How to Get the Most from Your Oven Heat Flux (a.k.a. Energy / Heat Transfer)
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1 How to Get the Most from Your Oven Heat Flux (a.k.a. Energy / Heat Transfer) Richard J. Starke Director B&CMA Technical Conference 2016 B&CMA 91 st Technical B&CMA 91Conference st Technical Conference Atlanta, Atlanta, GA GA
2 B&CMA Technical Conference 2015 All About Ovens Convection and Recirc Ovens John Guy, President, Thermal Systematics Air Impingement Convection Oven Jeff McLean, Sales Manager-North America, Spooner Vicars Bakery Direct Gas Fired (DGF) Ribbon Burner Ovens Mihaelos Mihalos, Senior Associate Principal Engineer, Mondelez International Baking Curves Richard Starke, Director, Reading Thermal B&CMA 91 st Technical B&CMA 91Conference st Technical Conference Atlanta, Atlanta, GA GA
3 B&CMA Technical Conference 2016 How to Get the Most from Your Oven Heat Flux (a.k.a. Energy / Heat Transfer) B&CMA 91 st Technical B&CMA 91Conference st Technical Conference Atlanta, Atlanta, GA GA
4 What Is Heat Flux? Heat Flux is the amount of energy passing through an imaginary surface of specific cross sectional area per unit time. Units: Btu / hr ft 2 or kw / m 2 Flow of Heat Energy Imaginary Surface What if we collect this energy?
5 What Is Heat Flux? Heat Flux is the amount of energy passing through an imaginary surface of specific cross sectional area per unit time. Units: Btu / hr ft 2 or kw / m 2 Flow of Heat Energy Imaginary Surface Collector / Product Total Heat is the amount of energy experienced (collected) over a period of time. Units: Btu / ft 2 or kj / m 2
6 What Is Heat Flux? Heat Flux is the amount of energy passing through an imaginary surface of specific cross sectional area per unit time. Units: Btu / hr ft 2 or kw / m 2 Flow of Heat Energy Analogous to Rain Being Collected in a Bucket Raindrops are packets of energy Imaginary Surface Measuring energy as it enters the bucket yields Rain Flux Collector / Product Raindrops collected over a period of time yields Total Rain Total Heat is the amount of energy experienced (collected) over a period of time. Units: Btu / ft 2 or kj / m 2
7 What Are The Types Of Heat Flux? Heat is transferred to a product via three different mechanisms, each of which can be described by a Heat Flux component associated with Conduction, Convection, and Radiation. Each of these modes of heat transfer is present in baking and other thermal applications. Every product has its own unique mix of heat flux components; there is not one optimal heat flux profile for all products.
8 What Are The Types Of Heat Flux? Conduction (Q b ) heat transfer from the band Q b = k x A x (T b T c ) k = thermal conductivity coefficient A = area of product in contact with the band T b = temperature of the band T c = temperature of the product in contact with the band Heat transfer is highly dependent on the contact between the band and the product, and k the thermal conductivity coefficient for the product.
9 What Are The Types Of Heat Flux? Convection (Q c ) heat transfer from the air Q c = h c x A x (T a - T c ) h c = convective heat transfer coefficient A = area of product in contact with the air T a = temperature of air hitting the product T c = temperature of product surface There is no easy way to calculate Q c because h c is a complicated value based on air velocity, density and viscosity, all effected by temperature and pressure.
