Augmentation of convective heat transfer in the cooling zone of brick tunnel kiln using guide vanes: An experimental study

Refaey, H.A.; Abdel-Aziz, Ali A.; Ali, Rashed; Abdelrahman, H.E.; Salem, Mohamed

doi:10.1016/j.ijthermalsci.2017.08.018

Cited by 28 publications

(17 citation statements)

References 13 publications

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“…Then, it is possible to propose alternatives to obtain better quality products, as well as to reduce processing the time and energy consumption. Several studies of thermal analysis in kilns can be found in the literature [32][33][34][35][36][37][38][39][40][41][42][43][44].Yu [32] developed a transient mathematical model for tunnel kilns. Using the model, the author was able to predict several parameters of the process, such as the temperature distribution in parts, energy consumption, heat losses, rate at which energy is accumulated, etc.…”

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confidence: 99%

Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

et al. 2019

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Drying and firing of ceramic products are processes that require high energy consumption. Making these processes more efficient can improve product quality, reduce processing time and energy consumption, and promote economic and environmental gains. In this sense, this work aims to quantify heat transfer in an intermittent ceramic kiln during the heating and cooling stages, with and without thermal insulation. All mathematical formulation is based on the first law of thermodynamics. From the results, we conclude that the greatest heat loss occurs by radiation in the sidewalls of the equipment, and that a considerable amount of energy is required to heat the sidewalls, base, and ceiling of the kiln. Further, with the use of thermal insulation, it was concluded that a high reduction in the heat lost through the sidewalls was achieved, thus providing a global energy gain of approximately 35% and a reduction in the maximum external surface temperature from 249.34 to 79.47 °C when compared to the kiln without thermal insulation, reducing the risks of work accidents and thermal discomfort when in operation.

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confidence: 99%

Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

et al. 2019

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“…[ [112][113][114][115][116][117][118] Modelling and optimisation of thermal process and plants Development of models which describe the specific thermal processes of a ceramic plant (more incidentally tunnel kilns) and the application of optimisation methods to improve the operation of plants.…”

Section: Best Practices and Limitationsmentioning

confidence: 99%

Review on Energy Efficiency Progresses, Technologies and Strategies in the Ceramic Sector Focusing on Waste Heat Recovery

2020

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Thermal processes represent a considerable part of the total energy consumption in manufacturing industry, in sectors such as steel, aluminium, cement, ceramic and glass, among others. It can even be the predominant type of energy consumption in some sectors. High thermal energy processes are mostly associated to high thermal losses, (commonly denominated as waste heat), reinforcing the need for waste heat recovery (WHR) strategies. WHR has therefore been identified as a relevant solution to increase energy efficiency in industrial thermal applications, namely in energy intensive consumers. The ceramic sector is a clear example within the manufacturing industry mainly due to the fuel consumption required for the following processes: firing, drying and spray drying. This paper reviews studies on energy efficiency improvement measures including WHR practices applied to the ceramic sector. This focuses on technologies and strategies which have significant potential to promote energy savings and carbon emissions reduction. The measures have been grouped into three main categories: (i) equipment level; (ii) plant level; and (iii) outer plant level. Some examples include: (i) high efficiency burners; (ii) hot air recycling from kilns to other processes and installation of heat exchangers; and (iii) installation of gas turbine for combined heat and power (CHP). It is observed that energy efficiency solutions allow savings up to 50–60% in the case of high efficiency burners; 15% energy savings for hot air recycling solutions and 30% in the when gas turbines are considered for CHP. Limitations to the implementation of some measures have been identified such as the high investment costs associated, for instance, with certain heat exchangers as well as the corrosive nature of certain available exhaust heat.

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“…The approach of lumped and distributed numerical analysis under time-dependent operating parameters is well defined [16]. The investigation of hydrogen production by different process parameters under best energy efficiency formation was incorporated by modelling the entire plant [17]. Recently, augmentation techniques with diverse attack angles head-to-head tunnel kiln wall by using guide vanes was conducted [18].…”

Section: Introductionmentioning

confidence: 99%

Thermal Analysis and Energy Efficiency Improvements in Tunnel Kiln for Sustainable Environment

et al. 2021

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Kiln is a prime need in the ceramics industry, where energy loss is a major part which consumes about 60% production cost through thermal energy for different applications. Higher density of fired and tunnel kiln refractory material lowers the thermal diffusivity and the proper selection of fired material minimizes the energy loss along the kiln. In particular, this research analysed the results of a heat recovery system comprised of a metallic recuperator which gives around 8% energy savings in natural gas consumption. In this work, detailed power quality analysis of low-power factor motors of a tunnel kiln was carried out and a power factor improvement solution was suggested to save electrical energy with payback period of 0.8 y. The motor operating at a low-power factor consumes more reactive power which does not produce beneficial work. A low-power factor around 0.4 causes network power loss, increases in transformer loss and voltage drops. The solution with accumulative capacitance power of 148.05 uF was installed to achieve the power factor to 0.9. Flu gas analyzer was installed to monitor the range of O2 in pre-heating, oxidation, and firing zones of the kiln which should be ≥8% and 3%, respectively. Regression analysis for thermal energy consumption of a tunnel kiln is done to find the forecast thermal energy consumption. This analysis can be used to find operational efficiency, supporting decisions regarding dependent variable of thermal energy consumption and independent variable of production. This research is very helpful for the ceramics industry to mitigate the energy loss at SMEs as well as in mass production level.

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Augmentation of convective heat transfer in the cooling zone of brick tunnel kiln using guide vanes: An experimental study

Cited by 28 publications

References 13 publications

Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis

Review on Energy Efficiency Progresses, Technologies and Strategies in the Ceramic Sector Focusing on Waste Heat Recovery

Thermal Analysis and Energy Efficiency Improvements in Tunnel Kiln for Sustainable Environment

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