Analysis of Irreversible Manufacturing Processes

P M V Subbarao
Professor
Mechanical Engineering Department

Special Parameter to Account Entropy Generation

in MP…..
 Second Law for A Generalized Manufacturing System
THS
W PP
in
 MF o

 MF ,k
 in
Q  scrap
HS  MF H
m k 1

 MF
 o

 MF ,k
mat
H  scrap
S
i 1
k 1
m

 MF
S mat
i 1
Q MF
loss
env
n n
 H
j 1
prod
MF , j  MF , j
 prod
S
Q HS
in
Q loss m j 1
 MF
 MF env  Sirr, MF   SMF
mat
,i
THS T0 i 1
n o
dS MF
   SMF
prod
,j    scrap
S MF , k
dt j 1 k 1
 Model Equations for Generalized Manufacturing
System
• Conservation of mass:
m n o
dmMF
 m  MF ,i   m
mat
 MF , j   m
prod
 MF
scrap
,k
dt i 1 j 1 k 1

• First Law
m n o
dEMF
  H MF   H MF , j   H MF
mat prod scrap
,k   in
Q HS MF   loss
Q MF env  W in
PPMF
dt i 1 j 1 k 1

• Entropy Balance:

dS MF m n o 
Q in 
Q loss
  SMF
mat
,i   S MF , j 
 prod  S scrap  HS MF  MF env  S
MF , k irr, MF
dt i 1 j 1 k 1 T HS T 0
 SSSF Model Equations for Manufacturing System
• Conservation of mass:
m n o

 MF ,i  MF , j  MF ,k  0

m mat

i 1
 
m prod
 
m scrap

j 1 k 1
• First Law
m n m

 H
i 1
mat
MF   H
j 1
prod
MF , j   H MF
i 1
scrap
,k   in
Q HS MF   loss
Q MF env  W in
PPMF  0

• Entropy Balance:
m n m 
Q in 
Q loss

 MF ,i  MF , j
 mat  S prod
S
i 1 j 1
  SMF
i 1
scrap
,k  HS  MF
THS
 MF env
T0
 
S irr, MF  0

Thermal pollution generated by a Manufacturing Process

 m  mat n m 
Q in

Q MF
loss
env  T0  S MF ,i   S MF , j   S MF ,k 
 prod  scrap HS MF 
 Sirr, MF 
 i 1 j 1 i 1 THS 
 Power Consumed by an irreversible Manufacturing
System
m n m

 H
i 1
mat
MF   H
j 1
prod
MF , j   H MF
scrap

i 1
,k   in
Q HS MF   loss
Q MF env  W in
PPMF  0

n m m
W in
PPMF   H prod
MF , j   H scrap
MF , k   H MF
mat
 Q HS
in
MF   loss
Q MF env
j 1 i 1 i 1

 m  mat n m 
Q in

Q MF
loss
env  T0  S MF ,i   S MF , j   S MF ,k 
 prod  scrap HS MF 
 Sirr, MF 
 i 1 j 1 i 1 THS 
n m m
W PP
in
 MF   MF , j  MF ,k  MF HS MF

H prod

j 1

H scrap
 
H mat
  in
Q
i 1 i 1

 m  mat n m 
Q in

 T0  S MF ,i   S MF , j   S MF ,k 
 prod  scrap HS  MF 
 S irr, MF 
 i 1 j 1 i 1 THS 
Vegetable Production System : Jagadishpr , Sonipat
Design : Krishi Vigyan Kendra ,Jagdishpur, Sonipat
5KW design with 3.7KW Irrigation Pump
 ADVANTAGES OF IIT Delhi DESIGN
• Non-Renewable sources of petrol and diesel are not utilized
• Whole system is noiseless and does not disturb the
surrounding with sound pollution
• Water flowing through the turbine (partial pressure design II)
get oxygenated thereby effecting chemical and biological
oxygen demands which have a bearing on self regeneration
capacity of the soils [Pawlikewich]
• A pump with a high discharge head could be utilized with this
turbines hence Water storage in upper reaches facilitate
ground water recharge.
• The efficiency is the major player in power transmission and
the water wheel is set to take on the costlier reaction turbines
in its efficiency if it is properly worked on.
• The whole irrigation system costs around 700$ range.
 Effect of Planting methods on total irrigation time (hrs.) and yields of Cauliflower

and Pigeon pea (Quintals /ha)

Crops PlantingIrrigations Water Average Value of Ferti use

method Nos. market Rates Yields Irrigation
& (Time, total (Q/ha) the produce
hrs)/ I* irrigatime Water
Irrigation
Preliminary results show timethat
used farmers using the micro turbine
(US$ )
pumped water supplies stand to gain US$ 2.25 / hour of
Cauliflo Raised 8 (3.0) $53 100 $1100 DAP<70%
wer beds pumping. Drainage
Yhereby saving $53-73 in cauliflower and US$ 31-47no in otherpigeon
water
pea. ferti used
Raised
Flat bed 6planting
(5.5) improved
$73 the89value of the produce
$990 byDAP
20 kg/ha 10
percent. ‘’
no other
Pigeon Raised bed 4 (3.5) $47 223 $890 ‘’
pea ‘’
Flat 3(7.0) $31 200 $800 ‘’
‘’
Efficient Reuse of Low Quality water linked to Micro Hydro

