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Energies 2020, 13, 6446 21 of 26 important factor for consideration. This is because the capital cost of the heat recovery system and operational heat losses are directly proportional to the distance. Moreover, in some factories, the whole hot water demand is supplied by Combined Heat and Power systems. Therefore, there may be no requirement for installing an additional hot water generation system. On the other hand, the heat recovery technology involving preheating of combustion air is independent of the hot water demand of the manufacturing site. However, for the preheating technology to perform better than others, there should be adequate heat sinks (combustion air flow rate or multiple ovens) available in the factory. This technology will deliver the best possible results if there is more than one oven in the factory. In the absence of hot water demand and sufficient combustion air sink, an RORC or VAR system can be considered to generate direct electrical savings, perhaps more valuable form of energy than natural gas and can be exported to the grid. Some heat recovery technologies perform notably better than others. However, in general, all exhibit their own merits when energy and operating cost savings are considered, as shown in Table 15. A wholesale price of £1.8 per MWh of gas and £6 per MWh of electricity taken from Ofgem UK has been considered to calculate operational cost savings. While the electricity price is three times more than the gas price, the RORC and VAR does not save enough electricity to be an attractive option for operational (fuel) cost saving compared to gas saving cases. Implementing these heat recovery technologies in food manufacturing will also reduce considerable amount of CO2 emissions (see Table 15), thus, making the food producers more complacent with the legislation. A comparison of payback period for all the heat recovery options are given in Table 16. The combustion air preheating technologies with single and multiple ovens used only one heat exchanger, and therefore, were found to have the lowest investment cost of £35,616 and £54,557, respectively. The reheating process water technology requiring a heat exchanger and a pump has the third lowest investment cost of £59,346. The investment calculations considered that the heat sink (water to be heated) is close to the oven. Hence, the cost of laying out long piping is not taken into account. The same assumption is taken for the combined preheating and reheating process water technology. It is found that air preheating using multiple ovens has the lowest payback period, of 1.57 years, followed by reheating process water technology with 2.26 years and combined preheating combustion air and reheating process water technology with 3.25 years. This is mainly because a high operational saving was obtained on a nominal investment from these three technologies. The RORC and VAR has a payback period of 15.75 and 32.72 years, respectively. Both these processes use several units, such as heat exchangers, pumps, turbine and process vessels, and hence, have a significantly high investment cost. In addition to that, the operational/fuel cost savings were also low, which ultimately resulted in high payback periods. 3.9. Route to Election of Heat Recovery Technology Figure 12 shows the systematic methodology or the process map for selecting a suitable waste heat recovery technology for the baking process discussed in this work. It is recommended to operate the baking oven at a fully optimised condition ahead of selecting a heat recovery system. This will provide an accurate estimation of the available waste heat from the oven exhaust. Therefore, initially, an optimisation study should be conducted to investigate the scope of the operational improvements. Additionally, historical data on the oven performance accounting for the changes in production scales, operational hours, cleaning and maintenance schedules should be obtained. This will help in understanding the variations in the waste heat production by the oven and selecting a suitable heat sink. Once the technical feasibility of a heat recovery solution is affirmed, it should be investigated further for economic viability before proceeding with the construction and installation of the heat recovery system. As understood from the results discussed above and indicated by the process map in Figure 12, the heat recovery solution involving combustion air preheating is investigated first, followed by hot water production (or combined hot water and combustion air preheating). The process map recommends investigating VAR before ORC, although the results shown in Figure 11 and Table 14PDF Image | Waste Heat Recovery Technologies for the Food Processing Industry
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