STRUCTURAL CERAMIC

ENERGY SAVINGS AND EFFICIENCY IN TUNNEL AND SHUTTLE KILNS AND DRYERS

The application of the OPTIMA® System in tunnel or shuttle kilns in the technical and structural ceramics industry (especially the manufacture of extruded stoneware, tiles and bricks) is very useful.

TUNNEL AND SHUTTLE KILNS

The OPTIMA® System allows continuous monitoring of the oxidizing/reducing level of the combustion atmosphere, enabling the immediate detection of quality problems without having to wait for the product to be released and, therefore, obtaining significant savings in both time and resources. energetic. Likewise, it allows the regulation of the kiln to be adjusted to the changing atmospheric and climatic conditions throughout the year, the flame lengths of the burners, the different heights of the packages, the unequal distribution of load, etc.

The free O₂% present in the combustion gases in a tunnel kiln depends on each product. The real-time analysis of the atmosphere allows the regulation of the furnace to be improved, thus avoiding possible problems in the product due to the existence of changes in tone, poor oxidation of carbonates, black heart, etc.

Thanks to the OPTIMA® System, our clients adjust the regulation of temperature curves, side draft and contraveil fans, regulation of burner air pressure, gas solenoid valves, jets, etc.

By measuring the combustion atmosphere of a given product, it can be controlled without the variations existing in the oven over time being a problem.

Using the OPTIMA® XA System, the following results are obtained:

Improvement of the quality of the final product (black heart, tones, etc.).
Reduction of specific thermal consumption (4%-6%).
Reduction of polluting emissions such as CO and NOX.
Characterization of oxidation levels by format and type of enamel.
Control of kiln’s pressure curve.
Optimized fan regulation.

OPTIMA® Analyzers

CERAMIC DRYERS

In a structural ceramic plant, the dryer is generally (with the permission of the atomizer) the second source of greatest energy consumption.

The results that can be obtained by regulating the different parameters of the dryer depending on the relative humidity, temperature and pressure of the combustion gases are immediate.

Each area of the dryer requires a different “drying atmosphere”, which requires exhaustive control of the recirculation and exhaust air through humidity and temperature in the entire burner area.

This control guarantees both the overall performance of the drying process and an adequate level of quality of the pieces by ensuring correct and progressive removal of moisture. Reduced humidity levels at the entrance to the dryer can cause unnecessary heat extraction, favoring excessive consumption and the appearance of cracks in the pieces.

In the same way, controlling the temperature at the exit of the dryer makes it possible to know and standardize the working conditions on each of the dryer floors.

Control of the drying atmosphere provides greater stability to the drying process and adequate removal of moisture from the pieces. By ensuring constant humidity in each area, the pieces do not suffer strong drying variations due to the existence of gaps in the drying room.

Using the BLUESKY® RH System, the following results are obtained:

Reduction of specific thermal consumption (>15%)
Reduction of electricity consumption (>35%)
Greater quality control (cracks, explosions, condensation at the entrance, etc.)
Characterization of humidity levels by format, type of product and glaze (glossy/matte).
Optimized regulation of humid air suction fans and recirculation motors.
Control of drying atmospheres in the dryer.
Homogeneity and uniformity of atmospheres in the face of gaps.
Reduction of CO₂ and NO_X
Reduction of the production cycle.
Control loop for regulating wet air suction motors and recirculation motors.

BLUESKY® RH Analyzers

REQUEST MORE INFORMATION

If you are interested in our combustion control systems, do not hesitate to contact us. Our team will advise you to improve the efficiency of your combustion processes.