Irrigation charges @ $ 2.25 /h, amounts for savings as in

cauliflower US$20/ha and pulse US$40/ ha on an average on
the Whole Produce.{( KVK (HAU) , Sonepat,HARYANA,INDIA}
 Workshop Powered by Pico-hydel Unit at
Naya Gharat , Lacchiwala

Gear Box Generator

Main Shaft

Canal

Forbay Grinding Wheel

Bush Bearing

12” Pulley

10” Pulley
Grinder
Penstock adjusting
lever
Water Wheel

New Design
Wooden Base
 Impact of System irreversibility on actual Power
consumption
n m m
W in
PP MF   H prod
MF , j   H scrap
MF , k   H MF
mat
 Q HS
in
 MF
j 1 i 1 i 1

 m  mat n m 
Q in

 T0  S MF ,i   S MF , j   S MF ,k 
 prod  scrap HS  MF 
 S irr, MF 
 i 1 j 1 i 1 THS 
The quantity n H-TS is backbone m of thermo-economic/ecological
W PPMF   H MF , j  T0 SMF , j    H MF ,k  T0 SMF ,k    H MF ,i 
m
in prod prod scrap scrap mat
 T0 SMF
mat
analysis
j 1
and is referred to
i 1
as the Gibbs free
i 1
energy.
 Q HS
in

 Q in
HS  MF  T0   MF
  T0 Sirr, MF
 THS 

   H   H 
n m m
Win
PP MF   H prod
MF , j  T0 S prod
MF , j
scrap
MF , k  T0 S scrap
MF , k
mat
MF  T0 SMF
mat
,i
j 1 i 1 i 1

 in T0  in 
 Q HS  MF  Q 
HS  MF   T0 S irr, MF
 THS 
 Thermo-economics/Thermo-ecology
• The quantity H-TS is known as the Gibbs free energy.
• In manufacturing system, a different quantity appears, H -
T0S.
• The difference between this and the same quantity
evaluated at the reference state is called flow exergy, B.

  H  T0 S   H  TS 0
• Exergy represents the maximum amount of work that could be
extracted from a system as it is reversibly brought to equilibrium
with a well-defined environmental reference state.
 Exergy
• In general, the bulk-flow terms may include contributions that
account for both the physical and chemical exergies.
• Hence =  ph+  ch, as well as kinetic and potential exergy.
• The physical exergy is that portion of the exergy that can be
extracted from a system by bringing a given state to the
“restricted dead state” at a reference temperature and pressure
(T0,p0).
• The chemical exergy contribution represents the additional
available energy potential that can be extracted from the system at
the restricted dead state by bringing the chemical potentials at that
state (T0, p0) to equilibrium with its surroundings at the “ultimate
dead state”.
 Dead State
• Consider a quantity of mass that undergoes a steady-state
process.
• With a given state for the mass entering the control volume, the
reversible work will be a maximum when this mass leaves the
control volume in equilibrium with the surroundings.
• This means that as the mass leaves the control volume, it must be
at the pressure and temperature of the surroundings, be in
chemical equilibrium with the surroundings, and have minimum
potential energy and zero velocity.
 Dead State

   H   H 
n m m
W
in
PP MF   H prod
MF , j  T0 S prod
MF , j
scrap
MF , k  T0 S scrap
MF , k
mat
MF  T0 SMF
mat
,i
j 1 i 1 i 1

  in T0  in 
 QHS MF  QHS MF   T0 Sirr, MF
 THS 
 Flow Exergy Balance Equation

   H   H 
n m m
W in
PP MF   H prod
MF , j  T0 S prod
MF , j
scrap
MF , k  T0 S scrap
MF , k
mat
MF  T0 SMF
mat
,i
j 1 i 1 i 1

  in T0  in 
 QHS MF  QHS MF   T0 Sirr, MF
 THS 

   H   H 
n m m
W
in
PP MF   H prod
MF , j  T0 S prod
MF , j
scrap
MF , k  T0 S scrap
MF , k
mat
MF  T0 SMF
mat
,i
j 1 i 1 i 1

  in 
   H 
m m
T0  in
 QHS MF  QHS MF   T0 Sirr, MF   H MF
mat
 TSMF
mat
,i 0
mat
MF  TSMF
mat
,i 0
 THS  i 1 i 1

  mat 
H MF  TS MF
mat
 0
 m mat
MF h  Ts 0
 Dead State Definition


 mat 
H MF  TS MF
mat

0
 m mat
MF h
mat
MF  Ts mat

MF 0

h
mat
MF  Ts   h
mat
MF 0
prod
MF  Ts   h
prod
MF 0
scrap
MF  Ts scrap
MF 0
 Actual and Ideal Power Consumption in terms of
Flow exergy
n m m
 T0 
W
in
PPMF  
 prod
MF , j  
 scrap
MF , k   MF  QHS MF 1 
 mat  in
  T0 Sirr, MF
j 1 i 1 i 1  THS 

 T0 
W 
n m m
in
PPMF ideal  
 prod
MF , j  
 scrap
MF , k    mat  Q in
MF HS MF 1  
j 1 i 1 i 1  THS 

Second Law efficiency of a Manufacturing System

 in
WPPMF ideal
 MF second law   in
 
WPPMF
 Degree of Perfection

• DoP is defined as ratio of Exergy rate of useful

products to Exergy flow rate of input material

 prod
 MF  P  material

