The new Enviro kiln concept – countertravel kiln for the 21st century

Germany‘s energy transition is the embodiment of a fundamental change in how energy is supplied, and one almost automatically thinks of renewable energy sources in that connection. Energy efficiency, though, is just as important and of central significance. Why? Because energy that is not expended need not be generated. Keller HCW has therefore taken it upon itself to sustainably enhance the energy efficiency of its brickworks, hence reducing their energy-related CO2 emissions.

In order to drastically reduce the amount of energy needed for firing, Keller HCW has thoroughly revised the principle behind countertravel kilns. Known studies and fundamentals of the countertravel concept were intensively examined in preparation for creating the new “Enviro” countertravel kiln via redesign and modification. This kiln eliminates prior drawbacks and exploits known advantages to yield a completely new firing concept with high potential for conserving energy. Following extensive theoretical investigations conducted, for example, with the help of Fluent software, Keller HCW built a pilot kiln measuring 5 m wide by 16 m long and 5 m high. For months on end, a team of employees conducted numerous test firings with different products in order to ensure the integrity of current insight and findings while obtaining well-founded test data. Heat transition via convection and radiation was investigated, and the results show that the typical solid-solid mode of energy transfer in counter travel kilns actually works.

At the 2014 Würzburg Brick and Tile Training Course, the initial findings were presented to the German-speaking professional audience, including depiction of the major potential for reducing energy expenditures. Taking a typical roof tile plant as an example, this figures to more than 30 %. Now, the concept is being explained to an international professional audience, including presentation of the latest findings.

Ulrich Hagemann/Rainer Hüsing, Keller HCW GmbH,
Ibbenbüren-Laggenbeck, Germany

x

Related articles:

Issue 08/2014

Enviro kiln, an innovative new kiln concept with high energy saving potential

To drastically reduce the energy requirement for firing, Keller HCW is closely examining the principle of the countertravel kiln. Known research and principles have been studied intensively and the...

more
Issue 08/2014

High energy saving potential with the new Enviro kiln concept

1 Introduction The turnaround in the energy policy is a task for society as a whole. It has been the subject of discussion in Germany for years and is meanwhile supported by a majority of the...

more

Keller Division presents itself at ceramitec

At Keller Division’s ceramitec stand, visitors can experience a live demonstration of Morando’s new Genius fine roller mill and the advanced Keller HCW cutter generation. The highlight for the trade...

more
Issue 7/2015

Keller Division presents itself at ceramitec

At Keller Division’s ceramitec stand, visitors can experience a live demonstration of Morando-Rieter’s new Genius fine roller mill and the advanced Keller HCW cutter generation. The highlight for...

more
Issue 07/2014 Bachelor dissertation completed with top mark of 1.0

Keller HCW successfully working together with Osnabrück University of Applied Sciences

Tobias Nimz has completed his bachelor dissertation in the process engineering department of Keller HCW with the top mark of 1.0. With his dissertation on “Thermodynamic examination of heat transfer...

more