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Thermo-economic optimisation of industrial milk spray dryer exhaust to inlet air heat recovery

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  • Walmsley, Timothy G.
  • Walmsley, Michael R.W.
  • Atkins, Martin J.
  • Neale, James R.
  • Tarighaleslami, Amir H.

Abstract

This study reports a thermo-economic design optimisation of an industrial milk spray dryer liquid coupled loop exhaust heat recovery system. Incorporated into the analysis is the ability to predict the level of milk powder fouling over time and its impacts on heat transfer and pressure drop. Focus is given to a finned round tube, a bare round tube and a bare elliptical tube. Modelling results show that spray exhaust heat recovery is economically viable for the considered industrial case study. Based on the results, the best liquid coupled loop heat exchange system uses a finned tube heat exchanger to recover heat from the exhaust air with a face velocity of 4 m/s and 14 tube rows, which gives a net present value of NZ$2.9 million and an internal rate of return of 71%. The developed thermo-economic assessment method has the ability to cater to site specific needs that affect the utility savings and the capital cost for implementing exhaust heat recovery.

Suggested Citation

  • Walmsley, Timothy G. & Walmsley, Michael R.W. & Atkins, Martin J. & Neale, James R. & Tarighaleslami, Amir H., 2015. "Thermo-economic optimisation of industrial milk spray dryer exhaust to inlet air heat recovery," Energy, Elsevier, vol. 90(P1), pages 95-104.
    • Handle: RePEc:eee:energy:v:90:y:2015:i:p1:p:95-104
    DOI: 10.1016/j.energy.2015.03.102
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    References listed on IDEAS

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    1. Walmsley, Timothy G. & Walmsley, Michael R.W. & Atkins, Martin J. & Neale, James R., 2014. "Integration of industrial solar and gaseous waste heat into heat recovery loops using constant and variable temperature storage," Energy, Elsevier, vol. 75(C), pages 53-67.
    2. Han, Xiaoqu & Liu, Ming & Wang, Jinshi & Yan, Junjie & Liu, Jiping & Xiao, Feng, 2014. "Simulation study on lignite-fired power system integrated with flue gas drying and waste heat recovery – Performances under variable power loads coupled with off-design parameters," Energy, Elsevier, vol. 76(C), pages 406-418.
    3. Tippayawong, N. & Tantakitti, C. & Thavornun, S., 2008. "Energy efficiency improvements in longan drying practice," Energy, Elsevier, vol. 33(7), pages 1137-1143.
    4. Laurijssen, Jobien & De Gram, Frans J. & Worrell, Ernst & Faaij, Andre, 2010. "Optimizing the energy efficiency of conventional multi-cylinder dryers in the paper industry," Energy, Elsevier, vol. 35(9), pages 3738-3750.
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    Citations

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    Cited by:

    1. Walmsley, Timothy G. & Atkins, Martin J. & Walmsley, Michael R.W. & Neale, James R., 2016. "Appropriate placement of vapour recompression in ultra-low energy industrial milk evaporation systems using Pinch Analysis," Energy, Elsevier, vol. 116(P2), pages 1269-1281.
    2. Caglayan, Hasan & Caliskan, Hakan, 2017. "Sustainability assessment of heat exchanger units for spray dryers," Energy, Elsevier, vol. 124(C), pages 741-751.
    3. Kapustenko, Petro O. & Klemeš, Jiří Jaromír & Arsenyeva, Olga P. & Kusakov, Sergey K. & Tovazhnyanskyy, Leonid L., 2020. "The influence of plate corrugations geometry scale factor on performance of plate heat exchanger as condenser of vapour from its mixture with noncondensing gas," Energy, Elsevier, vol. 201(C).
    4. Diana L. Tinoco-Caicedo & Alexis Lozano-Medina & Ana M. Blanco-Marigorta, 2020. "Conventional and Advanced Exergy and Exergoeconomic Analysis of a Spray Drying System: A Case Study of an Instant Coffee Factory in Ecuador," Energies, MDPI, vol. 13(21), pages 1-19, October.
    5. Arsenyeva, Olga & Klemeš, Jiří Jaromír & Tovazhnyanskyy, Leonid & Klochok, Eugeny & Kapustenko, Petro, 2023. "Estimating parameters of plate heat exchanger for condensation of steam from mixture with air as a component of heat exchanger network," Energy, Elsevier, vol. 283(C).
    6. Walmsley, Timothy G. & Atkins, Martin J. & Walmsley, Michael R.W. & Philipp, Matthias & Peesel, Ron-Hendrik, 2018. "Process and utility systems integration and optimisation for ultra-low energy milk powder production," Energy, Elsevier, vol. 146(C), pages 67-81.
    7. Arsenyeva, Olga & Klemeš, Jiří Jaromír & Klochock, Eugeny & Kapustenko, Petro, 2023. "The effect of plate size and corrugation pattern on plate heat exchanger performance in specific conditions of steam-air mixture condensation," Energy, Elsevier, vol. 263(PC).
    8. Jaber, Hassan & Khaled, Mahmoud & Lemenand, Thierry & Murr, Rabih & Faraj, Jalal & Ramadan, Mohamad, 2019. "Domestic thermoelectric cogeneration drying system: Thermal modeling and case study," Energy, Elsevier, vol. 170(C), pages 1036-1050.
    9. Klemeš, Jiří Jaromír & Varbanov, Petar Sabev & Walmsley, Timothy G. & Jia, Xuexiu, 2018. "New directions in the implementation of Pinch Methodology (PM)," Renewable and Sustainable Energy Reviews, Elsevier, vol. 98(C), pages 439-468.

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