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Energies 2020, 13, 6446 18 of 26 Table 12. Key performance indicators of the industrial-scale baking oven before and after heat recovery. Parameter Gas usage Load Effectiveness of heat recovery system Oven productivity 3.7. VARC for Oven Heat Recovery Units Nm3/h kW % kWh/kg of wafer Baseline 75.55 835.25 - 3.32 After Heat Recovery 70.93 784.17 30.6 3.11 The simulation results summarised in Table 13 for the proposed heat recovery system involving VAR indicates that cooling can be generated at a rate of 55.5 kW by recovering 167 kW of waste heat available from the oven exhaust. The heat recovery system attains a cooling efficiency of 33.2%. The parasitic power consumed by the auxiliary equipment is 1.03 kW. A VCR system with a coefficient of performance (COP) of 3.5 [69,70] will consume 15.85 kW of electricity to produce the same cooling effect as produced by the VAR. Thus, the VAR system saves 15.85 kW of electricity by recovering waste heat and yields a net thermal efficiency of 9.49%. Table 13. Aspen Plus simulation results of heat recovery system using VAR. Parameter Units Value Parameter Gas usage Load Effectiveness of heat recovery system Oven productivity Units Nm3/h kW % kWh/kg of wafer Baseline 75.55 835.25 - 3.32 After Heat Recovery 72.37 800.09 21.08 3.18 Heat available in the exhaust kW 167 Cooling produced by the system kW 55.5 Cooling efficiency % 33.2 Parasitic power consumption kW 1.03 Net electricity saved kW Electrical efficiency of VAR % 9.49 The cooling effect produced by VAR is first converted into electrical savings and then to gas savings to maintain uniformity in comparison to the key performance parameters of the heat recovery systems studied. A typical gas engine with an efficiency of 45% would require to burn 3.18 Nm3/h or 35.22 kW of natural gas to generate 15.85 kW of electricity. The key performance parameters of the oven before and after the heat recovery involving VAR are summarised in Table 14. The effectiveness achieved by the heat recovery system is 21.08%. The results also indicate an improvement of 4.2% in the oven productivity. Table 14. Key performance indicators of the industrial-scale baking oven before and after heat recovery. 15.85 3.8. Comparison of Heat Recovery Technologies The performances of the heat recovery technologies discussed in Sections 3.1–3.7 are evaluated against each other based on four key criteria: (i) oven gas consumption, (ii) oven productivity, (iii) effectiveness of heat recovery system and (iv) cost savings payback period. Figure 11 illustrates the graphical comparison of the heat recovery technologies based on the first three criteria, whereas the fourth criteria is compared in Tables 15 and 16. The heat recovery system involving VAR technology incurs the least gas savings of 4.2%, yielding a gas consumption rate of 72.37 Nm3/h against the baseline consumption of 75.55 Nm3/h. The VAR technology is followed by RORC technology and preheating technology for single oven with a gas consumption reduction by 6.11% and 6.59%, respectively.PDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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