goessling2013_thermodynamicsandresourceconsumption
TRANSCRIPT
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65Thermodynamics and ResourceConsumption: Concepts, Methodologies,and the Case of Copper
Stefan Goßling-Reisemann
Abstract
Analysis and minimization of resource consumption is an essential aspect of
sustainability. Engineers in this field need to be equipped with concepts and
methodologies for assessment and sustainable design of products and processes.
Thermodynamics offers these concepts and methodologies. In the current debate
on material flows, the throughput of matter and energy is the primary focus.
Consumption, however, starts when material and energy is transformed and
loses its potential to be useful in further products or processes. On the physical
level, this loss of potential utility is well described by entropy production or
exergy destruction, two related concepts from thermodynamics. Using these
concepts, methodologies for analyzing resource consumption were constructedand have been successfully applied to a large number of processes, products,
and services. Here, a very brief introduction to thermodynamics is given to
enable the interested reader to understand the underlying concepts and help in
the application of thermodynamics to analyze resource consumption. Established
measures for resource consumption can be grouped into those approaches which
are based on the first law of thermodynamics (the conservation of energy
and matter) and those approaches which are based on the second law of
thermodynamics (entropy production and the devaluation of energy and matter).
A brief summary of the currently used approaches is given and how they
relate to the thermodynamic interpretation of resource consumption. Exergy and
entropy analysis are introduced as analytical tools and also briefly explained,
with recommendations for further self-study to get more familiar with the
methodologies. An example, copper making from sulfidic ore concentrates is
presented as a case study for the application of entropy analysis, and the results
S. Goßling-Reisemann
Faculty of Production Engineering, Division of Technological Design and Development, artec jResearch Center for Sustainability Studies, University of Bremen, Bremen, Germany
e-mail: [email protected]
J. Kauffman, K.-M. Lee (eds.), Handbook of Sustainable Engineering,
DOI 10.1007/978-1-4020-8939-8 54,
© Springer Science+Business Media Dordrecht 2013
1263
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1264 S. Goßling-Reisemann
are compared to results from other (exergy) analyses. Finally, an interpretation of
entropy production in the context of ecological sustainability and finite resources
is offered, based on the finite entropy disposal rate of the earth, which enables
the reader to evaluate the meaning of the presented results.
1 Introduction
Decreasing resource consumption is a cornerstone of sustainability. Especially
engineers in the field of sustainability need to have a clear concept of how to assess
and how to optimize resource consumption in complex technological settings. Of all
subdisciplines in engineering and the natural sciences, thermodynamics offers the
most suitable set of concepts and methodologies to help the engineer in this respect.As will be shown, entropy production or exergy loss is the concept that delivers the
best physical interpretation of resource consumption and should thus be used as a
measure when assessing resource consumption. The respective methodologies are
well developed in the literature and accessible to everyone with a background in
engineering or the physical sciences.
2 Throughput Versus Change in Quality
When talking about resource consumption, two aspects have to be distinguished:
throughput of matter and energy and the accompanying change in quality of the
material and energy flows. The current discussion around resource consumptionmainly focuses on the quantity of flows, rarely on their quality. Legislation on
closing material loops, for example, is mainly concerned with increasing the amount
of materials circling within the economy, and the success of recycling strategies
is measured by the increase in recovered tons of materials. The quality of the
returned materials is only rarely assessed or included in recycling strategies, and
also the economic or technical importance of the primary and secondary materials
is not (yet) considered in most legislative approaches toward sustainable resource
management. Regarding the importance of primary resources, this seems to be
changing lately, visible by the many studies on critical or strategic materials being
commissioned by governments around the globe (e.g., NRC 2008; Angerer et al.
2009; European Commission 2010). For secondary materials, the discussion of
quality is equally important, especially since it is the quality of the recyclates that
determine the options for reuse. The problem of diminished quality is especially
pronounced for metals: impurities in bulk metals, known as tramp elements, threaten
the goal of a closed loop economy (Janke et al. 2006; von Gleich 2006; Amini
et al. 2007). As long as there are sufficient primary resources available, the focus
on quantities is understandable. The situation changes when there is a need to
significantly increase the amount of circulated material. The natural tendency
of recycling processes is that materials are becoming mixed and the material
dissipation increases. However, dissipation of materials can be avoided by clever
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65 Thermodynamics and Resource Consumption 1265
organization of material flows by appropriate dismantling of products and by a
thermodynamically optimized process design. Keeping the quality of recyclates up
is thus a matter of organization, interfaces between members of the recycling chain
and intelligent process design (Castro et al. 2004; Reuter et al. 2005; Hageluken
et al. 2005; Hageluken 2007).
Thermodynamics can offer some help in assessing and designing material
transformation processes, from primary extraction to recycling, for better efficiency
and effectiveness. The main rationale behind the thermodynamic approach is that
the “usefulness” of matter and energy flows depends on their actual physical and
chemical state. The change in thermodynamic states is what constitutes resource
consumption, as is explained in the next sections.
3 Resources and Consumption
The conventional interpretation of physical resources is based on the assumption
that they are delivered by the surroundings, the natural environment in most cases,
and are somehow “used up” in a process called resource consumption. This sounds
like they would be “gone” after they have been used, which is definitely not the
case, as every physicist or chemist would be eager to point out. The laws of physics
dictate that the sum of energy and matter in any given process stays fixed (see any
basic physics textbook, as, e.g., Feynman et al. 2009). For nonnuclear processes
(no fission, no fusion), energy and matter are even conserved individually. So how
can one speak about consumption then? Merriam-Websters dictionary explains(economic) consumption as “the utilization of economic goods in the satisfaction
of wants or in the process of production resulting chiefly in their destruction,
deterioration, or transformation” (Merriam-Webster 2011).
