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Energies 2020, 13, 6446 3 of 26 development and experimental testing of a novel low-grade gas-to-gas waste heat recovery solution for Energies 2020, 13, x FOR PEER REVIEW 3 of 26 the baking sector for pre-heating the combustion air. The recovered waste heat from an industrial-scale baking oven at a UK-based confectionary manufacturing site was recycled to pre-heat the oven’s to pre-heat the oven’s combustion air. These experimental results were compared with analytical and combustion air. These experimental results were compared with analytical and modelling results for modelling results for other heat recovery technologies mentioned above to develop the methodology other heat recovery technologies mentioned above to develop the methodology of arriving at the most of arriving at the most rewarding solution for heat recovery. rewarding solution for heat recovery. Not only the baking industry, but a variety of similar low temperature and energy-intensive Not only the baking industry, but a variety of similar low temperature and energy-intensive food food manufacturing processes can benefit from the observations and findings presented in this work. manufacturing processes can benefit from the observations and findings presented in this work. 2. Methodology 2. Methodology Six different types of waste heat recovery solution involving direct fuel/gas saving, electricity Six different types of waste heat recovery solution involving direct fuel/gas saving, electricity generation, cooling and hot water production have been investigated through modelling and generation, cooling and hot water production have been investigated through modelling and experiments. A detailed description of the industrial baking machinery used for analysis is given in experiments. A detailed description of the industrial baking machinery used for analysis is given in Section 2.1. A gas-to-gas low-grade waste heat recovery technology to preheat oven’s combustion air Section 2.1. A gas-to-gas low-grade waste heat recovery technology to preheat oven’s combustion using heat from exhaust gases was designed, developed and tested through experiments and air using heat from exhaust gases was designed, developed and tested through experiments and modelling. Its performance was compared with other existing waste heat recovery technologies, modelling. Its performance was compared with other existing waste heat recovery technologies, ORC, VAR and gas-to-liquid heat recovery. Simulation models for ORC, VAR and gas-to-liquid heat ORC, VAR and gas-to-liquid heat recovery. Simulation models for ORC, VAR and gas-to-liquid heat recovery technologies were developed using experimentally derived inputs and existing literature. recovery technologies were developed using experimentally derived inputs and existing literature. Sections 2.2–2.6 describe the experimental, modelling and techno-economic assessment methodology Sections 2.2–2.6 describe the experimental, modelling and techno-economic assessment methodology followed for the comparisons. followed for the comparisons. 2.1. Baking Oven A fully automatic wafer baking oven, shown in Figure 1, producing ffllat rectangular wafer sheets, was used for the experiments and analysis. A mixture of water, flflour and ffllavouring ingredients was usedttopprreeppaarereththeebabtatettre,rw,hwichhicwhawsathsetnhepnouproeudroendtonthtoebthaekibnagkpinlagtepslfiaxtesdfinxetodnignftroanmgesfr.aTmhest.oTnhges atorengfisxeadrewfiixtehdgwraipthigterabpehairtienbgesaarnindgasraenrdevaorlevreedvaoclvroesdsatchreolsesntghtehleonf gththe ofvtehneuosvineng ulosninggclhoaning cdhraivine pdoriwverpeodwbeyread5bkyWa e5lkecWtrieclemctortiocrm. Tohtoerb. Takhienbgapkliantgespalaretehseaarteehdetaotethdetodethsiereddestiermedpteermatpuererastausrethseays athreytrarnesptroarntesdpotrhtreodutghrothueghovthene boyvebnubrnyinbguranminigxtaurmeioxftunraetuorfanl agtausralngdaasmanbidenatmabirie(natlsaoirca(alllesdo coamllebducsotimonbuosrtpiornimoarrpyriamira)riny athire)tirniathnegutrliarnbgurlnarerbsulronceartsedlobcealtoewd btehleowtonthgecthoaningsc.hTahinesb.aTkhienbgapkliantge spularfteacseutrefamcepeteramtupreer,amtuerea,sumreadsurseindguasinpgyraompyertoemr,eretegru,lraetgeusltahtesbtuhrenbeurrbnleorwbelrowfrerqufrenqcuyenancydatnhde ftuhelf-uaierl-mairxmfloixwfltohwrotuhgrhouagZhearoZPereosPsurersesRuereguRleagtourl.ator. Figure 1. Schematic of a pilot-scale wafer baking oven highlighting the key components of the oven [37]. Figure 1. Schematic of a pilot-scale wafer baking oven highlighting the key components of the oven [37]. The Automatic Wafer Baking Machine consists of: 1. Service door. 2. Emission extraction unit. 3. Burner device. 4. Baking space. 5. Batter depositing station. 6. Wafer take-off station. 7. Control pane. The Automatic Wafer Baking Machine consists of: 1. Service door. 2. Emission extraction unit. 3. Burner device. 4. Baking space. 5. Batter depositing station. 6. Wafer take-off station. 7. Control pane. 8. Waste scraper. 9. Wafer inspection device. The batter is baked into wafer sheets in one revolution. These wafer sheets are carefully collected in the wafer sheet take-off station and sent to the processing line. The oven is also supplied with a cooling or secondary air flow through the sidewalls to protect the bearings from any damage 8. Waste scraper. 9. Wafer inspection device.PDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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