Radial Wafer Oven Heating With Thermal Oil Heat Exchangers
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Solution Overview
Problem
Conventional wafer ovens have low efficiency due to waste gas losses, limited baking plate size, and emissions issues, with restrictive fuel options and corrosion problems from high-pressure heating mediums like steam.
Innovation Solution
The oven features a wheel-like carrier with radially extending baking plates and heat exchangers operating at low pressure, allowing for more plates and uniform heating, using a thermal oil medium to reduce energy consumption and emissions, and enabling larger plate sizes for increased capacity.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Temperature
If direct gas firing with burners is used to heat baking plates, then heating capability is improved, but energy efficiency deteriorates due to waste gas losses of approximately 36%
Solution Approach 1:
A thermal oil intermediary medium is introduced to transfer heat from the burners to the baking plates. The thermal oil circulates through channels in the baking plates, absorbing heat from the burners and directly transferring it to the plates, thereby eliminating waste gas losses and improving energy efficiency while maintaining effective heating capability.
2Reliability
If additional oxygen is drawn through the oven using a venting fan to achieve complete combustion, then combustion efficiency is improved, but energy efficiency deteriorates due to heating and transporting air out of the oven
Solution Approach 1:
The thermal oil acts as an intermediary that absorbs heat directly at the burner location and transports it to the baking plates through controlled channels. This eliminates the need for forced air circulation, as the thermal oil naturally circulates through the system, thereby avoiding the energy losses associated with heating and transporting large volumes of air through the oven.
3Temperature
If flame length is increased to improve heating effectiveness, then heating capability is improved, but emissions increase due to disruption of flames by reinforcing elements
Solution Approach 1:
The thermal oil intermediary allows for more controlled and uniform heat distribution to the baking plates without requiring excessively long flames. The thermal oil absorbs heat from the burners and distributes it evenly through the plate channels, reducing the need for long flames that would be disrupted by reinforcing elements and thereby reducing harmful emissions.
4Temperature
If high-pressure steam is used as a heating medium, then heating capability is improved, but reliability deteriorates due to corrosion of baking plates and system components
Solution Approach 1:
The system transitions from using high-pressure steam to using thermal oil as the heating medium. This parameter change in the heating medium eliminates the corrosion problems associated with steam while maintaining effective heating capability, as thermal oil does not cause corrosion of baking plates and system components.
5Productivity
If baking plate size is increased to improve production capacity, then productivity is improved, but device complexity increases due to difficulty in applying holding forces for closing plates
Solution Approach 1:
The thermal oil circulation system with integrated channels in the baking plates provides a stable structural framework that can support larger plate sizes. The channels and connecting elements act as structural reinforcements, allowing larger baking plates to be used without proportionally increasing the complexity of holding force application mechanisms.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This configuration enhances baking efficiency, reduces emissions, and allows for larger baking plates, increasing production capacity while minimizing energy costs and avoiding corrosion, thus achieving a higher yield with improved baking results.
Implementation Method 1
at least one heat exchanger assigned to the baking plates through which a medium tempered by a heat source flows
Implementation Method 2
a medium tempered by a heat source flows
Data Source
AI summary
An oven for baking batter goods, in particular, a wafer oven, has several baking plates assigned to one another in pairs, and at least one heat source for tempering or heating the baking plates. Particularly efficient production of wafers or similar products can be achieved in that the baking plates are mounted in a wheel-like carrier that can be rotated about an axis so that they extend essentially radially away from the axis, at a distance from it. Furthermore, at least one heat exchanger may be assigned to the baking plates, in each instance, through which a medium tempered by a heat source and supplied by way of a ring line flows.