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Fundamentals of Exergy Cost

A. Valero
Accounting and
L. Serra Thermoeconomics. Part II:
J. Uche1
e-mail: javiuche@unizar.es
Applications
CIRCE Foundation Part II of this paper develops the mathematical formulations of three applications of the
(Centre of Research for Energy Resources thermoeconomic analysis methodology described in Part I of the paper: the operation
and Consumptions)/University of Zaragoza, diagnosis study, including new concepts that helps to separate different contributions to
c/Mara de Luna 3, those inefficiencies; the local optimization process in case of special conditions for the
50018 Zaragoza, Spain whole plant, and the benefit maximization (a direct application of the exergy costs ac-
counting analysis). The operation diagnosis, which is the most complex and sophisticated
application, is presented with the help of an example: the co-generation plant, as it was
described in Part I. DOI: 10.1115/1.2134731

m
Introduction E0 * g j
Exergy Cost Accounting and Thermoeconomics finds out how xi
= k x
i=1
j
i
1
energy and resources degrade, which systems work better, how to
improve designs to reduce consumption and prevent residues from which expresses the effect on additional resource consumption
damaging the environment. Assessing the cost of the various when an internal parameter xi is modified.
streams and processes in a plant helps to understand the process of In order to clarify the explanation of the proposed method we
cost formation, from the input resources to the final products. use the simple example a more complex one applied to a real
Despite of their importance and the valuable and useful infor- power plant can be found in Valero et al. 1 presented in Part I,
mation they provide, the exergy and/or thermoeconomic costs of a the co-generation plant depicted in Fig. 1 of Part I, whose design
complex system are only the tip of the iceberg in Thermoeconom- and operational exergy flow values are shown in Table 1. The
ics. They are the starting point for further thermoeconomic appli- plant has two products: process steam in the Heat Steam Recovery
cations. In this Part II are presented the fundamentals of thermo- Generator HRSG, flow 7 together with the electric energy pro-
economic diagnosis and optimization of complex energy systems, duced in the turbo-generator flow 6.
including local optimization and benefit maximization. Special at-
tention is focused to the inefficiency diagnosis because it requires Technical Exergy Saving. Once the exergy flows have been
the introduction of new concepts: induced and intrinsic malfunc- supplied by an appropriate performance test or a model simulator,
tions, and dysfunctions. the irreversibilities in each productive unit can be obtained from
the exergy balance. But not all exergy losses can be saved in
practice. In fact, the potential exergy saving is limited by technical
Operation Diagnosis and/or economic constraints. It also depends on the decision level
Diagnosis is the art of discovering and understanding signs of that limits the actions to be undertaken. In contrast to conven-
malfunction and quantifying their effects. In the case of Exergy tional thermodynamic analysis, Exergy Cost Accounting and
Cost Accounting and Thermoeconomics, the effect of a malfunc- Thermoeconomics assume a reference situation of the plant oper-
tion is quantified in terms of additional resources consumed to ating under optimized design conditions. From this perspective, in
obtain the same production, both in quality and in quantity. To do the co-generation plant Fig. 1 of Part I only 133 kW e.g.,
that, it is needed: 11914-11781 of the 7.06 MW of total irreversibilities e.g.,
11914-2500-2355 can be saved with respect to design optimized
A procedure that accurately determines the state of the plant conditions.
a simulator or Data Acquisition System could provide Therefore, the additional fuel consumption can be expressed as
enough data to perform the mass, energy, entropy and ex- the difference between the resource consumption of the operating
ergy plant balances. plant and the resource consumption for a reference or design op-
A theory to provide the concepts and tools to understand and timized condition with the same production objectives:
explain the causes of this state.
FT = FT FT0 2
The methodology presented here is based on the Structural
Theory formalism presented in Part I to provide the tools to in- and it can be broken up into the sum of the irreversibilities of each
vestigate the causes of the irreversibilities and the cost formation process unit:
process. The basis of the inefficiency diagnosis is focused on the
n n
marginal cost k* when production is modified: applying the
chain rule of mathematical derivatives, we can get to the equation FT = IT = I I = I
j
0
j j 3
1 j=1 j=1

However, even though the methods based on Second Law Analy-


Contributed by the Petroleum Division of ASME for publication in the JOURNAL OF
sis 2 and Technical Exergy Saving are useful to quantify the
ENERGY RESOURCES TECHNOLOGY. Manuscript received February 28, 2005; final additional fuel consumption, they fail when trying to identify the
manuscript received July 8, 2005. Review conducted by Andrew K. Wojtanowicz. real causes of the additional resources consumption.

