Waste Heat Recovery Technologies for the Food Processing Industry

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Waste Heat Recovery Technologies for the Food Processing Industry ( waste-heat-recovery-technologies-food-processing-industry )

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Energies 2020, 13, 6446 17 of 26 provides a comparison of the oven’s key performance parameters before and after the heat recovery. An overall system effectiveness, which is the ratio of gas savings from all five ovens and recoverable heat from a single oven exhaust, of 164.8% was achieved by the heat recovery system. A 33.1% improvement in the productivity of the oven used as heat source (exhaust gas) has been achieved after the heat recovery. Table 10. Key performance indicators of the industrial-scale baking oven before and after heat recovery to preheat combustion air of five ovens. Parameter Gas usage Load Effectiveness of heat recovery system Oven productivity 3.6. RORC for Oven Heat Recovery Units Nm3/h kW % kWh/kg of wafer Baseline 75.55 835.25 - 3.32 After Heat Recovery 50.65 559.96 164.8 2.22 The key performance parameters obtained from Aspen Plus simulation model for the proposed RORC system generating electricity using the heat extracted from baking oven’s exhaust gases are summarised in Table 11. A hot water stream at 2 bars and 90 ◦C is fed to a heat exchanger, where it is heated to 100 ◦C by cooling the oven’s exhaust gases down to 110 ◦C and extracting 167 kW of heat. This hot water, at 100 ◦C, is used in the evaporator to vaporise 3.9 litres of liquid refrigerant every minute. The vapourised refrigerant at 90 ◦C and 10 bars is expanded to 1.1 bar in an expander, producing 23.99 kW of electricity. The refrigerant stream exiting the expander at 38 ◦C and 1.1 bar is sent to the regenerator to extract heat by preheating the liquid refrigerant before the refrigerant is fed to the evaporator. The parasitic power consumed by the three pumps (refrigerant, condenser cooling water and coolant; see Figure 5) is 0.97 kW. The RORC system delivers a net electrical output of 23.02 kW with a net thermal efficiency of 13.78%, which is comparable to the efficiency range reported in literature [20,24–26,56]. Table 11. Results of the RORC Aspen Plus simulation. Parameter Units Heat available in the exhaust kW Gross electricity generated by the turbine kW Parasitic electrical power consumption kW Net electrical output kW RORC system efficiency (electrical) % Value 167 23.99 0.97 23.02 13.78 The key performance parameters of the oven before and after the heat recovery involving RORC are summarised in Table 12. The RORC system converts waste heat into electrical output. However, to maintain uniformity and continuity in the key performance parameters used for evaluation of the studied heat recovery technologies, the electrical output was converted or represented in the form of gas savings. A gas engine with an efficiency of 45% would require to burn 4.62 Nm3/h or 51.15 kWh of natural gas to generate 23.02 kW of electricity [68]. Therefore, the effectiveness achieved by the heat recovery system involving RORC is 30.6%. A 6% improvement in the oven productivity was achieved after the heat recovery using the RORC system.

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