Analysis of energy saving in domestic ceramic industry kilns

Ceramic industrial kiln refers to the combustion equipment for ceramic production, which generally refers to roller kiln, shuttle tunnel kiln and shuttle kiln. Roller kiln refers to the kiln with continuous firing and rotating roller as the vehicle of the billet body; Tunnel kiln refers to the kiln which adopts continuous firing and takes rail kiln car as the transport vehicle of billet body. Shuttle kiln refers to the kiln which is fired intermittently and consists of kiln car, kiln chamber and kiln door. Factors influencing energy saving of kiln include construction materials, kiln structure, combustion technology, thermal insulation performance and automation control.

Thermal Performance Combined with Cooling System Parameters Study for a Roller Kiln Based on Energy-Exergy Analysis

Roller kilns, characterized as high energy consumption equipment, are widely used in the firing process of ceramic tiles. To evaluate the thermal performance of a roller kiln, a detailed energy and exergy analysis is carried out employing the operating values from a typical ceramic factory. In this study, parametric studies are performed that examine the impacts of the roller kiln’s cooling system on thermal performance, fuel-saving, cost-saving, and environmental influence. The results show that the targeted energy only accounts for 13.4% and 9.7% of the total energy and exergy inputs, indicating the poor efficiency of the roller kiln. This research also identifies that the exergy destruction is the largest cause of the exergy loss in the system, accounting for 85.1% of the total exergy input—of which 50.9% is due to heat and mass transfer, and 37.9% is caused by fuel combustion. Based on the parametric studies, it has been found that with every 1% increase in cooling air mass flow, the energy and the exergy efficiencies of the kiln increase by 0.06% and 0.04%; with every 1% increase in cooling gas temperature, the energy and the exergy efficiencies of the kiln drop by 0.09% and 0.07%; with every 1% increase in cooling gas residence time, the energy and the exergy efficiencies of the kiln increase by 0.16% and 0.12%. Furthermore, results show that the cooling air residence time has the main impact on the cost-saving and carbon dioxide emission reduction, followed by cooling air mass and cooling air temperature.

Recycling Of The Mixture Resulted From Sanitary Ware Waste, Roller Kiln Waste And Ceramic Tiles Sludge Waste In The Manufacturing Of Ceramic Floor Tiles

Ceramic tiles industry is a big source for wastes that have a bad effect on the environment. The first source of waste is associated with roller kilns as it needs a periodic surface grinding to its rollers which results in a waste powder. The second type of waste is ceramic tiles sludge which produced from a water treatment plant. The third waste is sanitary ware waste which coming out from sanitary ware industry. The main aim of this paper is to investigate the ability of substituting part of the main body mixture of floor tiles by these three types of waste powder. Many Experiments were done on the raw materials. Rectangular tile specimens were moulded, dried and fired. Sintering parameters and mechanical properties were determined. The sample that consist of 2% Roller Kiln, 39% Ceramic tiles sludge, 15% sanitary ware waste, and 44% Floor tiles mixture has the optimum properties.Ceramic tiles industry is a big source for wastes that have a bad effect on the environment. The first source of waste is associated with roller kilns as it needs a periodic surface grinding to its rollers which results in a waste powder. The second type of waste is ceramic tiles sludge which produced from a water treatment plant. The third waste is sanitary ware waste which coming out from sanitary ware industry. The main aim of this paper is to investigate the ability of substituting part of the main body mixture of floor tiles by these three types of waste powder. Many Experiments were done on the raw materials. Rectangular tile specimens were moulded, dried and fired. Sintering parameters and mechanical properties were determined. The sample that consist of 2% Roller Kiln, 39% Ceramic tiles sludge, 15% sanitary ware waste, and 44% Floor tiles mixture has the optimum properties.

Recycling of the Mixture Resulted from Roller Kiln Waste and Ceramic Tiles Sludge Waste in the Manufacturing of Ceramic Floor Tiles

Ceramic tiles industry produced many types of wastes that are routinely discarded as stock piles. One of the environmental problems associated with roller kilns is the periodic need to grind its rollers which results in a waste powder. The second type of waste is ceramic tiles sludge which produced from a water treatment plant in the ceramic tiles factory. This paper investigates the probability of substituting part of the main body of floor tiles mixture by these two types of waste powder. Many Experiments were done on the raw materials. Rectangular tile specimens were molded, dried and fired. Linear firing shrinkage, loss on ignition, sintering parameters, and mechanical properties were determined. It was found that the samples with the composition (1% Roller Kiln, 35% Ceramic tiles sludge, and 64% Floor tiles mixture) or (2% Roller Kiln, 24% Ceramic tiles sludge, and 74% Floor tiles mixture) have the optimum properties.