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

Abstract

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.

Determining the Thermal Efficiency of Firing of a Cross Draft Kiln using Methane and Liquefied Petroleum Gas

“…The heat balance and thermal efficiency of a traditional cross draft kiln were determined using the heat balance approach and the main findings of the study are summarized: (1) The traditional cross-draft kiln currently employed in firing ceramic wares is grossly thermally inefficient and its design needs to be improved to minimize heat losses; (2) Heat losses through radiation, convection, and heat carried away by wasted heat and combusted exhaust gas were identified as sources of heat wastage in the traditional cross draft kiln; (3) Thermal heat losses through radiation and convections are highest in both methane and LPGfired kiln. More than half of the energy (53.6%) was lost in methane-fired kiln, while in the LPG fired kiln only 1.9 % of the energy was utilized; (4) Firing time and fuel consumption rate were higher in the methane-fired kilns.…”

“…However, the high rate of energy consumption is not only responsible for the over-use of resources, and the emissions of pollutants, but also impacts the cost of ceramic production. Up to 60% of the cost of ceramic production, is due to thermal energy losses occurring in the form of waste heat [3].…”

The Relationship between Environmental Factors, Satisfaction with Life, and Ecological Education: An Impact Analysis from a Sustainability Pillars Perspective

“…The most relevant are: the consumption of alternative fuels [77] and consumption of non-genetically modified products. Similarly, the students from Ias , i Technical University brought into discussion the need for other questions to be added to the questionnaire, which would include elements regarding the sustainable dimension of consumption or such as the valorisation of waste [78], as well as obtaining energy from alternative renewable sources [79,80]. The students from economics emphasized the valorization in the questionnaire of the native anthropic and cultural dimensions, as well as the resources as specific elements of sustainability.…”

Experimental investigation to thermal performance of different photo voltaic modules for efficient system design

“…Solar energy is very fair and clean which causes no pollu-tion. Now it is time to invest in solar power projects that is crucial and is the need of the hour [22][23][24][25][26].…”