The key message here is that economic goods are destroyed or deteriorated, that
is, they lose some of their functionality or their “potential utility” (cf. Goßling-
Reisemann 2008a). The “potential utility” is a theoretical concept describing the
amount of useful applications of goods or material and energy flows. A given set of
goods or flows have a limited number of potential uses, depending of course on the
ingenuity of the user and the tools available. Once these goods and flows have been
used for a certain product or service, they cannot be used for something else, unless
one invests more goods and flows.
The simplest example is that of a certain amount of wood, water, and energy
(plus the right tools): you can convert them into paper, using up all the material and
energy flows, but then you could not produce any alternative products anymore, like
furniture, for example. You could have chosen to build a boat instead or a wooden
hot tub but either way: once you have decided on one product path, there is no
turning back. Well, almost no turning back: when you are willing to burn some of
the furniture, you could produce enough energy to convert the rest of the furniture
(and the left over water) into paper, but you will not gain as much paper as you
would have by using all of the wood for papermaking in the first place.
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The purpose of this little thought exercise is to highlight the importance of the
irreversible nature of consumption. It also shows that consumption is a gradual
concept: goods can be partly consumed and partly remain in the products which have
been produced from them. The degree of consumption obviously has some relation
with the irreversibility of the transformation of the goods. The examples here
were deliberately oversimplified: in reality, you would need many more material
resources to producepaper from wood and water, for example. Also, one should note
that the transformations leading to the loss of potential utility cannot in all cases be
quantitatively linked with the actual loss of potential utility. Small transformations
can have dramatic consequences for the usability of the economic goods involved,
like in the case of dispersing a tiny amount of toxic substances with drinking water.
The main observation remains true, however: consumption is about irreversible
transformations.The irreversibility of the consumption process is a defining characteristic and
thus a good starting point for measuring consumption itself. In economics, it
was Georgescu-Roegen who first drew attention to this (Georgescu-Roegen 1971),
leading to a scientific debate about resources and their finality which still goes on
today (see, e.g., the discussion between Arrow et al. (2004), Daly et al. (2007) and
Arrow et al. (2007)).
This chapter is concerned with physical resources, not economic goods. How-
ever, the meaning of consumption is basically the same: it is about irreversibly
changing the structure and quality of material and energy flows making them
less available for further processing. Taking the above dictionary definition as
a starting point and applying it to physical resources, the key to understanding
(physical) consumption lies in understanding the changes in the physical resourcesby destruction, deterioration, or transformation.
When the above definition of consumption is applied to all process stages from
extraction of resources to disposal and recycling of discards, it becomes clear that
all material and energy flows can be interpreted as resources, although to a different
degree. Thus, consumption is not localized to one defined area of the economic
system (as it might appear from the economically motivated dictionary definition),
but is happening wherever there are material and energy flows transformed and thus
lose potential utility.
In summary of the above paragraphs, the terms resource and consumption can
now be defined in a concise and meaningful way for the following discussion:
Resources in this context are to be understood as reservoirs or flows of matter and energy
that are used to produce products and services. Material resources can appear in the form
of raw materials, semi-products, final products, auxiliary materials, or wastes. Energetic
resources can appear as chemical energy stored in energy raw materials, heat, radiation,
potential energy, or any other form of physical energy.
Consumption is to be understood as the transformation of resources resulting in a loss
of possible further pathways for producing products and services. This loss in potential
utility comes about by chemical and physical processes, like dissipation, dilution, mixing,
chemical reactions, structural changes, heat transfer, and others.
Thermodynamics offers the right concepts to measure these kinds of changes in
physical resources, as it is the discipline of physics that analyzes energy and
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65 Thermodynamics and Resource Consumption 1267
material flows with regard to their transformation and conversion (Kondepudi and
Prigogine 1998). The above-mentioned irreversible “loss of potential utility” as a
measure for resource consumption has a more rigorously defined counterpart in
thermodynamics: entropy production. Economic resource consumption can then be
approximated by physical resource consumption, and entropy production can be
introduced as a measure.
4 Thermodynamics Background
Thermodynamics is the discipline of physics dealing with the conversion of energy,
including the transfer of heat and work, and the relation between different state
variables of matter and energy. Its origins lie in the assessment of the consumption of energetic resources and the efficiency of steam machines (Kondepudi and Prigogine
1998). The thermodynamic theory is based on four major laws, which very generally
describe limiting conditions for all physical systems.
The “zeroth” law of thermodynamics describes that any two systems which are
in thermodynamic equilibrium with a given third system are also in equilibrium with
each other (Kondepudi and Prigogine 1998). Thermodynamic equilibrium between
two systems is reached when there are no further driving forces for exchanging
matter or energy. This is equivalent to saying that the corresponding thermodynamic
potential is equal in both systems. For exchanges of heat only, as an example, this is
the case when both systems have the same temperature.
The first law of thermodynamics describes the conservation of energy. In essence,
it says that energy cannot be produced; it can only be converted from one formto another. The energy of a system is usually referred to as the internal energy.
It is given by the sum of all internal kinetic energies (e.g., of the particles
moving with respect to the center of mass) and all internal potential energies (e.g.,
electrostatic energy between charged particles or energy stored in chemical bonds).
