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Energies 2020, 13, 6446 2 of 26 system in the last 60 years. With the rapid increase in the world population and consequent rising food demands, the energy consumption in the food manufacturing sector is expected to continue to rise in the future [3,7–9]. A study conducted by Paolo et al. [10] showed a 3- and 2.5-fold increase in global crop and animal production, respectively, in the past 50 years. The processing/manufacturing phase in the food chain has considerably higher fossil fuel consumption rates [11]. In the UK, the food and drink manufacturing sector consumed 60.5 TWh of energy compared to 12 TWh by agriculture and 12 TWh by retail in 2011 [12]. An article published by the European Commission [5] reported that 6.6 GJ of energy was consumed by the processing phase alone in the EU, which is 28% of the total energy consumption by the entire food chain. The processing phase consists of food manufacturing operations such as baking, drying, frying, roasting, general heating, etc. These manufacturing processes rely on the direct heat released from burning fossil fuels, usually natural gas or propane, in specially designed equipment. A proportion of the heat supplied to these ovens contributes to the actual product processing and the rest is vented to the surrounding area with the exhaust gases as waste heat at 150 to 250 ◦C. In the UK alone, the food and drink manufacturing sector releases circa 2.8 TWh of recoverable waste heat into the atmosphere, annually [13]. Increasing the energy efficiency of modern manufacturing machinery by design improvement is extremely challenging, as it may already be operating at high efficiency according to the original design. However, an alternative option is to capture and recycle the waste heat back into the system to reduce the overall energy footprint of the manufacturing site. It is estimated that recovering waste heat from the UK food and drink manufacturing sector can potentially save £70 million and 500,000 tonnes of CO2 emissions, annually [13]. In order to realise this huge opportunity for energy efficiency and carbon reduction, the Department for Business, Energy and Industrial Strategy (BEIS) of the UK government has launched several ambitious grant programmes for industry such the £18 million Industrial Heat Recovery Support (IHRS) [14] programme in 2018 and £315 million Industrial Energy Transformation Fund (IETF) [15] in 2020, especially targeting waste heat recovery from industrial processes. Many mature technologies for waste heat recovery and utilisation are commercially available on the market, such as the Organic Rankine Cycle (ORC), to convert waste heat into electricity, Vapour Absorption Refrigeration (VAR), to produce a cooling effect, production of hot water or steam through an economiser, pre-heating combustion air through a recuperator and pre-heating the feedstock using a regenerator. Numerous studies on the application of ORC and VAR for waste heat recovery are available [16–28] in various industrial sectors. A few studies comparing ORC with VAR are available [29]. However, there is little information on the process of systematically selecting the best technical and economic solution from all the choices available, especially in food manufacturing processes where the waste heat leaves through the exhaust air at relatively low temperatures [29–31]. The quantity and quality of heat source available from a food manufacturing process determine the design operating conditions for ORC and VAR systems and have a direct influence on their performances. Therefore, the existing ORC and VAR models in the literature cannot be directly used for estimating their techno-economic feasibility against any other waste heat recovery solution such as combustion air preheating for food manufacturing processes. Additionally, the option of air-to-air heat recovery has not been adequately explored, especially for the food industry. Although the air-to-air heat recovery technology is fairly established for power generation cycles where the temperatures are comparatively higher, it is essential to assess its suitability for industrial baking, as the baking mechanism, machinery and conditions are different [32–36]. The focus of this work is not on the development of new technology or improving existing technology. Rather, the focus is on the development of a systematic approach for determining the best heat recovery solution based on technical, environmental and economic considerations. This work develops a systematic methodology for comparing various low grade waste heat recovery solutions for the industrial baking process based on fuel savings, operational cost savings, CO2 savings and return on investment (ROI) using analytical and numerical models. It also carries out actual design,PDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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