Energy conservation via optimized preparation and shaping

»1 Determining parameters for pan mill power consumption

»2 Comparison of various grid plates

»3 Practical example: older-model pan mill with peripheral feed

»4 Optimized pan mill

»5 Determining parameters for roller mill power consumption

»6 Practical example: scraper with heavy duty blade obviously allowing clay to pass at several points

»7 Hard-facing materials for fine roller mills

»8 Determining factors for de-airing extrusion unit power consumption

»9 Practical example: older-model extruder with 15-bar extrusion pressure

»10 Practical example: older-model extruder with 25-bar extrusion pressure

»11 Practical example: extruder converted for 25-bar extrusion pressure

»12 De-airing double-shaft mixer

»13 Mixer-outlet connection to de-airing chamber: hub with intensive wear exposure fitted with ceramic platelets for protection

»14 More ways to save energy

»15 Extruder simulation model ESM

While preparation and shaping account for less than 5% of the overall energy consumption of a typical brickyard, their share of the plant‘s electric power consumption alone, though, comes to nearly 50%. Obviously, then, it is worth one’s while to exploit all possible means of energy conservation. There is, however, no Royal Road to an energy optimized plant. It takes numerous individual but coordinated, customer- and works-specific measures to achieve that. This contribution surveys new developments and trends and calls attention to an unending stream of innovations for opening up new ways to save energy.

1 Introduction

Some 150 years ago, when Friedrich Hoffmann introduced his Hoffmann annular kiln, it was a huge success, not least because it required as much as 70% less fuel than the intermittent kilns that were customarily employed at the time. Even then, we see, energy conservation was a hot topic.

What really imposed the subject of energy conservation on us in the late 20th century was the first oil crisis in 1973. Ever since then, that key theme has been a permanent issue for all of us and simply refuses to die down in the brick and tile industry, particularly since everyone by now is aware...