For isolated systems, that is, systems with no exchange of matter or energy with
the surroundings, this law implies that the energy of the system stays constant for
all times. For closed systems, that is, systems that have no exchange of matter
with the surroundings, the first law implies that the internal energy can only be
changed by exchanging physical work or heat with the surroundings. For open
systems, additional energy changes can appear by exchanging material flows with
the surroundings. These flows change the internal energy of the system by adding
kinetic energy, gravitational energy, and enthalpy. Enthalpy is formally the sum of
internal energy of the flow and the product of its pressure and volume. Thus, a flow
of matter can add energy to a system by adding, for example, chemically stored
energy or by adding volume at constant pressure.
The second law of thermodynamics describes the devaluation of energy during
material or energetic transformations. In simple terms, it states that, although the
absolute amount of energy in any transformation is always conserved, the “quality”
of the energy decreases. The quality of a given amount of energy is measured by the
amount of physical work one could extract from this energy by ideal (i.e., lossless)
processes. Since the second law states that this quality always decreases, another
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1268 S. Goßling-Reisemann
interpretation is that every conceivable process will always result in the loss of
potential physical work. The mathematical formulation of the second law uses the
concept of entropy as the measure for the “unavailability” of energy. This physical
quantity was introduced by Clausius (1850) to describe the limited efficiency of
steam engines, and he discovered that entropy is only conserved in a process when
the process is reversible. Reversible processes can be run “backwards,” meaning
that the changes in their state variables and all exchanges of matter and energy
with other systems can be passed though in reversed order. Entropy itself is a state
variable, that is, it is only dependent on the state of the system, not on its path of
evolution. It is an empirical observation that there are no reversible processes, even
if some processes can be made to approach reversibility arbitrarily close. Following
Clausius, the second law can be expressed more elegantly with the help of entropy:
The entropy of the universe can only increase and approaches a maximum.
With regard to a certain observed system and its transformational processes,
the following expression of the second law is more helpful (cf. Kondepudi and
Prigogine 1998):
The sum of the entropies of a given system and its environment cannot decrease. They
remain constant only in the (ideal) case of reversibility.
The meaning of the second law goes beyond energy conversion processes, as
could be inferred from its definition. When pure materials are mixed, for example,
the entropy increases, too. The simple interpretation is that the sum of the energies
stored within the pure material flows is generally less available to further processing
when the flows are mixed. The availability can, in the reversible case, remain
constant, but it cannot increase. The irreversibility of the process is obvious from
the fact that one would have to spend additional energy to de-mix the material flows;
a spontaneous de-mixing will not occur.
One consequence of the second law is that in any real process, the availability
of energy can only decrease. The amount of the loss of availability is directly
proportional to the entropy produced during the process. The entropy increase can
be brought about by all kinds of physical or chemical transformations: mixing,
combustion, chemical reactions, phase changes, heat transfer, etc.
The third law of thermodynamics simply states that as the temperature of a
perfect crystal approaches the absolute zero of temperature (0 K), the entropy of
the crystal also approaches zero (Kondepudi and Prigogine 1998). This then defines
the absolute zero of the entropy scale. Real materials do not necessarily satisfy the
“perfect crystal” condition, that is, they do not have a unique ground state. In gen-eral, quantum mechanics predicts “degenerate” ground states for systems containing
particles with half-integer spins (like electrons). Degenerate means, that for a given
energy, several physical configurations of the constituents are possible. Even if
thus the entropy of many systems does not approach zero for the absolute zero of
temperature, the third law defines an absolute zero for entropy. This is different from
the definition of energy, where there is no “natural” zero level and all comparisons
(and measurements!) have to be made with respect to a chosen baseline.
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Especially the first law and the second law have relevancy for assessing resource
consumption. The first law offers a way to close the balance on material and energy
flows entering and leaving a system. It is therefore useful in setting up resource
balances or resource accounts for systems. Balances derived in this way highlight
the throughput of matter and energy as the basis for assessing consumption, without
addressing the change in quality of material and energy flows. The second law,
on the other hand, addresses precisely this defining characteristic of resource
consumption: the devaluation of matter and energy due to transformation of physical
flows.
5 Established Measures for Resource ConsumptionThere have been many attempts to find an adequate measure for resource consump-
tion. These can broadly be distinguished by those measures that are based on the first
law of thermodynamics (conservation of energy or mass) and those that are based
on the second law of thermodynamics (irreversibility and entropy generation).
5.1 Measures Based on the First Law of Thermodynamics
Since the first law of thermodynamics does not address the change in quality of the
materials and energy flows, the methodologiesderived from it cannot really measure
resource consumption as defined above. They rather measure resource throughputor resource use. However, this distinction is rarely made, and, in general, one will
find these methodologies usually being discussed within the context of resource
consumption. The application range of these measures varies from the product or
service level up to the level of nation states and the worldwide economy. A few
typical examples include:
Cumulative energy demand (CED): developed in the 1990s, mainly by the Oko-
Institute in Germany (VDI 1997), it measures the aggregated input of all primary
energy into the production, distribution, use, and disposal of products or services.
Raw material flows are only considered when they are principally suitable as
energy carriers, which include natural gas, crude oil, and rapeseed oil but ex-
cludes, for example, iron ore or freshwater. The CED distinguishes nonrenewable
from renewable energies, like solar, wind, and hydro. The methodology is usually
applied on the product or service level.
Material intensity per service unit (MIPS): developed at the Wuppertal Institute
in Germany and part of the material-intensity-analysis framework (MAIA)
(Schmidt-Bleek and Kluting 1994; Schmidt-Bleek 1998; Ritthoff et al. 2002;
Wuppertal Institut 2011), it measures all material movement associated with
the production, use, and disposal of products or services. The methodology
focuses on the movement of material flows, which are further distinguished into
biotic, abiotic, water, air, and moved soil. Transformation of these flows is not
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1270 S. Goßling-Reisemann
considered. The methodology has been applied to the product level, to regions,
and whole economies.
