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Energies 2020, 13, 6446 16 of 26 Energies 2020, 13, x FOR PEER REVIEW 16 of 26 Table 9. Key performance indicators of the industrial-scale baking oven before and after heat recovery 3.5. Preheating Combustion Air of Multiple Ovens to preheat combustion air and reheat returning process water. As discussed in Section 3.4, the heat recovery system with preheating combustion air does not Savings/Preheating Combined fully rePcaorvamerettehr e heat availUanbiltes in the exBhaaseulsintedue to having a smallerShaveiantgs/iRnekhetahtiang the available heat. An alternative solution for maximising the heat recovery is preheating combustion air of Gas usage Nm3/h 75.55 70.57 60.29 55.3 multiple ovens by using exhaust heat from a single oven. Large confectionary manufacturing sites Load kW 835.25 780.19 666.54 611.37 typEicffaeclltyiveonpeessraoftehematore than one baking ovens simultaneously. These ovens are placed in parallel and % - 32.96 101 134 Oven productivity kWh/kg of wafer 3.32 3.10 2.65 2.43 additional equipment costs. Aspen Plus models of preheating combustion air were developed with gradual increments in the number of combustion air streams with each stream representing a recovery unit close to each other to facilitate batter supply from a common batter preparation unit, thus avoiding 3.5. Preheating Combustion Air of Multiple Ovens different oven. It was assumed that all ovens have identical designs, sizes and operational parameters. The findings from the Aspen Plus simulation models are shown in Figure 10. As discussed in Section 3.4, the heat recovery system with preheating combustion air does not It can be seen from the figure that a total of five combustion air streams or five baking ovens are fully recover the heat available in the exhaust due to having a smaller heat sink than the available heat. required to extract maximum recoverable heat from exhaust of a single oven. The five combustion An alternative solution for maximising the heat recovery is preheating combustion air of multiple air streams manage to extract 95.4% of the 167 kW of recoverable heat available in the exhaust. The ovens by using exhaust heat from a single oven. Large confectionary manufacturing sites typically cumulative gas savings achieved from all five ovens is 24.9 Nm3/h or 275.28 kW. This cumulative gas operate more than one baking ovens simultaneously. These ovens are placed in parallel and close to saving has been transferred to a single oven for the simplicity of performance evaluation. Table 10 each other to facilitate batter supply from a common batter preparation unit, thus avoiding additional provides a comparison of the oven’s key performance parameters before and after the heat recovery. equipment costs. Aspen Plus models of preheating combustion air were developed with gradual An overall system effectiveness, which is the ratio of gas savings from all five ovens and recoverable increments in the number of combustion air streams with each stream representing a different oven. heat from a single oven exhaust, of 164.8% was achieved by the heat recovery system. A 33.1% It was assumed that all ovens have identical designs, sizes and operational parameters. The findings improvement in the productivity of the oven used as heat source (exhaust gas) has been achieved from the Aspen Plus simulation models are shown in Figure 10. after the heat recovery. 300 250 200 150 100 50 100 90 80 70 60 50 40 30 20 10 Heat available for recovery Fuel Savings Heat Recovered (kWh) Heat recovery percentage 00 0123456 Number of Oven Figure 10. Savings obtained by preheating combustion air of multiple ovens. Figure 10. Savings obtained by preheating combustion air of multiple ovens. It can be seen from the figure that a total of five combustion air streams or five baking ovens are Table 10. Key performance indicators of the industrial-scale baking oven before and after heat required to extract maximum recoverable heat from exhaust of a single oven. The five combustion recovery to preheat combustion air of five ovens. air streams manage to extract 95.4% of the 167 kW of recoverable heat available in the exhaust. Parameter Units Baseline After Heat Recovery The cumulative gas savings achieved from all five ovens is 24.9 Nm3/h or 275.28 kW. This cumulative Gas usage Nm3/h 75.55 50.65 gas saving has been transferred to a single oven for the simplicity of performance evaluation. Table 10 Air Savings kWh PercentagePDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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