Successfully completed bachelor thesis: Increasing the energy efficiency of kiln and dryer

Roman Flatau has completed his bachelor ­thesis entitled „Efficient waste heat recovery in the heavy clay industry by generating electricity from a steam process with reference to technical and economic criteria“ at Keller HCW. In cooperation with Professor Dr Ralf-Gunther Schmidt of the University of Applied ­Sciences in Osnabrück, a system was developed where, on the one hand, the excess kiln air is used in a steam process to generate electricity and, on the other hand, where condensation energy is used to substantially reduce the gas consumption of the dryer.

Extensive measurements were made at the tunnel kiln of the Meyer-Holsen roofing tile factory to create an energy balance of the cooling zone. A process was developed on the basis of the measured data which exactly matches the plant-specific parameters. The energy contained in the kiln air is used to generate electricity in a steam process. The simulation software Ebsilon professional was used to determine ideal parameters for the steam process. The condensation energy is then fed into the dryer through specially arranged heat exchangers, thus reducing the costs for electricity and gas. The developed system sets benchmarks for the future especially with regard to further increasing energy costs.

In addition to the technical and thermodynamic process layout, the economic analysis of the elaborated solution is also part of the bachelor thesis. Economic indicators such as return on investment, amortization period and cash flow were determined and a static and dynamic capital expenditure budget was prepared.

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