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Table 1 Design and operation exergy flow values of the co-generation plant Fig. 1, part I

Flow kW 1 2 3 4 5 6 7 8

Design 11 781 2704 9614 3831 2977 2500 2355 388


Operation 11 914 2758 9753 3887 3056 2500 2355 424

Impact on Resources Consumption. The fuel/product diagram calculated following Eq. 4, as is written in Table 4.
is the source point to start up the diagnosis of a complex system. Equation 18 in Part I is used to obtain the increment of the
Once it is built for the design and operating conditions, Eqs. 14 total resources of an operating plant with respect to the reference
and 15 of Part I are automatically solved and then the diagnosis conditions:
can be studied. Table 2 shows the F/P diagram corresponding to
the cogeneration plant of our example. For the sake of simplicity FT = teP0 + teP 5
we did not consider thermal and mechanical exergies as separate The increase of the process unit production from Eq. 15, Part I,
entities. Flow 8, produced in part in the combustor and in the may be expressed in terms of the unit exergy consumption as:
compressor, also leaves the system as a residue. Following the
productive structure depicted in Fig. 2 of Part I, the way to com- P = Ps + KPP0 + KPP 6
plete this table is the following.
hence, applying Eq. 16 from Part I, we obtain:
1st row P0: The only fuel coming from the environment
P0 = E1 is fuel of the combustor F1. P = PPS + KPP0 7
2nd row P1: The product of the combustor P1 = E3 E2 is If we want to analyze the fuel impact due to an increment of the
fuel of the turbine F3 = E3 E4 and the HRSG F4 = E4 exergy unit consumption of the process units, Eq. 5 could be
E8. The auxiliary variable r1 = E3 E2 / E3 corresponds to written as:
the part of the fuel of the turbine coming from the combus-
tor. So the final quantity to put in column F3 is r1 E3 FT = teP0 + t*PKPP0 + t*PPs 8
E4. Similarly, the final value in column F4 is r1 E4 If no change in the total production of the plant is assumed, then
E8. the last term could be neglected:
3rd row P2: The product of the compressor P2 = E2 is also
fuel of the HRSG and the turbine. In this case, the exergy FT = te + tk*PKPP0 9
ratio r2 for multiplying the F3 and F4 columns in row P2 is
or in scalar format showing the ij elements:
r 2 = E 2 / E 3.
4th row P3: The products of the turbine are the net work
leaving the plant F0 = E6 and the work delivered to the
compressor, which is the fuel of the compressor F2 = E5. Table 3 KP matrix for design conditions in the cogeneration
5th row P4: The HRSGs product leaves the cogeneration plant
plant and it is therefore an external output F0 = E7
e 1,7769 0,0000 0,0000 0,0000
In order to bring together the problem of the impact of re-
sources consumption with inefficiency diagnosis we need to know KP 0,0000 0,0000 0,7588 1,0505
the increase of the unit exergy consumption of each process unit 0,0000 0,0000 0,2971 0,4110
0,0000 1,1472 0,0000 0,0000
of the plant j. A performance test or a simulator can provide 0,0000 0,0000 0,0000 0,0000
the actual values of the unit consumptions, which can be com- k 1,7769 1,1472 1,0559 1,4616
pared with the design values or different plant states.
The values of the unit exergetic consumption increase are found
as:
ij = ijx ijx0 4
To do that, the KP matrices in the operating and design condi-
tions are firstly needed, starting from the F/P table see Table 2 for
the design conditions. Table 3 shows the KP matrix for the
design conditions.
The ij values obtained in this table are calculated by dividing
each component of the jth column of the F/P table by the product
P j. Then the ij values for the plant in Fig. 1 can be easily

