IDEAS home Printed from https://ideas.repec.org/a/gam/jeners/v13y2020i23p6446-d457501.html
   My bibliography  Save this article

Techno-Economic Assessment of Waste Heat Recovery Technologies for the Food Processing Industry

Author

Listed:
  • Sanjay Mukherjee

    (National Centre of Excellence for Food Engineering, Sheffield Hallam University, Sheffield S9 2AA, UK)

  • Abhishek Asthana

    (National Centre of Excellence for Food Engineering, Sheffield Hallam University, Sheffield S9 2AA, UK)

  • Martin Howarth

    (National Centre of Excellence for Food Engineering, Sheffield Hallam University, Sheffield S9 2AA, UK)

  • Jahedul Islam Chowdhury

    (School of Aerospace, Transport and Manufacturing, Cranfield University, Bedford MK43 0AL, UK)

Abstract

The food manufacturing sector is one of the most dominant consumers of energy across the globe. Food processing methods such as drying, baking, frying, malting, roasting, etc. rely heavily on the heat released from burning fossil fuels, mainly natural gas or propane. Less than half of this heat contributes to the actual processing of the product and the remaining is released to the surroundings as waste heat, primarily through exhaust gases at 150 to 250 °C. Recovering this waste heat can deliver significant fuel, cost and CO 2 savings. However, selecting an appropriate sink for this waste heat is challenging due to the relatively low source temperature. This study investigates a novel application of gas-to-air low temperature waste heat recovery technology for a confectionary manufacturing process, through a range of experiments. The recovered heat is used to preheat a baking oven’s combustion air at inlet before it enters the fuel-air mixture. The investigated technology is compared with other waste heat recovery schemes involving Regenerative Organic Rankine Cycles (RORC), Vapour Absorption Refrigeration (VAR) and hot water production. The findings indicate that utilising an oven’s exhaust gases to preheat combustion air can deliver up to 33% fuel savings, provided a sufficiently large heat sink in the form of oven combustion air is available. Due to a lower investment cost, the technology also offers a payback period of only 1.57 years, which makes it financially attractive when compared to others. The studied waste heat recovery technologies can deliver a CO 2 savings of 28–356 tonnes per year from a single manufacturing site. The modelling and comparison methodology, observations and outcomes of this study can be extended to a variety of low temperature food manufacturing processes.