Direct material input (DMI) and domestic material consumption (DMC): mea-
sures developed within the framework of material flow accounts (European
Commission 2001), used primarily to measure the input and consumption of ma-
terials in national economies. DMI measures all material flows of economic value
(i.e., which are used for production and/or economic consumption, excluding
water) entering a national economy, aggregated on mass basis. DMC is calculated
from the physical trade balance (direct material input less exports) and domestic
extraction of resources. The methodology is typically applied to nation states, but
other regional scopes are used (the methodology is extensively used for assessing
material flows for the EU as a whole, for example).
5.2 Measures Based on the Second Law of Thermodynamics
The approaches based on mass and energy conservation are merely balancing
inputs and outputs without considering qualitative changes in the material and
energy flows. Methodologies based on the second law of thermodynamics can thus
complement these balances by including an actual reference to the consumption as
defined above: the loss of potential utility.
5.2.1 Exergy Destruction as Resource ConsumptionThe methodologies that do consider the loss of potential utility can broadly be those
using entropy production as a concept and the ones using exergy loss or exergy
destruction. In essence, the two approaches are equivalent, as can be seen from the
definition of exergy (cf. Rant 1956; Szargut et al. 1988; Brodyansky 1994).
The exergy of a flow of matter or energy is the quantity of work which can be extracted
from it by reversible interactions with the environment until complete equilibrium (with the
environment) is reached (based on the definition in Brodyansky 1994).
The exergy of a system is thus dependent on the state of its environment, which must
be individually defined for each system under investigation. Furthermore, exergy has
the same units as energy, but it is not a conserved quantity, very much like entropy.
The difference is that while the entropy of an isolated system is always increasing,
its exergy is constantly decreasing. In an isolated system, exergy can be destroyed,
but never be created. This feature makes exergy destruction a promising candidate
for measuring resource consumption.
The (specific) exergy flow " of a material flow can be partitioned into different
contributions, reflecting the physically independent equilibration processes: poten-
tial, kinetic, thermal, mechanical, and chemical exergy:
" D "pot C "kim C "th C "mech C "chem:
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The potential and the kinetic exergy of a flow are equal to its potential and kinetic
energy. The thermal contribution "th is the work rate extractable by reversible
processes when bringing the material flow to thermal equilibrium with the reference
environment without changing either its composition or its other thermodynamic
parameters. The mechanical contribution "mech is defined similarly for the work rate
obtainable from reversible equilibration of pressure differences. The sum of "th and
"mech is also called physical exergy and denoted "ph. It can be derived from the
specific enthalpy h and the specific entropy s of the flow
"ph D "mech C "th D PmŒh h0 T 0.s s0/
where the subscript 0 denotes the values in the reference state of the environment
and Pm is the mass flow rate (mass/time).
The chemical exergy flow rate of a material flow can be obtained from analyzing
the chemical reactions leading from the material flow’s chemical composition to
the chemical composition of the reference environment. This can be achieved by
using the chemical potentials of the flow’s components j at reference temperature
T 0; j 0, the component’s chemical potential in the reference environment,j 00, and
the respective mass fractions xj of the components:
"ch D PmXj
.j 0 j 00/xj :
The reader is referred to the books by Szargut et al. (1988) and Brodyansky (1994)
for a detailed description.
The exergy flow "qs of a heat flow q across a surface area s at temperature T s is
obtained from the Carnot factor:
"qs D
1
T 0
T s
q:
With the above expressions, the exergy flow balance of a steady-state system can be
set up, and the exergy destruction is obtained from
Xi
"ini
Xi
"outi
Xs
"qs PW PI D 0;
with "ini denoting the various incoming exergy flows, "out
i outgoing exergy flows,PW physical work (rate), and PI denoting exergy consumption rate. For nonsteady-
state systems, the 0 on the right hand side has to be replaced by "sys the exergy
change of the system itself. With the help of the Gouy-Stodola theorem, the exergy
consumption rate can be related to the entropy production PS rate of the system:
PI D T 0 PS:
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Exergy analyses have been performed on many systems, with the longest and most
successful tradition in analyzing and optimizing energy conversion technologies
and chemical processing (see Brodyansky 1994; Kotas 1995; Szargut 2005; Borel
and Favrat 2010), and are now successfully applied to assess natural resources
and resource consumption in life-cycle assessments (Bosch et al. 2007; Dewulf
et al. 2007) and in natural resource accounting and analysis (see the extensive
bibliography on http://www.exergoecology.com).
5.2.2 Entropy Production as a Measure for Resource ConsumptionAs discussed above, entropy production can serve as a proxy for resource consump-
tion by measuring the decrease in thermodynamically allowed pathways for utilizing
material and energy flows. Entropy is not a conserved quantity, as was also true for
exergy; thus, the balance equation for any real process must include a productionterm for entropy. In general, the change in the entropy of a system can be partitioned
into the entropy being exchanged with the system’s environment, eS sys, and the
internally produced entropy, iS sys (Kondepudi and Prigogine 1998):
S sys D eS sys CiS sys:
In the case of ideal, that is, reversible, processes, the internal production term is
zero. In all real processes, however, entropy is produced. In many cases, the entropy
change of the system itself can be neglected .S sys D 0/. This is especially true for
steady-state processes, where the system state is static, or cyclic processes, where
the system is repeatedly going through the same states such that for an appropriately
chosen time interval, the net change in entropy is zero. The latter definition holds,for example, for batch processes.
