Drying of Industrial Hollow Ceramic Brick: Analysis of the Moisture Content and Temperature Parameters

Araújo, Morgana Vasconcellos; Santos, Rosélia Maria de Sousa; Silva, R. Moura da; Lima, Antônio Gilson Barbosa de

doi:10.4028/www.scientific.net/ddf.380.72

Cited by 16 publications

(16 citation statements)

References 10 publications

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“…A mathematical model used for simulation of roof tiles in the kiln manufacturing process was introduced [19]. The experimental results revealed that the required mean flow velocity must be in the range of 20 m/s by using tiles of roofs showing specific numerical simulation to envisage moisture contents, temperature profile in the hollow setting of ceramic bricks during the procedure of drying in industry [20]. In the preheating zone of the tunnel kiln two axial flows in mixing ware by means of side nozzle is examined.…”

Section: Introductionmentioning

confidence: 99%

“…AC induction motors usually work with a load much less as compared to their maximum rating. Many surveys show that the average load factor for these motors is 57-68% of their ratings, and machine often operate with more less load, even in between 3-16% [20]. It was observed that 44% of motors installed in industrial sector are loaded at less than 40% of their rated power [26].…”

Section: Introductionmentioning

confidence: 99%

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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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Section: Introductionmentioning

confidence: 99%

Section: Introductionmentioning

confidence: 99%

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

et al. 2021

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“…Its purpose is to identify better drying conditions (optimized process), with less process time, in order to reduce or eliminate dry material waste, by using a CFD analysis. The authors have contributed to the numerical study of the drying ceramic brick considering the mass and heat transfer and fluid flow in the air around the solid in previous works [19][20][21][22].…”

Section: Introductionmentioning

confidence: 99%

Convective Drying of Ceramic Bricks by CFD: Transport Phenomena and Process Parameters Analysis

et al. 2020

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In the manufacturing process of ceramic brick, the step of drying needs the control of process variables to uniformly dry the porous material, producing a good end-product. The majority of numerical simulations involving drying of ceramic materials is performed considering only the solid domain, resulting in a very simplified and limited study. This way, the objective of this work is the analysis of the drying process with hot air of an industrial hollow clay brick inside the oven at different temperatures by using computational fluid dynamic (CFD). The results of the temperature and water mass distribution inside the brick and of air in the oven at different times of the drying process are shown, analyzed and checked with experimental data, and it was obtained in a concordance with the data. An equation to calculate the brick water mass diffusivity depending on the drying air temperature was proposed.

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“…If the drying process is not performed correctly, it can lead to material defects, loss of productivity, and increase in the energy consumption. According to the literature [6][7][8][9][10][11][12][13][14][15][16][17][18], the operating variables that influence the drying process are temperature, relative humidity and velocity of the drying air, time, shape, thickness, area/volume ratio, particle size, initial moisture content, and properties of the ceramic material.…”

Section: Introductionmentioning

confidence: 99%

Transient Thermal Analysis in an Intermittent Ceramic Kiln with Thermal Insulation: A Theoretical Approach

Gomez

Porto

Magalhães

et al. 2020

Advances in Materials Science and Engineering

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Increasing the thermal efficiency of drying and firing processes of ceramic products plays an important role for industries that want to remain competitive in the market. Thus, this work aims to evaluate the influence of the type and thickness of thermal insulations, applied on the external sidewalls of an intermittent ceramic kiln, on heat transfer, temperature distribution in the insulating material, maximum external surface temperature, and energy gain, compared to the kiln without thermal insulation. All proposed mathematical formulations are based on the energy conservation, and mathematical procedures are implemented in Microsoft Excel software. Here, it was tested four types of thermal isolators: fiberglass, rockwool, calcium silicate, and ceramic fiber. Results indicate that the greater the thickness of the thermal insulation, the lower the maximum external surface temperature and the greater the energy gain when compared to the kiln without thermal insulation. In addition, fiberglass is the insulating material, among the four types analyzed, which provides greater energy gain and greater reduction in maximum external surface temperature.

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Drying of Industrial Hollow Ceramic Brick: Analysis of the Moisture Content and Temperature Parameters

Cited by 16 publications

References 10 publications

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

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

Convective Drying of Ceramic Bricks by CFD: Transport Phenomena and Process Parameters Analysis

Transient Thermal Analysis in an Intermittent Ceramic Kiln with Thermal Insulation: A Theoretical Approach

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