Table 2 Fuel and energy flows kW in design conditions for Fig. 1 Fuel impact and technical saving
the co-generation plant shown in Fig. 1 part I
Table 4 Increase of unit exergetic consumption 100ij
F0 F1 F2 F3 F4 Total
e 0.4006 0.0000 0.0000 0.0000
P0 0 11,781 0 0 0 11,781
P1 0 0 0 4,156 2,474 6,631
KP 0.0000 0.0000 0.1667 0.3857
P2 0 0 0 1,627 968 2,595 0.0000 0.0000 0.1593 0.4636
P3 2,500 0 2,977 0 0 5,477 0.0000 1.1147 0.0000 0.0000
P4 2,355 0 0 0 0 2,355 0.0000 0.0000 0.0000 0.0000
Total 4,855 11,781 2,977 5,783 3,443 k 0.4006 1.1147 0.0074 0.8493

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n

MFi = Pi0ki = P
j=0
0
i ji 12

Exogenous irreversibility or dysfunction induced DF in the


process unit by the malfunction of other subsystems, which forces
it to consume more local resources to obtain the additional pro-
duction required by the other process units:
DFi = ki 1Pi 13
Fig. 2 Malfunction and fuel impact The malfunction only affects the behavior of the process units; the
dysfunction is a result of how the process units adapt themselves
to maintain the total production. The dysfunction generated DI

FT =
n

k
i=1
n

j=0
P,j ji
*
Pi0 10
by a process unit is defined as:
DIi = Fi MFi 14
Using the above equation, the additional resource consumption Table 5 shows the malfunctions, dysfunctions, impact on fuel and
FT also called Fuel Impact 3 can be expressed as the sum of increase of irreversibility of the example analyzed here. In this
the contributions of each process unit. The KP matrix is the case is not included matrix notation, but using similar equations
key to predict the impact on fuel of a physical variation of a than the previous 5, it should be calculated the dysfunction DFij
parameter in the system, because their coefficients ij represent representing the part of the ith component dysfunction generated
in some extent the efficiency deviation of each plant component by component j. Note that the total DI and DF must be equal, and
with respect to the operating performance of the plant under de- also the total fuel impact and irreversibility generated in the
sign conditions. The total deviation must therefore be multiplied system.
by the total product of that component, e.g. ji P0i which is called Intrinsic and Induced Malfunctions. From results in Table 5,
malfunction. As this product has an exergy cost that depends on we find out three malfunctions in the gas turbine cycle: one each
the position of the component in the system, the malfunction im- in the combustor, compressor and HRSG. But, in fact, the actual
plies an additional fuel consumption or fuel impact due to ineffi- operation values shown in Table 1 only correspond to a 1% de-
ciencies in a system see Eq. 10. crease in compressor isoentropic efficiency. This means that
The proposed method provides the exact values of the addi- HRSG and combustor efficiencies can be changed by varying
tional resource consumption of each process unit malfunction for compressor efficiency; in general there is an operating parameter
any operational state. Other methods, such as the Theory of Per- xr affecting the efficiency of the ith process unit of the plant and
turbations 4, only provide an approximate predictive value, thus, in most cases, also indirectly affecting the efficiencies of the
based on marginal costs Lagrange multipliers which is valid for other plant process units.
an operating state close to the reference conditions. According to their effect on the process units efficiency in a
Figure 1 compares the fuel impact and the increase of irrevers- system, plant operating parameters could be classified as:
ibilities or the technical exergy saving of each process unit and Local variables: They mainly affect the behavior of the process
also compares first column the malfunction and the fuel impact unit related to the variable, e.g, the isentropic efficiency of a tur-
for each process unit. Three malfunctions in the plant are shown bine. From a practical point of view, a variable is considered local
in the combustor, the compressor and the Heat Recovery Steam and therefore related to a subsystem when the total fuel impact
Generator HRSG. The largest irreversibilities increase is in the due to its perturbation is basically located in this process unit.
combustor, but the largest fuel impact is in the compressor. The Global and/or zonal variables: This is the case when an oper-
question that arises is, what causes the irreversibilities increase ating parameter cannot be associated with a specific process unit.
and the fuel impact, and how are they related? We must identify them as operating set points, environmental pa-
Malfunction and Dysfunction Analysis. The degradation of a rameters and the production load or fuel quality.
process unit forces other process units to adapt their behavior in The key of the malfunction analysis is the calculation of the
order to maintain their production conditions and modify their ij components representing the unit exergy consumption in-
irreversibilities. Figure 2 shows how an increase of the unit con- crease of each process unit, due to the variation of an operating
sumption of a process unit will not only increases the irreversibili- parameter xr, is:
ties on it but also the irreversibilities of the previous process unit.
The irreversibility increase of a generic systems process unit is ijr = ijx0 + xr ijx0 15
given by: Therefore, it will be possible to approximate the malfunction of a
I = KDP + KD UDP
0
11 process unit as the sum of the contributions of each operating
parameter:
From the above expression, we can distinguish two types of in-
creased irreversibilities: n

