Energy consumption and CO 2 and NOx emissions Minimized in an Intermittent Ceramic Kiln – “ECONOMICK kiln” June 19-22, 2019, Iasi, Romania SE.TE.C. srl, Italy Keywords: sanitaryware, tableware, shutle kiln, energy reducton, Greenhouse gas emission minimized. 1. Introduction: Intermitent or shutle kilns are used for discontnuous producton, for low volumes, partcular pieces, and refring, with high energy costs and much fleξibility 6].. Intermitent or shutle kilns are used in about 2% of the ceramic sectors, eξcluding only tles industry. SE.TE.C.'s idea starts from the reuse of flue gases to heat the combus ton air by heat eξchangers. A novelty in shutle kilns that, about other technologies, can also be applied to eξis tng furnaces. ECONOMICK includes: 1. Integral reuse of the heat of the flue gas spread through the chimneys, obtained by heat eξchanger outside the kiln. 2. Innovatve COEL burners that allow to maξimize heat eξchange rate between the fumes and fred pieces, increasing efciency and performing the kiln and reducing NOξ emissions. 3. A fully computerized management of the air and gas flow, leading to a further minimizaton of thermal energy consumpton. . Redesign of the structure of the kiln with reduced thermal dispersion. The insulaton optmizaton is achieved by the design of the vault and walls, as with the use of advanced materials with high performances. 2. Experimental Part: The idea for the ECONOMICK project is born from seeks by market of our customers. The prototype constructon shutle kiln, with a volume of 9 m3, consists of a structure of reduced size in easy assembly. The fring chamber is constructed with refractory materials inside to be able to withstand the contnuous thermal changes and able to decrease to a minimum dispersing heat through the body of the kiln and the fuel consumpton. The validaton of the selected materials is carried out by using simulaton soſtware SIMU6THERM, a heat transfer calculaton soſtware, developed for design the kiln. This same soſtware has allowed us to check the maξimum temperature reached by the outer wall of the kiln. In the constructon of the intermitent kiln, frstly, it is important to check the combus ton process. Secondly, efectve insulaton is guaranteed. Thirdly, great atenton has been given to the opening valves of the chimneys since those valves must guarantee the homogeneity of the fring e the leak of the hot fumes during the cooling phase. The control panel, which controls the pilot kiln, is mounted near the panel with the supervisory system soſtware with PLC allowing precise metering of solid fuel, with adjustable ofsets for each delivery positon as to keep overall energy uniformity. Aſter the assembling and constructon phase a trial protocol covering all the operatons is performed. In sanitary ware and tableware producton, an evaluaton of energy performance and furnace emissions during the producton phase was performed. Those actvites allowed to of6set performance against the state6of6the6art intermitent kilns used as standard and available on the market. 3. Results and Discussions: The cycles considered are those of the sanitaryware fring 22 h, normally used in producton. By varying the insulaton, it was possible to check how the stratfcaton of the walls afects the heat released on the surface and simultaneously the absorbed heat. The choice of materials used on a shutle kiln mus t always be the result of a compromise: on the one hand, the need to increase insulaton, on the other the need to avoid an eξcessive increase in the kiln’s mass. The kiln atmosphere was controlled by determining the temperature of the wall and by measuring the real oξygen content in the combus ton chamber. The ECONOMICK kiln shown less heat dispersion especially through the door, with consequent homogeneity in the combus ton chamber. The use of insulatng materials with beter thermal performance thus gets a ceramic product with uniform fring in all its parts. A detailed study is then performed of the combus ton in the burners to control the eξcess air coefcient in the burners by O2 probe and by methane consumpton. The data obtained are then used to es tmate the recovery energy during the combus ton. Thanks to O2 probe, ECONOMICK kiln further reduced gas and electric energy consumpton. It’s important to observe: • Final ECONOMICK emissions saved are 67 • Coel burners confrm their efciency in the secondary NOξ decrease 6 2. • The soſtware change and probe introducton improved combuston efciency and kiln fleξibility. • Is possible to have shorter fring cycles 12:%% h and < 2% °C cold wall temperatures. • It’s been possible to reduce 861% sanitaryware thickness thanks to beter fring homogeneity inside the kiln. • Air combuston is preheated up to %%°C. The results with the ECONOMICK kiln in sanitaryware and tableware producton are reported in table below: Table1: Results obtained from the data registered during producton. 