Suggested Citation

  • Sanjay Mukherjee & Abhishek Asthana & Martin Howarth & Jahedul Islam Chowdhury, 2020. "Techno-Economic Assessment of Waste Heat Recovery Technologies for the Food Processing Industry," Energies, MDPI, vol. 13(23), pages 1-26, December.
    • Handle: RePEc:gam:jeners:v:13:y:2020:i:23:p:6446-:d:457501
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/1996-1073/13/23/6446/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/1996-1073/13/23/6446/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Cho, Soo-Yong & Cho, Chong-Hyun & Ahn, Kook-Young & Lee, Young Duk, 2014. "A study of the optimal operating conditions in the organic Rankine cycle using a turbo-expander for fluctuations of the available thermal energy," Energy, Elsevier, vol. 64(C), pages 900-911.
    2. Oluleye, Gbemi & Jobson, Megan & Smith, Robin & Perry, Simon J., 2016. "Evaluating the potential of process sites for waste heat recovery," Applied Energy, Elsevier, vol. 161(C), pages 627-646.
    3. Zeng, M. & Du, L.X. & Liao, D. & Chu, W.X. & Wang, Q.W. & Luo, Y. & Sun, Y., 2012. "Investigation on pressure drop and heat transfer performances of plate-fin iron air preheater unit with experimental and Genetic Algorithm methods," Applied Energy, Elsevier, vol. 92(C), pages 725-732.
    4. Donnellan, Philip & Cronin, Kevin & Byrne, Edmond, 2015. "Recycling waste heat energy using vapour absorption heat transformers: A review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 42(C), pages 1290-1304.
    5. Sun, Jian & Fu, Lin & Zhang, Shigang, 2012. "A review of working fluids of absorption cycles," Renewable and Sustainable Energy Reviews, Elsevier, vol. 16(4), pages 1899-1906.
    6. Lion, Simone & Michos, Constantine N. & Vlaskos, Ioannis & Rouaud, Cedric & Taccani, Rodolfo, 2017. "A review of waste heat recovery and Organic Rankine Cycles (ORC) in on-off highway vehicle Heavy Duty Diesel Engine applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 79(C), pages 691-708.
    7. Wu, Wei & Wang, Baolong & Shi, Wenxing & Li, Xianting, 2014. "Absorption heating technologies: A review and perspective," Applied Energy, Elsevier, vol. 130(C), pages 51-71.
    8. Toffolo, Andrea & Lazzaretto, Andrea & Manente, Giovanni & Paci, Marco, 2014. "A multi-criteria approach for the optimal selection of working fluid and design parameters in Organic Rankine Cycle systems," Applied Energy, Elsevier, vol. 121(C), pages 219-232.
    9. Yu, Guopeng & Shu, Gequn & Tian, Hua & Wei, Haiqiao & Liu, Lina, 2013. "Simulation and thermodynamic analysis of a bottoming Organic Rankine Cycle (ORC) of diesel engine (DE)," Energy, Elsevier, vol. 51(C), pages 281-290.
    10. Lorenzo Tocci & Tamas Pal & Ioannis Pesmazoglou & Benjamin Franchetti, 2017. "Small Scale Organic Rankine Cycle (ORC): A Techno-Economic Review," Energies, MDPI, vol. 10(4), pages 1-26, March.
    11. Lee, Seungro & Kum, Sung-Min & Lee, Chang-Eon, 2011. "Performances of a heat exchanger and pilot boiler for the development of a condensing gas boiler," Energy, Elsevier, vol. 36(7), pages 3945-3951.
    12. Tchanche, Bertrand F. & Lambrinos, Gr. & Frangoudakis, A. & Papadakis, G., 2011. "Low-grade heat conversion into power using organic Rankine cycles – A review of various applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 15(8), pages 3963-3979.
    13. Bao, Junjiang & Zhao, Li, 2013. "A review of working fluid and expander selections for organic Rankine cycle," Renewable and Sustainable Energy Reviews, Elsevier, vol. 24(C), pages 325-342.
    14. Pantaleo, Antonio M. & Fordham, Julia & Oyewunmi, Oyeniyi A. & De Palma, Pietro & Markides, Christos N., 2018. "Integrating cogeneration and intermittent waste-heat recovery in food processing: Microturbines vs. ORC systems in the coffee roasting industry," Applied Energy, Elsevier, vol. 225(C), pages 782-796.
    15. Lecompte, Steven & Huisseune, Henk & van den Broek, Martijn & Vanslambrouck, Bruno & De Paepe, Michel, 2015. "Review of organic Rankine cycle (ORC) architectures for waste heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 47(C), pages 448-461.
    16. Landelle, Arnaud & Tauveron, Nicolas & Haberschill, Philippe & Revellin, Rémi & Colasson, Stéphane, 2017. "Organic Rankine cycle design and performance comparison based on experimental database," Applied Energy, Elsevier, vol. 204(C), pages 1172-1187.