A general process can be thought of as a control volume with material flows Pmk(mass/time), heat flows eq (energy/time), and radiation flows es (energy/time) enter-
ing and leaving the system. The thermodynamic measure for resource consumption
is then given by the internally produced entropy. With S sys D 0 (steady-state or
cyclic process after full number of cycles), this quantity can be calculated from the
entropy balance (cf. Goßling 2001):
iS D
Z d iS
dt
dt D
Z 0@eoutq
T 0einq
T 0CXj
4
3
eouts;j
T outs;j
CXj
4
3
eins;j
T ins;j
Xk
sk Pmk
1A dt
where the e in;outq are the heat flows in and out of the system, respectively, e
in;outs;j are
the incoming and outgoing flows of (assumedly black body) radiation
received/emitted at surface area j , with T in;outs;j being the temperature of the
received/emitted radiation, and sk being the specific entropy of material mk.
5.2.3 The Energy BalanceWhen it is assumed that the system at hand does not perform physical work on
the environment (and vice versa), the heat flows in the above formula can be
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65 Thermodynamics and Resource Consumption 1273
derived from balancing the enthalpy of the incoming and outgoing flows, including
the incoming and outgoing radiation, and correcting for the internally dissipated
electrical energy eelq :
einq eout
q D eelq ein
s C eouts C
Xk
hk Pmk
with hk being the specific enthalpy of material mk. The emitted radiation flows eouts
can be derived from the temperature of the partial surface areas Aj with uniform
temperature (Kondepudi and Prigogine 1998):
eouts D
Xj
Aj.T outs;j /
4
where sigma is the Stefan-Boltzmann constant. The same formula holds for the
received radiation when the temperature is exchanged accordingly. The radiation
energy balance then becomes
eouts ein
s DXj
Aj h.T outs;j /
4 .T out
s;j /4i:
In many metallurgical and chemical processes, the temperature of the reaction
vessels is comparatively low (e.g., below 100ı
C) so that the radiation losses mightbe omitted. The heat balance is then determined by the electrical energy dissipation
and the enthalpies of the material flows.
The specific enthalpy of a material flow depends on its composition, and for ideal
mixtures, it is simply the weighted sum of the specific enthalpies of the components
of this mixture. For nonideal mixtures, the enthalpy of mixing has to be included.
5.2.4 Material Entropy FlowsAfter having settled the energy balance with the help of the above equations (heat,
radiation, enthalpy), the next step is determining the material entropy flows to
calculate the entropy production within the system under investigation. This can be
done with the help of tabulated values of molar entropies (or molar heat capacities)
found in thermodynamichandbooksand databases (see, e.g., Haynes and Lide 2010;CRCT 2011; Linstrom and Mallard 2010; Barin 1995). The specific entropy sk of a
material flow mk can then be calculated from the molar composition of the flows,
given by the molar amount nk in flow k, the respective molar share ykj of each
component j in this flow, and the molar entropy Nsj of the component j :
sk D1
mk
8<:Xj
nkykj Nsj R
Xj
nkykj ln.yki /
9=;
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1274 S. Goßling-Reisemann
with R being the universal gas constant (8.314472J/K/mol). The latter sum in the
above formula represents the entropy of mixing and is solely due to the mixing
of components in the material flow. The entropy of mixing can also be used for
assessing the quality of material flow management systems, for example, in waste
incinerators (Rechberger 1999), in recycling processes (Goßling-Reisemann et al.
2011), or on the level of economy-wide substance flows (Rechberger and Graedel
2002).
6 Application Example: Copper Production
6.1 Entropy Production
As an example for the application of using thermodynamics for assessing resource
consumption,the entropy production of copper production is presented (cf. Goßling-
Reisemann 2008b). The analysis is based on a process model describing the
mining and beneficiation of sulfidic copper ores and the metallurgy of these ores
to produce copper cathodes. The metallurgy itself consists of four main stages:
flash smelter, converter, anode furnace, and electrolysis, which are part of this
analysis. Other downstream processes are not considered: the offgas is further used
for the production of sulfuric acid as a by-product, residues from the electrolysis
are further treated to extract valuable metals, and the slag is processed to be used
as a construction material. The material flows most relevant for the calculation of
resource consumption for 1 t of refined copper are given in Table 65.1.The calculation of the entropy production proceeds as outlined in the previous
section: material compositions need to be established, energy flows have to be
calculated (enthalpy, heat, and radiation), and then the entropy balance can be
calculated. Since the system itself is not changing its entropy during the production
of copper, the steady-state condition is met, and the entropy production can be
calculated from the entropy balance.
As an example, consider the composition of the ore concentrate as given in
Table 65.2. The components of the concentrate have specific entropies which can be
looked up in thermochemistry tables (e.g., Barin 1995; Linstrom and Mallard 2010;
CRCT 2011), and the mixing contribution to this material’s entropy is calculated
from the formula given in the previous section.
As with the ore concentrate, all flows are evaluated and can then be analyzed. For
visual inspection, a Sankey diagram is most helpful; see Fig. 65.1 for the entropy
flows of the metallurgical stage. One can see at one glance that the entropy flows
associated with the electricity production are the largest in the system, directly
followed by the offgas flow from the converter. The entropy production due to
electricity production for the metallurgical stage can be read off the labels and is
10.4 MJ/K (per ton of refined copper, which is the functional unit in this case).
The entropy production for the mining and beneficiation stage and the metallurgical
processes is given in Table 65.3.