4. Conclusions: The thermal efciency of this prototype is in line with that of a contnuous furnace, through the recovery of sensible heat of the flue gas used for preheatng the combus ton air. In additon, the latest generaton of insulatng allows to greatly reducing the heat losses of the furnace. Finally, an optmized control system of the air / gas rato allows you to preserve a higher efciency. The almost complete reuse of warm air from cooling and advanced materials for thermal insulaton saves 7 for sanitaryware and 2% for tableware methane consumptons respect standard shutle kiln. This meant to reduce emissions of CO2, SOξ, NOξ, dust and HF. Thanks to ECONOMICK lining low thermal inerta is possible to have a short fring cycle in sanitaryware producton 12 h improving fleξibility. By subs ttutng traditonal tunnel kilns with ECONOMICK kiln, European industries 6 in partcular SMEs – can drastcally reduce their costs for producton. All this is realized in ECONOMICK project. References: . Zhou, Y ., Qin, C., 2%17, Energy efciency evaluaton of a shutle kiln based on feld test, Adv. Mech. Eng. 9 1 2. Sun, B., Chen, Z., 2%%7 Energy saving status and development trends of industrial furnace, Energ. Environ. 3 3% ]. Yang, J., Zhao, X., Wang, Z., 2%11, Energy status and development trends of industrial furnace, Energ. Metall. Ind. 3% 2 7. Kaden, M., 2%%2, Controlling the residual oxygen content of kiln gases, ZI Int. 28 8 2]. 5. Acknowledgments: Authors are indebted to Ceramica Kerasan srl Civita Castellana, Italy, partner of the project LIFE12 CCM/IT/%%%1% www.economick.eu. A Fortuna, DM Fortuna, E Martini, A Pozzovivo SE.TE.C. srl, via Enrico Fermi 6/18, 01033 Civita Castellana (VT), Italy. Email: [email protected]
Welcome message from author
This document is posted to help you gain knowledge. Please leave a comment to let me know what you think about it! Share it to your friends and learn new things together.
Transcript
Energy consumption and CO2 and NOx emissions Minimized in an
Intermittent Ceramic Kiln – “ECONOMICK kiln”
June 19-22, 2019, Iasi, Romania
SE.TE.C. srl, Italy
Keywords: sanitaryware, tableware, shutle kiln, energy reducton, Greenhouse gas emission minimized.
1. Introduction:
Intermitent or shutle kilns are used for discontnuous producton, for low volumes, partcular pieces, and refring, with high energy costs and much flexiibility [t4-6].. Intermitent ( or shutle kilns are used in about 50% of the ceramic sectors, exicluding only tles industry. SE.TE.C.'s idea starts from the reuse of flue gases to heat the combuston air by heat exichangers. A novelty in shutle kilns that, about other technologies, can also be applied to exiistng furnaces.ECONOMICK includes:1. Integral reuse of the heat of the flue gas spread through the chimneys, obtained by heat exichanger outside the kiln.
2. Innovatve COEL burners that allow to maxiimize heat exichange rate between the fumes and fred pieces, increasing efciency and performing the kiln and reducing NOxi emissions.3. A fully computerized management of the air and gas flow, leading to a further minimizaton of thermal energy consumpton.4-. Redesign of the structure of the kiln with reduced thermal dispersion. The insulaton optmizaton is achieved by the design of the vault and walls, as with the use of advanced materials with high performances.
2. Experimental Part:
The idea for the ECONOMICK project is born from seeks by market of our customers. The prototype constructon shutle kiln, with a volume of 9 m3, consists of a structure of reduced size in easy assembly. The fring chamber is constructed with refractory materials inside to be able to withstand the contnuous thermal changes and able to decrease to a minimum dispersing heat through the body of the kiln and the fuel consumpton. The validaton of the selected materials is carried out by using simulaton software ( SIMU6THERM , a heat transfer calculaton software, developed for design the kiln. This same software has allowed us to check the maxiimum temperature reached by the outer wall of the kiln.In the constructon of the intermitent kiln, frstly, it is important to check the combuston process. Secondly, efectve insulaton is guaranteed.Thirdly, great atenton has been given to the opening valves of the chimneys since those valves must guarantee the homogeneity of the fring e the leak of the hot fumes during the cooling phase.The control panel, which controls the pilot kiln, is mounted near the panel with the supervisory system ( software with PLC allowing precise metering of solid fuel, with adjustable ofsets for each delivery positon as to keep overall energy uniformity. After the assembling and constructon phase a trial protocol covering all the operatons is performed. In sanitary ware and tableware producton, an evaluaton of energy performance and furnace emissions during the producton phase was performed.Those actvites allowed to of6set performance against the state6of6the6art intermitent kilns used as standard and available on the market.
