A Comprehensive Presentation on Energy Recovery in Ceramics Manufacturing

1. CURING & DRYING SPECIALISTS
WASTE HEAT RECOVERY
AND
HEAT UTILIZATION SYSTEM

2. Why recover waste heat?
 In many cases the amount of waste heat recovered from the kilns is sufficient to
satisfy the heat demands of the Product Dryers and Curing Processes as well as
providing enough energy to heat the workshops via Air Handling Units.
 The system can be used for both continuous Tunnel kilns and intermittent Shuttle
Kilns
 The system can be applied to both existing and new Kilns and then utilized into
either new or existing Dryers and equipment.
 The system can be installed with virtually no disruption to the factory process.
 The return on investment period can be as little as two years, with every Kw
(Therm) of energy saved after than being a direct contribution to profit.

3. What can CDS offer?
 Design, consultation and feasibility study concerning the viability of the project.
 Factory survey identifying the potential energy users.
 Report of the Investment return period.
 Flexibility of contract structure.
Complete equipment supply from the UK or part ‘local’ content.
Supervision of ‘local’ labour or complete installation by CDS
Selection of control options.
 Comprehensive commissioning service.
 After sales service from the UK contribution to profit.

4. Q: Where can the waste heat be claimed from?
A: Waste heat can be reclaimed from all available sources on both
Tunnel Kilns and Shuttle Kilns. Depending on the design of Tunnel Kiln,
waste heat can be recovered from the ‘cooling’, ‘centre’ and ‘exhaust’.
On Shuttle Kilns, heat is recovered during the cooling part of the
curve.

5. Q: What medium is used to convey the recovered energy?
A: The heat may either be transferred in the form of ducted ‘hot air’ or
alternatively by means of hot water via pipe work. When used to heat dryers, the
hot water system is preferable so as not to compromise the humidity balance
within the dryers. Also transferring a large mass of energy is usually
uneconomical using ductwork.
 Photos show waste heat being collected from a Tunnel Kiln and
distributed into Dryers and a pre-kiln Glaze Dryer with residual used for
space heating the factory via Air Handling Units.

6. Q: How does the system work?
A: The following diagrams show:-
• How the ‘waste’ heat is recovered
• How the ‘waste’ heat is transferred
• How the ‘waste’ heat is utilized

14. Typical Control Architecture
Factory Network Providing Ethernet Switch
VPN Connection
RSView SCADA PC
for
Remote Access Located ‘remote’
from the users
Ethernet to PLC’s
PLC PLC PLC PLC
Allen Bradley
Panel View C600 HMI
Set point and process
variable monitoring
Heat Recovery
Ware Dryers Mould Dryers Environmental
systems