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65 Thermodynamics and Resource Consumption 1275
Table 65.1 Most relevant material flows for mining, beneficiation, and metallurgy of copper
(model description and data sources in Goßling (2001) and Goßling-Reisemann (2008b))
Input Output
Mining and beneficiation
Overburden 76.8 t Overburden 76.8 t
Crude ore 101.2 t Tailings 97.5 t
Final energy 10.7 GJ Ore concentrate 3.8 t
Electricity 8.3 GJ Discarded water 150.0 t
Diesel 2.4 GJ
Fresh water 150.0 t
Lime (CaO) 0.1 t
Metallurgy
Ore concentrate 3.8 t Copper (cathodes) 1.0 tFlux (SiO2) 0.5 t Slag 2.1 t
Final energy 9.1 GJ Offgas (to sulfuric acid plant) 3.9 t
Electricity 1.3 GJ Offgas (to filter/environment) 7.2t
Fossil fuels 7.8 GJ
Electricity production (for mining, beneficiation, and metallurgy)
Primary energy 25.9 GJ Electrical energy 9.6 GJ
Cooling water 618.4 t Cooling water discharge 223.2 t
Steam 395.2 t
Interpreting these results, it seems noteworthy that the resource consumption
of copper making is roughly halfway split between mining and beneficiationand metallurgy. It must further be noted that the upstream process of electricity
production plays an important role, especially for the mining and beneficiation
stage. This is mainly due to the necessary comminution of the raw ore, which is
facilitated by large mechanical crushers and grinders. Another noteworthy fact is
the importance of material transformations for resource consumption: a large part
of the entropy production in the flash smelter and the converter is brought about
by chemical reactions, mixing, and structural changes and not by converting final
energy carriers into heat, as one might assume. This highlights the importance of
looking beyond pure energy and mass balances for assessing resource consumption.
The heat losses in the offgas treatment deserve a closer look, as well. The
resulting entropy production, and thus resource consumption, is due to energy
transformations, that is, the transfer of heat across a finite temperature difference.
However, there are other factors influencing the entropy production associated with
handling the offgas flow: (a) a large amount of cooler ambient air is mixed with the
converter and anode furnace offgas due to the batchwise operation of these furnaces
and (b) the different offgas flows from flash smelter, converter, and anode furnace
have greatly differing temperatures, and the mixing of these flows thus produces
additional entropy. If the mixing with ambient air could be prevented and these
flows would be kept separate, the overall resource consumption could be decreased
by approximately 6 MJ/K or almost 7% of the metallurgical resource consumption.
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1276 S. Goßling-Reisemann
T a b l e
6 5 . 2
C o m p o s i t i o n o
f t y p i c a l o r e c o n c e n t r a t e , m o l a r e n t r o p i e s o
f t h e c o m p o n e n t s , a n d s p e c i fi c e n t r o p y o f t
h e c o n c e n t r a t e . C o m p o s i t i o n d e r i v e d f r o m
e l e m e n t a l c o m p o s i t i o n ( D a v e n p o r t a n d P a r t e l p o e g 1 9 8 7 ) a n d r e c a l c u l a t e d t o a c c o u n t f o r c h e m i c a l c o m p o u n d s t y p i c a l l y f o u n d i n o r e s ( c f . G ¨ o ß l i n g 2 0 0 1 )
( E n t r o p i e s t a k e n f r o m B a r i n
( 1 9 9 5 ) a n d L i n s t r o m a n d M a l l a r d ( 2 0 1 0 ) )
C o m p o n e n t
C u F e S 2
S i O 2
C
A l 2 O 3
Z n S
P b S
H 2 O
A s 2 S 3
N i
C a O
M a s s f r a c t i o n ( w t % )
8 4 :
4 2
7 :
4 0
2 :
3 0
2 :
2 4
2 :
1 2
0 :
3 5
0 :
3 0
0 :
3 0
0 :
0 5
0 :
5 2
M o l a r e n t r o p y ( J / K / m o l )
1 2 5 :
0
4 1 :
4
5 :
7
5 0 :
9
5 7 :
7
9 1 :
3
7 0 :
0
1 6 4 :
0
2 9 :
8
3 8 :
2
M o l a r w e i g h t ( g / m o l )
1 8 3 :
5 2 1
6 0 :
0 8 4 3
1 2 :
0 1 0 7
1 0 1 :
9 6 1 3
9 7 :
4 4
2 3 9 :
3
1 8 :
0 1
5 3
2 4 6 :
0 3 8
5 8 :
6 9 3 4
5 6 :
0 7 7
S u m o f s p e c i fi c c o m p o n e n t e n t r o p i e s ( J / K / g )
0 . 6 7 9
S p e c i fi c e n t r o p y o f m i x i n g (
J / K / g )
0 . 0 9 1
S p e c i fi c e n t r o p y ( J / K / g )
0 . 7 7 0
E n t r o p y o f 3 . 8 t c o n c e n t r a t e
( M J / K )
2 . 9 2 8
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65 Thermodynamics and Resource Consumption 1277
T2:Electricity Mix Germany 428 MJ/K
6.52 MJ/K
29.1 MJ/K
5.05 MJ/K
24.6 MJ/K
10.8 MJ/K
35.3 MJ/K
19.6 MJ/K
5.27 MJ/K
P4:Emissions
P3:Suphuric Acid Plant
P7: Flash smetter slag
P12: Anode slime
P13: Cathodes
P7:Converter slag
51.8 MJ/K
P5:Energy-Resources
P1:MetallurgicalResources
T5:Electrolysis
T4:Anode Furnace
T1:Flash Smelter
T3: Converter
417 MJ/K
P6
Fig. 65.1 Entropy flows of the metallurgy stage for copper production. All arrow widths are
proportional to the respective entropy flow, except for the hatched arrow from electricity mix to
emissions
Table 65.3 Entropy production along the process chain for producing refined copper from
sulfidic copper ore. Basis was the calculation in Goßling-Reisemann (2008b) with improved data
on efficiencies and material compositions. Also the model in Goßling-Reisemann (2008b) has been
updated so that the system border now includes the upstream process of electricity production and
the heat loss from the offgas treatment
Stage Entropy production (per ton of refined copper)
Mining and beneficiation
Direct processes 36.9 MJ/K
Electricity production (upstream) 58.0 MJ/KMetallurgy
Flash smelter 18.2 MJ/K
Converter 15.8 MJ/K
Anode furnace 8.7 MJ/K
Electrolysis 4.4 MJ/K
Electricity production (upstream) 10.4 MJ/K
Offgas treatment (heat loss) 33.0 MJ/K
Sum 185.3 MJ/K
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1278 S. Goßling-Reisemann
Technically, this is probably not fully feasible, but there are options for optimization:
the temperature difference between the flows and the surroundings could be used
for energy recovery (e.g., by producing steam or electricity), and the anode and
converter furnace can be equipped with more efficient offgas capture systems. Once
the flows have a uniform temperature, their heat content can further be used in heat
recovery systems, as long as their temperature does not fall below the optimum for
the subsequent sulfuric acid plant.
