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Energies 2020, 13, 6446 12 of 26 3. Results and Discussions 3.1. Pilot-Scale Combustion Air Preheating Experiments The pilot-scale wafer baking oven was operated at normal conditions, as described in Table 5, at the beginning of the experiments to collect baseline data on key performance parameters such as fuel and energy consumption, exhaust temperatures and flow rate, wafer quality and fuel conversion, shown in Table 6. The average hourly fuel consumption without combustion air preheating was recorded as 27.69 Nm3, indicating an energy consumption rate of 306.12 kW by the pilot oven. The oven produced 90 kg of wafer per hour with an energy consumption of 3.4 kWh per kg of wafer produced. The exhaust gases were released at 133 ◦C and 2.82 m3/s. Table 6. Baseline key performance indicators of pilot-scale baking oven. Parameter Gas consumption per hour Calorific value of gas Load Combustion air inlet temperature Exhaust temperature Exhaust flowrate Oven productivity Units Nm3/h kWh/m3 kW Value 27.69 11.0556 306.12 ◦C 30 ◦C 133 m3/s 2.82 kWh/kg of wafer 3.40 After this, the combustion air was preheated from 30 ◦C to 105 ◦C with incremental steps of 20 ◦C, using the industrial electrical resistance heater described in Section 2.2. For every increment made, Energies 2020, 13, x FOR PEER REVIEW 12 of 26 the key performance parameters were recorded. The effect of combustion air temperature on fuel consumption rate is shown in Figure 7. Preheating the combustion air increases the burner flame temperature, and consequently, also the baking oven plate temperature. The oven’s control system temperature, and consequently, also the baking oven plate temperature. The oven’s control system that that regulates the plate temperature responds instantly and brings down the temperature to the set regulates the plate temperature responds instantly and brings down the temperature to the set point point condition by reducing the fuel supply to the oven burners. It was observed from the condition by reducing the fuel supply to the oven burners. It was observed from the experiments that experiments that the oven fuel consumption dropped by 1% for every 18.5–20 °C rise in combustion the oven fuel consumption dropped by 1% for every 18.5–20 ◦C rise in combustion air temperature. air temperature. An overall drop in average fuel consumption by the oven of circa 4% was obtained An overall drop in average fuel consumption by the oven of circa 4% was obtained by raising the by raising the combustion air temperature by 75 °C (from 30 °C to 105 °C). combustion air temperature by 75 ◦C (from 30 ◦C to 105 ◦C). 120 100 80 60 40 20 0 29 28 27 26 25 24 23 Air temperature Gas consumption rate Time (HH:MM) Figure 7. Effect of combustion air temperature on the oven fuel consumption rate. Figure 7. Effect of combustion air temperature on the oven fuel consumption rate. Preheating the combustion air to higher temperatures reduces the air density, and hence, the oxygen mass flow rate. Any failure of the oven’s control system to adjust to the preheated combustion air conditions could cause incomplete combustion of the gaseous fuel in the oven burners. This will lead to fuel wastage and formation of carbon monoxide (CO) and can negatively impact the wafer quality. Therefore, the burner flame colours were regularly observed during the experiments to check 12:09 14:09 16:09 18:09 20:09 22:09 0:09 2:09 4:09 6:09 8:09 10:09 12:09 14:09 16:09 18:09 20:09 22:09 0:09 2:09 4:09 6:09 8:09 Air temperature (oC) Gas consumption rate (m3n/h)PDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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