solar panels depends on the sourounding temperature and the temperature of the liqid
for 11° sourounding temperature and 85° temperature of the solar panels about 50% efficiency can be achieved (we desed
efficiency: 0.5
Autor:
thik we should just calculate the remaining energy demand
available energy for use: 1919137.5 kWh/a AFTER!!! Heat recovery for this option

3. CHP (instead of gas boiler) With this calculation we did replace the "normal" gas boiler with a CHP plant -> the aim
information efficiency from the slides of the lecture "cogen", slide number 4

Autor:
efficiency_ele 35.3 %
replace by heat demand AFTER heat recovery?
efficiency_therm 50 %
Losses 14.7 %

Heat demand 1720 kW

elektric power 1214.32 kW this amount of electricity is possible zu produce - multiplied b
Losses 505.68 kW
total 3440 kW to supply heat and electricity, more fuel input is needed
ons for using biogas: 1st is to use all of it and put it with the natural gas to the gasboiler (as long as this is not more than 5-10% of the t
he biogas in a CHP-plant - we can sell teh electricity and use the heat in our processes (but we have to buy a CHP-plant)
of (waste) water is 1g/cm³

ed metahne can be used for energy production

ne can be produced per kg CSB

n be supplied by biogas

ogas for producing electricity and heat (CHP)

ture of the liqid

ciency can be achieved (we deseded to use a standard flat collector)

the remaining energy demand

his option

boiler with a CHP plant -> the aim was to produce as much heat as we need for running the processes; the electric energy is going to be

heat recovery?

possible zu produce - multiplied by operation hours of the year we get the produced energy during the year

ty, more fuel input is needed

 not more than 5-10% of the total gasamount, there are no reconstructions for the boiler necessary)
y a CHP-plant)

e electric energy is going to be soled

The first thing has to be heat recovery (improve efficiency) ; after this evaluate options for using renewable sources to supp

There are 2 possibilities where preheating is needed:

1st is cleaning water from 11° to 55° 256.67 kW are needed
2nd is fresh water for the washer from 11° to 80° 410.07 kW are needed

suggestions:
-) we produce biogas from waste water; with the biogas we can run a cogeneration /CHP (combined heat and power) to pro
is it possible to use the heat from CHP to heat the fresh water for the washer????
-) solar power we can use for preheating
-) waste heat (exhaust air) from the dryer has 70° - this can be used für pre heating the cleaning water (from 11° to 55°)

operating hours per yea 4500 h/a all processes are operating 4500h/a

E1= 1155015 kWh/a with using the operatin hours the energy demand can be calculated
E2= 1845301.5 kWh/a with using the operatin hours the energy demand can be calculated

The following RECP options can be proposed:

with solar power the amount of energy for the fresh water supply for the washer can be achieved
available solar power: 1919137.5 kWh/a

fresh water energy de 1845301.5 kWh/a we do not take solar energy for heating the fresh water for the washer - s
solar ratio= 1.04 solar ratio (S kWh_solar/kWh_process; question to be answered: how lar

fresh water for cleanin 1155015 kWh/a we deside to use the solar energy for heating the general cleaning water
solar ratio= 1.66 solar ratio (S kWh_solar/kWh_process; question to be answered: how lar

with biogas produced from waste water we can run a CHP plant or replace some natural gas at the boiler

Q_biogas_heat only= 51.7239281 kW amount of heat from biogas

? electricity produced
? heat produced
using renewable sources to supply the remaining energy demand

ombined heat and power) to produce electricity and use the heat in our process

aning water (from 11° to 55°)

demand can be calculated

demand can be calculated

he fresh water for the washer - solara ratio is around 1 - this leads to high system costs for sesonal storage, we desided to use here a he
uestion to be answered: how large is the storage

ating the general cleaning water - no sesonal storage necessary, cheeper system costs
uestion to be answered: how large is the storage

as at the boiler
e, we desided to use here a heat recovery system from the processes
Pinch analyse

m m m cp m*cp T_in
air for dryer 1 m_air 1.77 1 1.77 11
cleaning water 2 m_cw 1.38890693 4.2 5.83340909 11
fresh water 3 m_washer 1.415 4.2 5.943 11
waste water A m_ww 1.33 4.2 5.586 80
humid air B m_HA 1.76890909 1 1.76890909 180
flue gas C m_FG 0.66217949 1.2 0.79461538 150

calculation of the different parts to get a picture:

m m*cp T_in T_out Q (kW)

1,2,3 13.5464091 11 55 596.042
Cold streams 1,3 7.713 55 80 192.825
1 1.77 80 180 177
B 1.76890909 180 150 -53.067273
hot streams B,C 2.56352448 150 80 -179.44671
A,B,C 8.14952448 80 70 -81.495245
C 0.79461538 70 20 -39.730769

T Q_cold Q_hot
10 596.042
20 596.042 -39.730769
30 596.042 -39.730769
40 596.042 -39.730769
50 596.042 -39.730769
60 192.825 -39.730769
70 192.825 -39.730769
80 192.825 -81.495245
90 177 -179.44671
100 177 -179.44671
110 177 -179.44671
120 177 -179.44671
130 177 -179.44671
140 177 -179.44671
150 177 -179.44671
160 177 -53.067273
170 177 -53.067273
180 177 -53.067273
T_out Q (kW)
180 299.13
55 256.67
80 410.067
70 -55.86
70 -194.58
20 -103.3
Economic evaluation

Economic value of streams

cost of energy 60 €/MWh

cost of water 1 €/1000kg boxes
m_Boxes_dry 9700 kg/h
cost of water 9.7 €/h

Flow Q (Energy); Economic value EnerEconomic value Water €/a

m_air drayer 1346.085 € 80,765.10 - money we have to pay
m_cleaning waher 1155.015 € 69,300.90 0 money we have to pay
m_fresh water 1845.3015 € 110,718.09 money we have to pay
m_waste water -251.37 -€ 15,082.20 money what is getting lost via losses
m_humid air -875.61 -€ 52,536.60 money what is getting lost via losses
m_flue gas -464.85 -€ 27,891.00 money what is getting lost via losses

internal rate of return

Invest 10000 €
life time 8 years

Abschreibung 1250 jährliche Abschreibung €/a

Cash Flow Barwert Gewinne Abschreibung kummuliert
-1
0
1
2
3
4
5
6
7
8
9
10
11
12
13
14
15
16
 no storage big storage
Solar costs ( 350 €/m² 700 €/m²

getting lost via losses

getting lost via losses
getting lost via losses

Inflation Barwert
Erlössteigerung
Kostendegression
zirkelbezug

x= 0.80280373
x= 0.80280373 Zirkeltbezug unter Optionen -> Formel-> interative Kalkulationen erlauben
kulationen erlauben