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D APPENDIX D: TECHNOLOGY SOLUTIONS FOR ENERGY RECOVERY Low-Temperature Heat Recovery in the Food Processing Industry Food processing industries play a vital role in the U.S. economy and in foreign trade. This industry accounts for a large portion of the U.S. industrial energy use, ranking as the fifth largest energy-using industry after petroleum refining, chemicals, primary metals, and paper manufacturing. Unlike other energy-intensive industries, the food industry does not produce a homogeneous output and operates at significantly lower temperatures. Therefore, energy consumption in food industries comes from a wide range of production activities such as roasting, baking, cooking, frying, freezing, drying, refrigeration, pasteurization, evaporation, and distillation. There are also energy demands for supplying buildings with heat, light, and air conditioning. In 1994, roughly two-thirds of final energy demand for the food industries was fuel for boilers to provide steam and heat to various processes. There are many opportunities to take advantage of heat recovery in food processing, achievable by using all or part of the exhaust gas from one process as the inlet gas to another process. Alternatively, heat exchangers can capture heat in the exhaust and transfer it to another flow of gas or liquid. Energy savings from heat recovery in the food industry depends upon finding applications where heat recovery is economical and improves the process. Case studies illustrate there are many potential applications for cost-effective heat recovery applications in the food industry. In some of these projects, excess heat from one energy-intensive process step was used in another process step. These have been demonstrated in bakeries, vegetable processing plants, beverage facilities, drying of grains, drying of malt for breweries, and pulp drying in the sugar processing industry. Most of these applications utilize heat exchangers constructed from steel, except in caustic applications where the material of choice is nickel, nickel-steel alloy, or titanium. It is estimated that the food industry energy consumption in 2015 will be approximately 1700 TBtu of primary energy. Roughly 50 percent of this will be fossil fuel for boilers meeting steam demand for food processing. Another 15 percent of this will be fossil fuel used directly in processes. Thirty-five percent will be fuels consumed to meet the food industry’s electricity demand. Of the total energy consumed for steam demand, 20 to 25 percent is lost due to boiler inefficiencies. The use of heat recovery systems can lower the boiler systems to 12 to 16 percent in industries where there are opportunities for heat recovery. Assuming that 20% of energy use falls into this category and is retrofit for heat recovery by 2015, 14 TBtu of energy savings can be attained. Given that 16% of food industry energy is used for drying, and that potential savings from heat recovery systems for drying range from 10 to 50 percent, and assuming 20% drying energy demand is appropriate for heat recovery and retrofit by 2015 with an average dryer demand reduction of 25%, energy consumption will be lowered by 9.5 TBtu. 130PDF Image | Analysis for Recovering Energy from Industrial Waste Heat
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