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 2017-6

Optimizing the energy efficiency of a tunnel kiln by decoupling the kiln/dryer heat cycle

Decoupling the kiln/dryer heat cycle by means of an upstream or downstream kiln tunnel is an inexpensive way to optimize the energy efficiency of a clay products plant. This not only improves its...

Issue 2013-06

Utilization of Waste Heat and Combined Energy Systems in Brick Plants

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 2015-8

Use of heat pumps in brick drying

For a brickworks with a production rate of 400 tonnes per day fired ware, the mixing water content of around 20 mass% necessary for pressing means that every day around 80 t water must be expelled...

Issue 2012-11

Waste heat utilization and integrated energy supply in brick and tile factories

When, as a result of increasing energy prices, the costs incurred for the energy-intensive process steps of drying and firing rise, measures for energy saving and the economically efficient use of...


Hellmich GmbH & Co. KG

Hellmich is a company specializing in environmental engineering, which supplies, for example, solutions for flue gas cleaning, dedusting, tunnel kiln car cleaning and heat recovery. Much of the...