The evaporation unit generated the highest irreversibility of 100 MJ/ton of cane, while crystallization unit had the lowest functional exergy efficiency of 9.6% and the highest potential for improvement of 47.0 MJ/ton of cane. The overall sugar mill irreversibility and functional exergy efficiency were 217.3 MJ per ton of cane crushed and 9.7%, respectively. The exergy analysis of the cogeneration system, which has been found to be the principal sugar mill exergy destruction unit, is conducted separately and will be presented in a subsequent paper. The exergy analysis was based on rigorous mass and energy balances calculated from an Aspen PlusĀ® simulation of a typical 250 ton per hour sugar mill, along with an appropriate exergy methodology. This study presents a comprehensive exergy analysis of cane sugar production processes to identify inefficient components for improvement. Sugar mills are energy-intensive and historically not designed to be energy efficient, even though they may be energy self-sufficient. The sugar industry is the second largest agro-industry in the world, with more than 80% of sugar produced from sugarcane.
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