Prof. Dr.-Ing. Christian Schäffer

Hybrid-ring tunnel kiln with flue-gas-based combined heating system: 65% savings on energy – a concept study

In its 6/2015 issue, Zi Brick and Tile Industry International presented the Brickworks 4.1 concept in which hybrid heating and networked production and use of electricity yield significant cost reductions. The present contribution explains how brickworks can be operated with maximum utilization of the exergy content of primary energy sources – in addition to energy networking and hybridization – in order to achieve maximum possible energy and cost efficiency.

1 Introduction

The concept begins by dissolving the kiln/dryer combined heating system, instead supplying the dryer with energy via exergetically optimized heat flow from the kiln exhaust and power generation. The dissolved kiln-cooling/dryer combined heating system is replaced by a kiln-exhaust/dryer heating system.

A hybrid arrangement allows to choose between electric heating when electricity prices are low and, on normal operating mode, power generation both for captive use and feed-in to the public power grid.

The concept is also geared to converting and supplementing existing facilities...

Related articles:

Issue 2013-06

1 Introduction Owing to the combination of the heat systems of dryer and kiln, the dryer often remains undetected as the major consumer of energy in a brick plant. For the most part, the installation...

Issue 2009-08

1 General Hot flue gases from ceramic kilns can rarely be directly exploited as heat sources for other parts of plant, because they are always more or less heavily contaminated with undesirable...

Issue 2015-8 Prof. Dr.-Ing. Christian Schäffer

1 Introduction In Zi Brick and Tile Industry International 7/2015, the concept of a brickworks with a “hybrid-ring tunnel kiln” was presented, in which the kiln cooling/dryer combined heating system...

Issue 2015-2 Steffen Hauschel

1 Introduction In ceramic production, the high energy expenditures for operating the kiln and drying the wares are a crucial cost driver. In Germany, the financial burden of rising outlays for energy...

Issue 2015-7 Keller AG Ziegeleien, Paradies brickworks, Schlatt, Switzerland; Peter Krieg1, David Hartmann2

1 Introduction In brick production, the firing curve is determined in part by the type of raw material employed. This has been the subject of numerous investigations, the facts of which are surely...