Endogenous irreversibility or malfunction produced by an in-


crease of the unit consumption of the process unit itself:
MFi P
r j=1
r 0
ji i 16

Table 5 Malfunction and dysfunction table in kW

kW Combustor Compressor Turbine HRSG Total

DI 0.000 30.699 4.979 22.243 57.921


DF 46.664 6.849 4.408 0.000 57.921
MF 26.562 28.925 0.408 20.000 75.079
F 26.562 59.624 4.571 42.243 133.000
I 73.226 35.774 4.000 20.000 133.000

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According to the classification of operating parameters, the intrin- the cost of product of the process unit, j, e.g. the consumed
sic malfunction is that part of the process unit malfunction due to resources to produce it, and it could be defined as:
the degradation/improvement of the process unit itself, which is,
in turn, due to variation of local operating parameters:

MFiL
n

rLi j=1
rji Pi0 17 min
k
n

i=0
kijk*P,i P j 19

Thus the difference between total process unit malfunction and


intrinsic malfunction is called induced malfunction. It is due to the where the unit cost of the input resources k*P,i and the production
degradation of other plant process units, which provoke a varia- P j are known and constant. In real world optimization problems,
tion in the unit consumption of that process unit: the design free variables do not necessarily coincide with the tech-
nical production coefficients. In practice there will be a function
MFiG = MFi MFiL 18
of the actual design free variables which can be named, x.
It is important to note that intrinsic malfunctions can provoke not
only dysfunctions but also induced malfunctions. In general, it is We say that a free variable x is a local variable of a subsystem,
understandable that the consequences are noted downstream, but j, when the production coefficients ij of this subsystem only
if the system has one or several recirculations those could be also depend on x. If a design variable is attached to several sub-
provoked upstream of the malfunctioning component or device. systems, the previous expression must be extended to all con-
For instance, using the throttle valve in a power plant can destroy cerned subsystems.
a small additional amount of exergy but the downstream effects To determine whether a design free variable is local or not and
on turbine efficiencies can be quite serious. which process units are involved, the cost resource impact of the
design variables to each process unit can be computed
Thermoeconomic Optimization


In this section are presented two different applications of ther- n
moeconomic costs to the optimization. The first case local opti- ij z P,i
mization is oriented to the design of complex systems. The sec- C0,i
x
= k*P,i + Px 20
x x
ond one benefit maximization is oriented to a cost effective plant i=0

operation and management.


and the ratio calculated:
Local Optimization. The knowledge of the costs of a system,
which in the final instance give an economic meaning to the struc-
tural interactions between subsystems, allows us to formulate
problems related to their optimization and also to solve the opti- Co,j
x
ix = 21