10 What Are The Types Of Heat Flux? Radiation (Q r ) heat transfer from hot objects Q r = A x σ x ɛ (T 4 h T4 ) c A = area of radiating surface σ = Stefan Boltzmann constant for a black body (ideal) radiation ε = emissivity of the radiating object from 0 to 1 T h = absolute temperature (K) of hot object T c = absolute temperature (K) of cold product Note the importance of the temperature term: if the ΔT doubles the heat transfer rate multiplies by 16! Emissivity of dark objects approaches 1 while shiny objects approach 0. e.g. Carbon Steel = 0.5
11 Why Measure Heat Flux? 1. Because heat transfer related CONDUCTION, RADIATION, and CONVECTION defines the product bake. 2. Critical to understanding finished product characteristics is knowing the Total Heat experienced by the product, and the component quantities of Radiant and Convective heat fluxes. 3. While temperature is most often measured, and is easy to understand, it does not indicate heat transfer:
12 Why Measure Heat Flux? 1. Because heat transfer related CONDUCTION, RADIATION, and CONVECTION defines the product bake. 2. Critical to understanding finished product characteristics is knowing the Total Heat experienced by the product, and the component quantities of Radiant and Convective heat fluxes. 3. While temperature is most often measured, and is easy to understand, it does not indicate heat transfer: It s a HOT SUNNY DAY at the BEACH
13 Why Measure Heat Flux? 1. Because heat transfer related CONDUCTION, RADIATION, and CONVECTION defines the product bake. 2. Critical to understanding finished product characteristics is knowing the Total Heat experienced by the product, and the component quantities of Radiant and Convective heat fluxes. 3. While temperature is most often measured, and is easy to understand, it does not indicate heat transfer: HOT SUNNY DAY T1 = T2 E1 = E2 Couple 1 Couple 2
14 Why Measure Heat Flux? 1. Because heat transfer related CONDUCTION, RADIATION, and CONVECTION defines the product bake. 2. Critical to understanding finished product characteristics is knowing the Total Heat experienced by the product, and the component quantities of Radiant and Convective heat fluxes. 3. While temperature is most often measured, and is easy to understand, it does not indicate heat transfer: HOT SUNNY DAY T1 = T2 E1 E2 Couple 1 Couple 2
15 Heat Flux Sensor Measures convective and radiant heat fluxes at product level Displays Heat Flux: Q radiant Q convective Q total (Btu/hr ft 2 or W/m 2 ) Displays Total Heat: radiant & convective (Btu/ft 2 or Joules/m 2 ) Heat transfer to the product from above the conveyor Identify which modes of heat transfer are predominant Heat Flux & Total Heat define the product Main Application: Over time heat transfer characteristics Total heat experienced by the product Proportion of radiation & convection
16 Profile Graphs Heat Flux Profile Heat Flux Components (Btu / hr ft 2 ) Qr is radiant heat flux Qc is convective heat flux Qt is total heat flux (Qr+Qc) We can determine Total Heat experienced by the product via integration and finding the area under Qr and Qc.
17 Profile Graphs Heat Flux Profile Heat Flux Components (Btu / hr ft 2 ) Qr is radiant heat flux Qc is convective heat flux Qt is total heat flux (Qr+Qc) Total Heat Profile Total Heat (Btu / ft 2 ) Red Area is total radiant heat experienced by the product Blue Area is total convective heat experienced by the product Radiation and Convection are stacked to display Total Heat
18 Heat Flux Experiment Multi Grain Cracker Condition 1 Convection Heating Only Dwell Time = 1:34 sec All Convection Heat in Zones 1 & 2 Very little radiant heat flux...only from oven ceiling and sidewalls Each convection spike is related to air distribution ports Next, let s add 5 Radiant Burners to Zone 1.
19 Heat Flux Experiment Multi Grain Cracker Condition 1 Convection Heating Only Dwell Time = 1:34 sec All Convection Heat in Zones 1 & 2 Very little radiant heat flux...only from oven ceiling and sidewalls Each convection spike is related to air distribution ports Condition 2 Convection & Radiant Heating Dwell Time = 1:34 sec 5 Radiant Burners added to Zone 1 18,000 Btu per Burner (#67 orifice plate) Convective heat flux remains the same Radiant heat flux spikes occur at burner locations Total heat flux increases proportionally Next, let s look at the temperature profiles.
20 Heat Flux Experiment Multi Grain Cracker Condition 1 Convection Heating Only Tc is temperature profile Tc slope = 10.8 Tc reaches 350º F in 23 sec Next, how do the radiant burners affect temperature?