6.2 Comparison with Other Assessments
There have been other attempts at using thermodynamics to assess the resource
consumption of copper making. Most of them have used exergy analysis, but theresults are comparable since the entropy production can be calculated from the
exergy destruction via the Gouy-Stodola equation (see above). One of the earliest
studies was performed by Kolenda et al. (1992), in which three distinct processes
of copper making were analyzed: blast furnace, converter, and anode furnace.
The blast furnace is an outdated technology, which explains the poor results of
the exergetic analysis. A comparison with the entropy analysis above is given in
Table 65.4. Taking into account the distance in time between the two analyses (the
data in Goßling-Reisemann 2008b is from between 1999 and 2006), the agreement
is quite good, and the differences are probably explained by improvements in
process technology (note that the upstream process of electricity production and
the downstream process of offgas treatment are not included).
Another exergy analysis was performed by Ayres et al. (2006) with a technolog-ical setup very close to the one analyzed here and with data from around the same
period (around 1999). A comparison of their results with the one presented here
can be found in Table 65.5. The differences are quite remarkable and can only be
explained with more detailed knowledge of the processes analyzed. It is interesting
to note, however, that the ratio between entropy productions in the metallurgy stage
and the mining stage is between 1.27 and 1.40, respectively, and is thus in fairly good
agreement. This probably indicates a systematic difference between the process
models.
Table 65.4 Comparison of entropy production from an analysis performed by Kolenda et al.
(1992) with the analysis presented in this chapter (updated model of G oßling-Reisemann (2008b))
Kolenda et al. (1992) Goßling-Reisemann (2008b) + model update
Blast furnace 39.2 MJ/K/t Flash smelter 18.2
Converter 17.1 MJ/K/t Converter 15.8 MJ/K/t
Anode furnace 11.0 MJ/K/t Anode furnace 8.7 MJ/K/t
Total 67.3 MJ/K/t 42.7 MJ/K/t
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65 Thermodynamics and Resource Consumption 1279
Table 65.5 Comparison of entropy production from an analysis performed by Ayres et al. (2006)
with the analysis presented in this chapter (updated model of Goßling-Reisemann (2008b)). Note
that in the data taken from Ayres et al., upstream and downstream processes (electricity production
and offgas treatment/sulfuric acid production) have not been included to achieve comparable
system boundaries
Process stage Ayres et al. (2006) Goßling-Reisemann (2008b) + model update
Mining and beneficiationa 99.1 MJ/K/t 36.9 MJ/K/t
Metallurgy a 138.6 M J/K/t 47.1 M J/K/taOnly direct entropy production
6.3 Interpretation of Entropy Production
Interpretationof the results from thermodynamicanalyses can be done with different
goals. Historically, thermodynamics was used to optimize processes, most notably
energy conversion processes. This is still the main application also of analyses using
exergy or entropy (see, e.g., the long-standing tradition of the ECOS conferences
– International Conference on Efficiency, Cost, Optimization, Simulation, and
Environmental Impact of Energy Systems). In the paragraphs above, however, the
focus is explicitly on resource consumption of products, processes, and services
under a life-cycle perspective. The goal is to find an answer to the question of
how much resources are going to be destroyed in the satisfaction of a specific
demand. If different products or services are to be compared, the absolute amount
of resource consumption is less important; only the relative differences are relevant
for a decision. Still, the absolute value of the entropy production or exergy loss hasmeaning, too.