    17. F. Tchanche, Bertrand & Pétrissans, M. & Papadakis, G., 2014. "Heat resources and organic Rankine cycle machines," Renewable and Sustainable Energy Reviews, Elsevier, vol. 39(C), pages 1185-1199.
    18. Yu, Haoshui & Gundersen, Truls & Feng, Xiao, 2018. "Process integration of organic Rankine cycle (ORC) and heat pump for low temperature waste heat recovery," Energy, Elsevier, vol. 160(C), pages 330-340.
    19. Quoilin, Sylvain & Broek, Martijn Van Den & Declaye, Sébastien & Dewallef, Pierre & Lemort, Vincent, 2013. "Techno-economic survey of Organic Rankine Cycle (ORC) systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 22(C), pages 168-186.
    20. Robert W. R. Parker & Julia L. Blanchard & Caleb Gardner & Bridget S. Green & Klaas Hartmann & Peter H. Tyedmers & Reg A. Watson, 2018. "Fuel use and greenhouse gas emissions of world fisheries," Nature Climate Change, Nature, vol. 8(4), pages 333-337, April.
    21. Hung, T.C. & Shai, T.Y. & Wang, S.K., 1997. "A review of organic rankine cycles (ORCs) for the recovery of low-grade waste heat," Energy, Elsevier, vol. 22(7), pages 661-667.
    22. Iglesias Garcia, Steven & Ferreiro Garcia, Ramon & Carbia Carril, Jose & Iglesias Garcia, Denis, 2018. "A review of thermodynamic cycles used in low temperature recovery systems over the last two years," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 760-767.
    23. Liu, Bo-Tau & Chien, Kuo-Hsiang & Wang, Chi-Chuan, 2004. "Effect of working fluids on organic Rankine cycle for waste heat recovery," Energy, Elsevier, vol. 29(8), pages 1207-1217.
    24. Imran, Muhammad & Haglind, Fredrik & Asim, Muhammad & Zeb Alvi, Jahan, 2018. "Recent research trends in organic Rankine cycle technology: A bibliometric approach," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 552-562.
    25. Mansouri, Rami & Boukholda, Ismail & Bourouis, Mahmoud & Bellagi, Ahmed, 2015. "Modelling and testing the performance of a commercial ammonia/water absorption chiller using Aspen-Plus platform," Energy, Elsevier, vol. 93(P2), pages 2374-2383.
    26. Srikhirin, Pongsid & Aphornratana, Satha & Chungpaibulpatana, Supachart, 2001. "A review of absorption refrigeration technologies," Renewable and Sustainable Energy Reviews, Elsevier, vol. 5(4), pages 343-372, December.
    27. Zhai, Huixing & An, Qingsong & Shi, Lin & Lemort, Vincent & Quoilin, Sylvain, 2016. "Categorization and analysis of heat sources for organic Rankine cycle systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 64(C), pages 790-805.
    28. Chen, Huijuan & Goswami, D. Yogi & Stefanakos, Elias K., 2010. "A review of thermodynamic cycles and working fluids for the conversion of low-grade heat," Renewable and Sustainable Energy Reviews, Elsevier, vol. 14(9), pages 3059-3067, December.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Manel Issaoui & Guido Flamini & Amélia Delgado, 2021. "Sustainability Opportunities for Mediterranean Food Products through New Formulations Based on Carob Flour ( Ceratonia siliqua L.)," Sustainability, MDPI, vol. 13(14), pages 1-21, July.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. Imran, Muhammad & Haglind, Fredrik & Asim, Muhammad & Zeb Alvi, Jahan, 2018. "Recent research trends in organic Rankine cycle technology: A bibliometric approach," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 552-562.
    2. Kermani, Maziar & Wallerand, Anna S. & Kantor, Ivan D. & Maréchal, François, 2018. "Generic superstructure synthesis of organic Rankine cycles for waste heat recovery in industrial processes," Applied Energy, Elsevier, vol. 212(C), pages 1203-1225.
    3. Li, Jian & Ge, Zhong & Duan, Yuanyuan & Yang, Zhen & Liu, Qiang, 2018. "Parametric optimization and thermodynamic performance comparison of single-pressure and dual-pressure evaporation organic Rankine cycles," Applied Energy, Elsevier, vol. 217(C), pages 409-421.
    4. Steven Lecompte & Sanne Lemmens & Henk Huisseune & Martijn Van den Broek & Michel De Paepe, 2015. "Multi-Objective Thermo-Economic Optimization Strategy for ORCs Applied to Subcritical and Transcritical Cycles for Waste Heat Recovery," Energies, MDPI, vol. 8(4), pages 1-28, April.