mization of complex systems under certain conditions, in a very n
simple way. The main advantage obtained is that the global opti- Co,i
x
i=1
mization problem of a plant could be reduced to a sequence of
subsystem to subsystem optimization. Here we describe strategies
for optimizing complex systems as proposed by Lozano et al. 4, If this ratio is equal or close to 1, the design variable is local for
they are based on sequential optimization from process unit to process unit, j, if it is equal or close to zero, the design variable
process unit exploiting the information from the thermoeconomic is independent of the referred j process unit. In other cases the
costs of internal flows previously calculated by using the produc- design variable involves several process units. Some other meth-
tive structure. In this section, we see how the cost of the resources ods can be successfully applied if diagnosis has been performed
consumed by the system varies when the unit of the cost of the previously 5.
resources consumed, the technical production coefficients of the These ideas could be used to design a strategy for global opti-
productive structure and/or external demand of products vary. mization problems:
Once we know the relationship between the technical production 0 Determine which variables are local and which are zonal
coefficients and the design free variables the chain rule of deriva- involve several process units.
tion can be applied to distinguish the effect of a design free vari- 1 Determine a sequence for local optimization of each pro-
able on the internal economy of subsystems. cess unit.
Local optimization can be applied only if the optimum solution 2 Take an initial value of the design variables.
obtained for the unit coincides with the optimum solution for the 3 Calculate technical production coefficients and unit product
whole system. Of course, this is a condition that cannot be cost.
achieved in most real systems: the unit cost of the input resources 4 Find optimum values for local variables.
k*P,i and the production P j of the subsystem j should be known and 5 Find optimum values for global variables.
constant, but really P j and k*P,i change when design variables of
other process units change. But the more constant P j and k*P,i are, Iteration from 3 is maintained until the unit product cost does
the fewer iteration loops are needed to achieve the optimal solu- not vary. The decrease of the unit cost of total product must be
tion for the whole system. This condition is similar in some extent verified.
to the thermoeconomic isolation principle 6. Thus, the goal is
Benefit Maximization. Another approach of optimization can
not to achieve fully the condition previously referred to, but to
be done when thermodynamics is joined with the economic con-
approach it as closely as possible in order to obtain the maximum
cept of investment benefit. Price and cost concepts have different
advantages, which include:
nature. The price imposed on a product usually depends on the
1 Improvements and optimal design of individual units in market or political decisions. The cost clearly depends on the
highly interdependent complex systems. physical process and the thermodynamic efficiency of its forma-
2 The design and optimization of highly complex systems are tion process cost is the amount of resources used to produce a
greatly facilitated. unit of product.
Economists aim for maximum benefit. In general, the equation
The objective function to perform the individual optimization is expressing the benefit is:

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Benefitx,y,t = Pricex,t Costy,t 22 components, but once the causes provoking the inefficien-
cies are known the inverse problem of diagnosis. It re-
The temporary factor t could be neglected of the formula in the
mains unsolved the problem when detecting the real causes
two terms of equation, because seasonal demand usually affects
product and production cost. Product cost is the variable that plant provoking the inefficiencies in a plant from direct plant
managers control with operation plans. The y factors are only measurements which is the diagnosis problem, properly,
dependent on operating conditions and make up the unit exergy but new contributions are being introduced 8,9.
consumption k of each component. Thermoeconomic optimization: During the eighties several
The price of a product also involves external factors x that are thermoeconomic optimization techniques have been devel-
independent of the formation cost. The price of a product can be oped 1012. The problem of these techniques is that they
fixed by environmental, local or political reasons. Cost and price were based on the Lagrange Multipliers method, which re-
are often confused since real process costs are unknown in many quires strong computing effort when applied to real plants.
systems and product cost is associated with its price. The cost of Lozano et al. 4 proposed an optimization method, based on
the product depends on how easily it sells marketing, more than local optimization that can be applied to the optimization of
its capacity or quality. real plants in a simpler way because it optimizes separately
These assumptions imply that the benefit of production can be the different plant components. Unfortunately, the plant con-
increased even if the real cost of the products is not the lowest 7. figuration not always permits local optimization, and global
When the price imposed on a product is variable or there are optimization methods are needed. Another optimization ap-
bonuses for different production methods, it is usually useless to proach is the method proposed by Uche et al. 7, oriented to
find the lowest process cost. The managing strategy must control the optimization of the plant operation by maximizing the
the two terms in Equation 22 to maximize the benefit function, economical benefit in plants with several products, as for
taking into account the demand of the plant products electricity instance a cogeneration plant once the cost of those prod-
and steam in the case of the cogeneration plant of our example. ucts are really known.
In this type of problems it is usually obtained that the operating Thermoeconomic synthesis and design: Probably it is the
mode providing maximum benefit depends on price policy, even less-developed application of thermoeconomics because
when plant production demand electricity and steam remain un-
synthesis and design of complex systems becomes much
changed, that is depending on the price policy it is interesting to
more difficult than operation and design optimization. It is
operate the plant in a different way even when the total plant
demand remain unchanged 7. closely related with optimization, and in this case it requires
For an accurate benefit maximization it is very important to costing equations for the different plant components. In this
have available the real operation costs, particularly when prices of field El Sayed 13,14 has made very interesting contribu-
plant products e.g. electricity vary depending on the hour of the tions. When applied to real problems the costing equations
day. should be customized for the specific case to be analyzed.
Some authors 1316 have devoted efforts to the applica-
tion of thermoeconomics to the design and synthesis of
complex energy systems, but there is not developed yet a
systematic procedure. Thus, thermoeconomic design is a
Closure field that also needs further research.
Thermoeconomics is a promising tool of energy analysis. It is
Summarizing, thermoeconomics is not closed at all. It is now a
very powerful, because it contains the concept of energy quality
degradation and it provides a lot of information that conventional very useful and powerful tool for the analysis of complex energy
energy analysis techniques do not. Obviously, the validity of systems. However, a lot of work has to be done for completing the
whatever engineering technique it is not the amount of informa- unsolved problems and probably new applications will be discov-
tion providing, but its ability to solve problems in real plants. In ered in future.
this context, as shown in these introductory papers, Thermoeco-
nomics is able nowadays of answering some questions that con-
ventional energy analysis techniques do not, but it remains a lot of
theoretical and practical work to do.
In our opinion the state of the art of thermoeconomic analysis
applications is the next: Nomenclature
C total economic cost $/s
Exergy cost analysis: Exergy cost accounting provides the DF dysfunction generated in a component kW
costs of all mass and energy flows of a plant in energy and DI dysfunction generated by a component kW
monetary units. These costs are the fundamental tool of E exergy flow kW
whatever thermoeconomic analysis technique. Some appli- F fuel kW
cations, such as those presented in this paper, thermoeco- I irreversibility kW
nomic diagnosis, local optimization and benefit maximiza- k unit exergy consumption
tion, require costs with physical significance. Further k* exergy unit cost
theoretical research is needed in the field of searching the MF malfunction irreversibility increase due to a
procedure for building a productive structure providing inefficiency, kW
costs with physical significance. P product kW
Thermoeconomic diagnosis: Some significant and important r exergy ratio
advances have been made, and a lot of information, such as t time
presented in this paper, can be obtained applying the ther- x, y variables
moeconomic diagnosis technique. The obtained information
is very useful to understand the interactions among the plant Greek
components and to know deeply the plant behavior. How- increment
ever, thermoeconomic diagnosis needs further development. isolation ratio
The state of the art now allows an accurate explanation technical production coefficient
about the reasons that degrade the behavior of the plant exergy efficiency =F / P