As stated above, exergy and entropy are not conserved. The exergy available
for economic processes is limited mainly by the regeneration rates of terrestrial
resources, which again is dependent on the solar irradiation rate. For entropy,
something similar holds. Every living system is dependent on the expulsion of
the internally produced entropy (Ebeling et al. 1990; Glansdorff and Prigogine
1971; Nicolis and Prigogine 1977), or otherwise it collapses under accumulating
entropy waste. This expulsion rate is usually limited, for example, by physical limits
to the exchange of material and energy with the environment. The development
of lakes, amphibian eggs, and humans has been studied in this respect (Aoki
1991, 1995, 2008), and the analysis shows that the entropy production rate of these
biological systems varies with the developmental stage: early in their life, these
systems steadily increase their entropy production rate until it reaches a maximum,
after which the organisms seem to gradually optimize their resource consumption
and the entropy production rate converges toward a much lower stable value. If
this is translated into economic terms, nature seems to favor material growth in
early stages of development, without concern for resource consumption at all. In
later developmental phases, however, efficiency and resource conservation are the
guiding principles.
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1280 S. Goßling-Reisemann
How does this relate to the global economic system? Firstly, also the entropy
disposal rate of the earth is limited. The disposal of entropy occurs mainly via
the emission of long-wave radiation from the earth atmosphere into space. For
the current biophysical conditions, including the earth’s surface temperature, the
average entropy disposal rate of one square meter of surface area is around 1.2 W/K
(cf. Goßling-Reisemann 2008b). For different conditions, this might change; for
example, a higher surface temperature might change the atmospheric system and
induce currently unknown convective patterns in the atmosphere, leading to a higher
disposal rate of entropy. However, the transition from the current state of the climate
system to the “improved” state probably comes with intermittent turbulence, and the
resulting climatic system might be less favorable to humans than the one us humans
are used to. Precaution thus dictates to preserve the state of the climate system as
much as possible. This implies a limit to the amount of entropy produced globally,which in turn basically fixes the amount of entropy we as humans should be allowed
to produce. There is currently no rigorously defined limit for the sustainable human
entropy production rate, but for the argument of resource conservation, it suffices
to know that there is a limit at all. If there is consensus that the average entropy
production density on earth should not be above 1.2W/K/m2, this “natural” limit can
be used to give the entropy production of economic processes a new meaning, and
it can simultaneously be used as a “yardstick” to compare the entropy production of
all processes.
The above example calculation of the resource consumption for copper making
can be compared to this yardstick. The entropy production of 185.3 MJ/K per ton
of refined copper corresponds to the yearly disposal capacity of approximately
5m2
of earth’s surface. The global annual copper production in 2004 was about10 million tons, according to Graedel et al. (2004). This would imply the permanent
“occupation” of approximately 50 million m2 or 50 km2 of earth surface. For
comparison, the world primary energy consumption rate in 2008 was approximately
15 terawatt (BP 2009). If it is assumed that the primary energy is almost completely
transferred into heat at ambient temperature, the resulting “entropy footprint”
amounts to around 42;000 km2.
In this manner, human activities and economic processes can be evaluated against
a naturally given limit, and the resource side of sustainability can be assessed by
using thermodynamic principles and measures.
7 Further Reading
The application of thermodynamics for process evaluation is not limited to the
question of resource consumption, although there is a current scientific debate
around that topic (Connelly and Koshland 2001a, b; Seager and Theis 2002;
Goßling-Reisemann 2008a, b). As noted above, thermodynamic analysis, especially
exergy analysis, was most successfully applied in the design and optimization of
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65 Thermodynamics and Resource Consumption 1281
energy conversion systems (see Szargut et al. 1988; Kotas 1995; Bejan et al. 1996;
Szargut 2005; Borel and Favrat 2010).
Along the same lines, but on a more general level, entropy analysis has been
suggested to be used in finding the optimal design of a broader class of processes.
Bejan introduced entropy production (he uses the term entropy generation) as a
means of thermodynamically assessing and optimizing the losses connected with
heat transfer, fluid flow, and mass transfer irreversibility (Bejan 1996). Bejan’s
entropy generation minimization (EGM) approach is basically a way to optimize
the design of systems and to assess their efficiency. It requires knowledge of the
geometrical setup of the machines and the thermodynamic properties of the internal
flows of matter and energy inside the analyzed system (or model).
Exergy analysis is still developed further and finds its ways into ever more
applications. It is combined with economic evaluation in the field of exergoeco-nomics (Tsatsaronis 1999; Rosen 2010), and it is also used within the field of
life-cycle assessment (Cornelissen 1997; Cornelissen and Hirs 2002; Dewulf and
van Langenhove 2002a, b; Stewart and Weidema 2005; Bosch et al. 2007). Also
entropy analysis is applied to life-cycle assessment (Goßling-Reisemann 2011).
8 Summary
Exergy and entropy analysis have experienced a great success in application
throughout the recent decades in the fields of chemical engineering, energy con-version, and general technological design. However, there were comparatively less
applications as an approach toward measuring resource consumption. Resource
consumption is most often discussed within the field of life-cycleassessment (LCA),
a highly standardized methodology for assessing environmental impacts of products
and services. Despite decades of methodological development of LCA and at least
20 years of successful application of this methodology, there is still no consensus
on what resource consumption really is and how it should be included in LCA. The
main reason seems to be the high data requirements for thermodynamic analysis
in combination with the wide scope of typical LCA applications. First steps in
building a basis for future thermodynamic analysis in LCA have been made, for
example, by adding exergy values of natural resources to an LCA database (Bosch
et al. 2007), but the use of this data is still demanding and far from common
practice. Combining LCA databases with more general thermodynamic databases
might be another approach which might lead to a more widespread use of the
thermodynamically defined concept of resource consumption in LCA (cf. G oßling-
Reisemann 2011). Still, exergy and even more so entropy remain rather abstract
measures and need to be better communicated as valuable concepts for assessing the
material side of sustainability to a broader audience, especially engineers concerned
with sustainability.
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1282 S. Goßling-Reisemann
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