Energy efficiency analysis of an entire ceramic kiln: A numerical approach

The paper focuses on the numerical analysis of an industrial ceramic kiln to improve the energy efficiency and the fuel consumption as well as the pollutant emissions. The entire ceramic kiln is modelled by means of a lumped and distributed parameter model; particular care is devoted to the modelling of the heat transfer phenomena occurring within the system under actual operating conditions. Models for the simulation of the different components that are used for the kiln functioning are included in the modelling, such as the burners, the fan, the valves and the control system. The numerical approach demonstrates to predict accurately the temperature distribution of both the tiles and the hot gases along the kiln length. Numerical results are validated against experimental measurements carried out on a real ceramic kiln during regular production operations. The developed numerical approach demonstrates to be an efficient tool for investigating different design solutions for the kiln's components as well as for developing new control strategies. The kiln numerical model is employed to compare different configurations of heat recovery and solutions for improving the tiles' heat transfer. The considered designs are simulated and the performance in terms of energy efficiency and fuel consumption is determined.