3. Results and Discussions:
The cycles considered are those of the sanitaryware fring ( 22 h , normally used in producton. By varying the insulaton, it was possible to check how the stratfcaton of the walls afects the heat released on the surface and simultaneously the absorbed heat. The choice of materials used on a shutle kiln must always be the result of a compromise: on the one hand, the need to increase insulaton, on the other the need to avoid an exicessive increase in the kiln’s mass. The kiln atmosphere was controlled by determining the temperature of the wall and by measuring the real oxiygen content in the combuston chamber. The ECONOMICK kiln shown less heat dispersion ( especially through the door , with consequent homogeneity in the combuston chamber. The use of insulatng materials with beter thermal performance thus gets a ceramic product with uniform fring in all its parts.
A detailed study is then performed of the combuston in the burners to control the exicess air coefcient in the burners by O2 probe and by methane consumpton.The data obtained are then used to estmate the recovery energy during the combuston. Thanks to O2 probe, ECONOMICK kiln further reduced gas and electric energy consumpton.It’s important to observe:• Final ECONOMICK emissions saved are 64-7 • Coel burners confrm their efciency in the secondary NOxi decrease ( 6504- .• The software change and probe introducton improved combuston efciency and kiln flexiibility.• Is possible to have shorter fring cycles ( 12:%% h and < 50% °C cold wall temperatures.• It’s been possible to reduce 861% sanitaryware thickness thanks to beter fring homogeneity inside the kiln.• Air combuston is preheated up to 4-%%°C.The results with the ECONOMICK kiln in sanitaryware and tableware producton are reported in table below:
Table1: Results obtained from the data registered during producton.
4. Conclusions:
The thermal efciency of this prototype is in line with that of a contnuous furnace, through the recovery of sensible heat of the flue gas used for preheatng the combuston air. In additon, the latest generaton of insulatng allows to greatly reducing the heat losses of the furnace. Finally, an optmized control system of the air / gas rato allows you to preserve a higher efciency. The almost complete reuse of warm air from cooling and advanced materials for thermal insulaton saves 4-7 ( for sanitaryware and 50% ( for tableware methane consumptons respect standard shutle kiln. This meant to reduce emissions of CO2, SOxi, NOxi, dust and HF. Thanks to ECONOMICK lining low thermal inerta is possible to have a short fring cycle in sanitaryware producton ( 12 h improving flexiibility. By substtutng traditonal tunnel kilns with ECONOMICK kiln, European industries 6 in partcular SMEs – can drastcally reduce their costs for producton.All this is realized in ECONOMICK project.
References:
[t4-. Zhou, Y., Qin, C., ( 2%17 , Energy efciency evaluaton of a shutle kiln based on feld test, Adv. Mech. Eng. 9 ( 4- 1[t50. Sun, B., Chen, Z., ( 2%%7 Energy saving status and development trends of industrial furnace, Energ. Environ. 3 3%[t]. Yang, J., Zhao, X., Wang, Z., ( 2%11 , Energy status and development trends of industrial furnace, Energ. Metall. Ind. 3% 4-2[t7. Kaden, M., ( 2%%50 , Controlling the residual oxygen content of kiln gases, ZI Int. 508 ( 8 2].
5. Acknowledgments:
Authors are indebted to Ceramica Kerasan srl ( Civita Castellana, Italy , partner of the project LIFE150 CCM/IT/%%%1%4- ( www.economick.eu .
A Fortuna, DM Fortuna, E Martini, A PozzovivoSE.TE.C. srl, via Enrico Fermi 6/18, 01033 Civita Castellana (VT), Italy.
Email: [email protected]
Related Documents
