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Energies 2020, 13, 6446 13 of 26 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 if the oven’s control mechanism can precisely handle the variations in the operating conditions and if the fuel is being completely burned in the burners. A bluish flame with a yellow tip, as can be seen in Figure 8, indicates complete combustion of fuel in the burners. Moreover, the quality (moisture, weight, size, colour) checks performed on the wafer samples produced and collected during the experiments Energies 2020, 13, x FOR PEER REVIEW showed no negative impact on the wafer quality. 13 of 26 Figure 8. Flame colour before (a) and after (b) combustion air preheating. Figure 8. Flame colour before (a) and after (b) combustion air preheating. 3.2. Savings for an Industrial-Scale Baking Oven 3.2. Savings for an Industrial-Scale Baking Oven The observations and findings from the pilot-scale experiments were applied on an industrial-scale The observations and findings from the pilot-scale experiments were applied on an industrial- baking oven, which is a scaled-up version of the pilot oven used in the experiments and has a scale baking oven, which is a scaled-up version of the pilot oven used in the experiments and has a similar design, construction and working principle. The baseline key performance parameters of the similar design, construction and working principle. The baseline key performance parameters of the industrial-scale oven and the estimated changes after heat recovery are listed in Table 7. The average industrial-scale oven and the estimated changes after heat recovery are listed in Table 7. The average baseline fuel consumption of the industrial oven was 75.55 Nm3/h, equating to an energy consumption baseline fuel consumption of the industrial oven was 75.55 Nm3/h, equating to an energy rate of 835.25 kW. The oven produces 251.58 kg of wafer with a baseline productivity of 3.32 kWh per consumption rate of 835.25 kW. The oven produces 251.58 kg of wafer with a baseline productivity kg of wafer. The exhaust gases were released at 165 ◦C and 3.72 m3/s. of 3.32 kWh per kg of wafer. The exhaust gases were released at 165 °C and 3.72 m3/s. The combustion air of the industrial oven can be preheated up to a temperature 10 °C below the Table 7. Key performance indicators of the industrial-scale baking oven before and after heat recovery exhaust temperature. Thus, in the current scenario where the exhaust is at 165 °C, the combustion air to preheat combustion air of a single oven. could be preheated up to 155 °C; 125 °C higher than the baseline temperature of 30 °C. Using the Parameter Units Baseline After Heat Recovery relation between the combustion air temperature and oven fuel consumption obtained from the pilot- 33 scaleexperimenGtsa,siutswagaesestimatedthatamNaxmim/humfuelsavi7n5g.55of~6.6%i.e.,4.9780N.57m/hor55.05 Load kW 835 780 kWh could be achieved for the industrial baking oven by preheating its combustion air. The new gas Exhaust temperature ◦C 165 165 usage for the oven is calculated by subtracting the gas savings obtained due to heat recovery from Combustion air inlet temperature ◦C 30 155 the baseline gas consumption of 75.55 Nm3/h. A 6.6% of fuel savings will reduce the energy Effectiveness of heat recovery system % - 32.96 consumption per kilogram of wafer production from 3.32 kWh to 3.10 kWh, thus making the oven Oven productivity kWh/kg of wafer 3.32 3.10 more efficient. Table 7. Key performance indicators of the industrial-scale baking oven before and after heat recovery to preheat combustion air of a single oven. Parameter Gas usage Units Nm3/h Baseline 75.55 After Heat Recovery 70.57 Load kW 835 780PDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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