21 Heat Flux Experiment Multi Grain Cracker Condition 1 Convection Heating Only Tc is temperature profile Tc slope = 10.8 Tc reaches 350º F in 23 sec Condition 2 Convection & Radiant Heating Tc slope = 15.3 Tc reaches 350º F in 15 sec Radiant burners increase the slope of the temperature profile Next, let s look at the Total Heat profiles.
22 Heat Flux Experiment Multi Grain Cracker Condition 1 Convection Heating Only End of Zone 1 o Total Heat = 37 Btu / ft 2 o 87% Convective, 32 Btu / ft 2 o 13% Radiant, 5 Btu / ft 2 Next, how do the radiant burners affect Total Heat?
23 Heat Flux Experiment Multi Grain Cracker Condition 1 Convection Heating Only End of Zone 1 o Total Heat = 37 Btu / ft 2 o 87% Convective, 32 Btu / ft 2 o 13% Radiant, 5 Btu / ft 2 Condition 2 Convection & Radiant Heating End of Zone 1 o Radiant heat has doubled from 5 Btu / ft 2 to 10 Btu / ft 2 and is now 23% of the Total Heat o Convective heat is essentially the same o Total Heat has increased to 43 Btu / ft 2, essentially proportional to the radiant heat increase Next, what is the effect of reducing dwell time?
24 Heat Flux Experiment Multi Grain Cracker Condition 2 Convection & Radiant Heating Dwell Time = 1:34 sec Condition 3 Convection & Radiant Heating Dwell Time = 1:18 sec, reduced by 16 sec The magnitude (Btu / hr ft 2 ) of the heat flux profiles remains the same but occurs in a shorter period of time Lastly, what is the effect on Total Heat experienced by the product?
25 Heat Flux Experiment Multi Grain Cracker Condition 2 Convection & Radiant Heating Dwell Time = 1:34 sec Total Heat experienced by the product is 80 Btu / ft 2 Condition 3 Convection & Radiant Heating Dwell Time = 1:18 sec, reduced by 16 sec Total Heat experienced by the product is 67 Btu / ft Btu / ft 2 less All Radiant and Convective percentages remain the same Less heat transfer (less baking) but same Radiant / Convective % mix
26 How Can I Use Heat Flux Profiles? Often used when trying to produce the same product on two different lines, or when trying to transfer product from one line to another. When the heat flux profiles are matched, the two lines will produce the same product. Understand why two lines, supposedly identical, have different throughput, i.e. one consistently produces greater tonnage than the other. Used as a tool in speeding up production: Total Heat and %mix of Convection and Radiation must be maintained. R&D product development: moving from a test kitchen or pilot line to full scale production.
27 Direct Gas Fired (DGF) Ribbon Burner Oven Heat Flux: Total Heat Product Chocolate Sandwich Cookie Oven 5 Zones Length = 197ft Width = 1.2m Heavy Mesh Band (CB5) Bake Time = 5min Conveyor Speed = 39fpm Sensor Heat Flux Unit of measure is Btu/ft 2
28 Convection / Recirculation Oven Heat Flux: Total Heat Product Large Soft Chocolate Chip Cookie Oven 4 Zones Length = 171ft Width = 1.2m Solid Steel Band Bake Time = 10.4min Conveyor Speed = 16fpm Sensor Heat Flux Unit of measure is Btu/ft 2
29 Impingement Oven Heat Flux: Total Heat Product Baked Potato Chip Oven 8 Zones Length = 167ft Width = 1.5m Open Mesh Bake Time = 50sec Conveyor Speed = 200fpm Sensor Heat Flux Unit of measure is Btu/ft 2
30 Thank You! Richard J. Starke Director 7 Corporate Blvd. Sinking Spring, PA USA Ext richard.starke@readingthermal.com B&CMA Technical Conference 2016 B&CMA 91 st Technical B&CMA 91Conference st Technical Conference Atlanta, Atlanta, GA GA
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