    5. Chintala, Venkateswarlu & Kumar, Suresh & Pandey, Jitendra K., 2018. "A technical review on waste heat recovery from compression ignition engines using organic Rankine cycle," Renewable and Sustainable Energy Reviews, Elsevier, vol. 81(P1), pages 493-509.
    6. Li, Jian & Peng, Xiayao & Yang, Zhen & Hu, Shuozhuo & Duan, Yuanyuan, 2022. "Design, improvements and applications of dual-pressure evaporation organic Rankine cycles: A review," Applied Energy, Elsevier, vol. 311(C).
    7. Mondejar, M.E. & Andreasen, J.G. & Pierobon, L. & Larsen, U. & Thern, M. & Haglind, F., 2018. "A review of the use of organic Rankine cycle power systems for maritime applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 91(C), pages 126-151.
    8. Sarkar, Jahar & Bhattacharyya, Souvik, 2015. "Potential of organic Rankine cycle technology in India: Working fluid selection and feasibility study," Energy, Elsevier, vol. 90(P2), pages 1618-1625.
    9. Zhang, Jianhua & Lin, Mingming & Fang, Fang & Xu, Jinliang & Li, Kang, 2016. "Gain scheduling control of waste heat energy conversion systems based on an LPV (linear parameter varying) model," Energy, Elsevier, vol. 107(C), pages 773-783.
    10. Li, Jian & Ge, Zhong & Duan, Yuanyuan & Yang, Zhen, 2019. "Design and performance analyses for a novel organic Rankine cycle with supercritical-subcritical heat absorption process coupling," Applied Energy, Elsevier, vol. 235(C), pages 1400-1414.
    11. Fuhaid Alshammari & Apostolos Karvountzis-Kontakiotis & Apostolos Pesyridis & Muhammad Usman, 2018. "Expander Technologies for Automotive Engine Organic Rankine Cycle Applications," Energies, MDPI, vol. 11(7), pages 1-36, July.
    12. Pezzuolo, Alex & Benato, Alberto & Stoppato, Anna & Mirandola, Alberto, 2016. "The ORC-PD: A versatile tool for fluid selection and Organic Rankine Cycle unit design," Energy, Elsevier, vol. 102(C), pages 605-620.
    13. Sung, Taehong & Yun, Eunkoo & Kim, Hyun Dong & Yoon, Sang Youl & Choi, Bum Seog & Kim, Kuisoon & Kim, Jangmok & Jung, Yang Beom & Kim, Kyung Chun, 2016. "Performance characteristics of a 200-kW organic Rankine cycle system in a steel processing plant," Applied Energy, Elsevier, vol. 183(C), pages 623-635.
    14. van Kleef, Luuk M.T. & Oyewunmi, Oyeniyi A. & Markides, Christos N., 2019. "Multi-objective thermo-economic optimization of organic Rankine cycle (ORC) power systems in waste-heat recovery applications using computer-aided molecular design techniques," Applied Energy, Elsevier, vol. 251(C), pages 1-1.
    15. Kajurek, Jakub & Rusowicz, Artur & Grzebielec, Andrzej & Bujalski, Wojciech & Futyma, Kamil & Rudowicz, Zbigniew, 2019. "Selection of refrigerants for a modified organic Rankine cycle," Energy, Elsevier, vol. 168(C), pages 1-8.
    16. Lecompte, Steven & Huisseune, Henk & van den Broek, Martijn & Vanslambrouck, Bruno & De Paepe, Michel, 2015. "Review of organic Rankine cycle (ORC) architectures for waste heat recovery," Renewable and Sustainable Energy Reviews, Elsevier, vol. 47(C), pages 448-461.
    17. Imran, Muhammad & Pili, Roberto & Usman, Muhammad & Haglind, Fredrik, 2020. "Dynamic modeling and control strategies of organic Rankine cycle systems: Methods and challenges," Applied Energy, Elsevier, vol. 276(C).
    18. Xu, Bin & Rathod, Dhruvang & Yebi, Adamu & Filipi, Zoran & Onori, Simona & Hoffman, Mark, 2019. "A comprehensive review of organic rankine cycle waste heat recovery systems in heavy-duty diesel engine applications," Renewable and Sustainable Energy Reviews, Elsevier, vol. 107(C), pages 145-170.
    19. Feng, Yongqiang & Zhang, Yaning & Li, Bingxi & Yang, Jinfu & Shi, Yang, 2015. "Sensitivity analysis and thermoeconomic comparison of ORCs (organic Rankine cycles) for low temperature waste heat recovery," Energy, Elsevier, vol. 82(C), pages 664-677.
    20. Escalante, Edwin Santiago Rios & Balestieri, José Antônio Perrella & de Carvalho, João Andrade, 2022. "The organic Rankine cycle: A promising technology for electricity generation and thermal pollution mitigation," Energy, Elsevier, vol. 247(C).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jeners:v:13:y:2020:i:23:p:6446-:d:457501. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.