Numerical analysis of an entire ceramic kiln under actual operating conditions for the energy efficiency improvement

Milani, Massimo; Montorsi, Luca; Stefani, Matteo; Saponelli, Roberto; Lizzano, Maurizio

doi:10.1016/j.jenvman.2017.03.076

Cited by 36 publications

(25 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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“…Technological advances not only reduce emissions, but also save costs (Song and Wang, 2018), particularly in the ceramic industry (Mezquita et al, 2014;Milani et al, 2017;Cuviella-Suárez et al, 2019). In the past two decades, Huida Group Co. Ltd. has upgraded its facilities such as kilns and stoves to improve the energy efficiency.…”

Section: (A) Rates Of Fuel Savedmentioning

confidence: 99%

Life cycle assessment and life cycle costing of sanitary ware manufacturing: A case study in China

Zhang

et al. 2019

Journal of Cleaner Production

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Sanitary ware industry consumes vast amounts of energy and materials; however, little is known about the environmental impacts and economic costs associated with the production of sanitary ware. Selecting a factory of a leading Chinese sanitary ware company, Huida Co. Ltd., this paper employs a combined "cradle-to-gate" life cycle assessment (LCA) and life cycle costing (LCC) methodology to evaluate the environmental impacts and economic costs related to the production of one tonne of sanitary ware. The LCA results indicate firing and drying are the processes with the greatest environmental impacts, attributing to the combustion of coke oven gas. The LCC results show that casting, body preparation and firing are the greatest contributors to the total equipment, material and energy costs, respectively. The results of sensitivity analysis confirm that increasing fuel efficiency, natural gas usage and recycling rates can reduce the overall environmental impacts, but the total costs would be increased by 13.8% if coke oven gas is fully replaced by natural gas, even considering carbon tax. Based on the findings, recommendations such as using green materials and improving energy efficiency, are provided to promote both the environmental and economic sustainability of sanitary ware production.

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“…The fluid domain focuses only on the catalyst as ideally could be installed in the exhaust chimney of the real kiln. The boundary conditions of the 3D simulation are derived from the lumped and distributed parameter model of the entire kiln as detailed in [25]. In addition to the Navier-Stokes equation and the energy equation, the equation for the chemical reactions taking place in the catalyst are accounted for.…”

Section: Fig 2 Methane Conversion Yieldmentioning

confidence: 99%

A novel Carbon Capture and Utilisation concept applied to the ceramic industry

et al. 2019

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This paper investigates a new concept for the CO2 emission mitigation in the ceramic industry based on carbon reduction and methane formation. The concept is analysed as a retrofit to the natural gas fuelled ceramic kiln that represents the main responsible of this industry in terms of energy consumption and exhaust emissions. The carbon dioxide conversion to methane is obtained by reduction with hydrogen on a Ni catalyst and thus methane is used to fuel the standard burners that equip the kiln. The paper addresses different sources for the hydrogen used as a feedstock for the proposed concept as well as alternative catalysts are explored and compared in terms of reduction efficiency and costs. A lumped and distributed parameter simulation of the entire ceramic kiln is combined to the CFD simulation of the reactor to estimate the efficiency of the CO2 reduction and the corresponding methane production for a reference ceramic kiln. The results of the numerical simulations are then employed to discuss the potential benefits of the proposed concept in terms of carbon dioxide emission reduction for the ceramic production. An economic assessment of the system analysed is also carried out concept to determine the investment necessary to implement the technology in an existing ceramic kiln. The potential replicability for other industrial sector is also addressed.

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Numerical analysis of an entire ceramic kiln under actual operating conditions for the energy efficiency improvement

Cited by 36 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

Life cycle assessment and life cycle costing of sanitary ware manufacturing: A case study in China

A novel Carbon Capture and Utilisation concept applied to the ceramic industry

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