15. Product Dryers

16. Environmental Air Handling

17. Continuous Product Dryers

18. Heat Recovery Data
YEARLY FIGURES (based on 1 x 7 day working week per month)
High Temp Circuit (kw/hr's) Low Temp Circuit (kw/hr's)
Additional Heat Additional Heat
Month Waste Heat Available Total of Heat Users Surplus Heat Waste Heat Available Total of Heat Users Surplus Heat
Required Required
January 217,710 321,743 5,932 65,821 170,324 340,234 5,644 205,021
February 217,710 311,872 7,321 54,993 172,325 310,652 5,644 165,032
March 217,710 291,263 11,032 49,321 173,654 245,823 5,644 112,032
April 217,710 264,924 16,832 38,112 168,554 158,773 6,435 60,145
May 217,710 239,015 20,883 25,734 165,923 125,712 7,432 35,003
June 217,710 227,774 22,732 24,987 167,083 105,982 12,732 20,821
July 217,710 226,046 23,463 25,832 167,367 116,003 15,943 20,043
August 217,710 233,821 24,632 27,635 166,943 138,664 14,843 35,773
September 217,710 239,732 21,772 29,863 165,773 169,663 6,437 43,921
October 217,710 262,811 17,663 36,832 168,345 200,735 5,644 77,447
November 217,710 290,212 7,322 48,721 173,882 252,994 5,644 133,932
December 217,710 311,084 5,232 57,021 171,992 318,643 5,644 183,032
TOTALS = 2,612,520 3,220,297 184,816 484,872 2,032,165 2,483,878 97,686 1,092,202
YEARLY FIGURES (based on 338 days per annum)
High Temp Circuit (kw/hr's) Low Temp Circuit (kw/hr's)
Additional Heat Additional Heat
Month Waste Heat Available Total of Heat Users Surplus Heat Waste Heat Available Total of Heat Users Surplus Heat
Required Required
January 876,024 1,294,633 23,869 264,851 685,351 1,369,037 22,710 824,965
February 876,024 1,254,914 29,458 221,281 693,403 1,250,004 22,710 664,057
March 876,024 1,171,987 44,391 198,458 698,751 989,145 22,710 450,795
April 876,024 1,066,004 67,729 153,355 678,229 638,872 25,893 242,012
May 876,024 961,751 84,029 103,549 667,643 505,841 29,905 140,845
June 876,024 916,519 91,469 100,543 672,310 426,451 51,231 83,780
July 876,024 909,566 94,411 103,943 673,453 466,774 64,152 80,649
August 876,024 940,851 99,114 111,198 671,747 557,958 59,725 143,944
September 876,024 964,636 87,606 120,163 667,039 682,692 25,901 176,730
October 876,024 1,057,501 71,073 148,205 677,388 807,719 22,710 311,632
November 876,024 1,167,758 29,462 196,044 699,668 1,018,000 22,710 538,917
December 876,024 1,251,743 21,053 229,442 692,063 1,282,159 22,710 736,486
TOTALS = 10,512,283 12,957,862 743,664 1,951,033 8,177,045 9,994,652 393,070 4,394,813
Total Combined Waste Heat Available = 18,689,328 kw/hr's
HT Waste Heat Utilised = 9,768,618 kw/hr's LT Waste Heat Utilised = 7,783,975 kw/hr's
%age HT Waste Heat Utilised = 92.93% %age LT Waste Heat Utilised = 95.19%
HT Additional Energy Req'd = 1,951,033 kw/hr's LT Additional Energy Req'd = 4,394,813 kw/hr's
MAXIMUM AVAILABLE HEAT RECOVERY PER YEAR = 18,689,328 kw/hr's
COMBINED USAGE OF HEAT RECOVERY PER YEAR = 17,552,594 kw/hr's
%age WASTE HEAT UTLISATION IN THE DRYERS = 93.92%
SURPLUS ENERGY PER YEAR = 1,136,734 kw/hr's
ADDITIONAL ENERGY REQUIRED PER YEAR = 6,345,845 kw/hr's
Note: The surplus 6.08% heat can be used for ancillary heating such as canteen, office space, warehouse etc...

19. Heat Recovery Data
High Temperature Circuit Low Temperature Circuit
1,400,000 1,400,000
1,200,000 1,200,000
1,000,000 1,000,000
Kw/Hr's per month
Kw/Hr's per month
800,000 800,000
600,000 600,000
400,000 400,000
200,000 200,000
0 0
January
February
March April May June July August
September November
October December January
February
March April May June JulyAugust
September November
October December
Waste Heat Available Total of Heat Users Waste Heat Available
Total of Heat Users
Surplus Heat Additonal Heat Required Surplus Heat

20. Payback Period
• Maximum available heat recovery per annum = 18,689,328 kw/hr’s
• Combined usage of heat recovery per annum = 17,552,594 kw/hr’s
• Percentage waste heat utilisation in the factory = 93.92%
• The remaining 6.08% waste heat can be used in the warehouse,
canteen, offices etc…
• Surplus energy per annum = 1,136,734 kw/hr’s
• Additional energy required per annum = 6,345,845 kw/hr’s
• Assumed cost of natural gas per kw = $0.033
• Estimated annual fuel cost saving = $579,236
• Investment cost for waste heat system = $1,500,000
• Return on investment period = 2.59 years

21. There can be NO
COMPROMISE when it
comes to QUALITY &
RELIABILITY.