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ed., London. 151160.
3 Reini, M., 1994, Analisi e sviluppo dei metodi termoeconomi per lo studio 17 Erlach, B., Serra, L., and Valero, A., 1999, Structural Theory as Standard for
degli impianti di conversione dellenergia, Ph.D. thesis, Universit di Padova. Thermoeconomics, Energy Convers. Manage., 40, 16271649.

Luis M. Serra is permanent associate professor of the Mechanical Engineering Department at the Univer-
sity of Zaragoza since 1997. He has participated and led several research and development projects on
energy systems and energy saving in general and particularly on thermoeconomic analysis, process inte-
gration (polygeneration) and environmental assessment. Serra has been the co-recipient of the best paper
award on Advanced Energy Systems from ASME (Edward F. Obert Award 2003). He is author and co-author
of more than 70 papers and books and reviewer for several international journals, e.g., ASME Journal of
Energy Resources Technology, Solar Energy and International Journal of Life Cycle Assessment.

Dr. Javier Uche Marcuello. Ph. D. Industrial Engineer since June 2000. Assistant professor of the Uni-
versity of Zaragoza (Department of Mechanical Engineering) since October 2000. More than 40 papers in
international journals, book articles and international conferences (mainly in Desalination and integration
of water and energy issues). Two books about desalination and economic aspects of irrigation. Consultant
of the Government of Aragon in water issues.

14 / Vol. 128, MARCH 2006 Transactions of the ASME

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Antonio Valero is Full Professor at the University of Zaragoza since 1986. Director of CIRCE, Center for
Research of Energy Resources and Consumptions, a research Foundation currently composed of sixty
researchers. Founder scientist of the sciences of Thermoeconomics and Exergoecology. ASME James H.
Potter Gold Medal96 Award, also awarded four times (86, 87, 88 and 03) with the Edward F. Obert for
its contributions to the science of Thermoeconomics and Energy Systems. Author of more than 200 papers
on energy, and Associate Technical Editor of many important Journals of Thermodynamics and Energy
Saving Systems. ASME Member since 1986 and other associations.

Journal of Energy Resources Technology MARCH 2006, Vol. 128 / 15

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