Ceramic Sector Focusing on Waste Heat Recovery

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Ceramic Sector Focusing on Waste Heat Recovery ( ceramic-sector-focusing-waste-heat-recovery )

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Energies 2020, 13, 6096 2 of 24 achieving clean and low carbon objectives regarding sustainability at the EU and worldwide level [6]. In this prospect, the adoption of a consistent energy management, in addition to the practices related to industrial symbiosis [7], the promotion of eco-efficiency [8] and the use of alternative fuels coming from renewable sources, attractive in energy-intensive sectors to reduce environmental impacts without compromising the technical requirements in the involved processes [9,10] are relevant to improve energy efficiency and promote sustainability in industry. The ceramic industry is an energy intensive sector, similar to the steel, cement and glass industries [11]. A reference document for the best available techniques (BAT) is available in the EU for the ceramic industry [12] and its revision is currently ongoing. Overall, the improvement opportunities in this sector range from waste heat recovery, for which examples are given in [13], equipment optimisation examples are demonstrated in [14], and those for the use of renewable energy are expressed in [15]. The framework of energy efficiency improvement measures within the ceramic sector have been studied. However, as most recent studies have been focusing on the progresses achieved until the end of the 1990s [16], such frameworks are outdated. Furthermore, generalist studies have been performed for the framework of WHR technologies in the industry [17]. An updated review on energy efficiency technologies and strategies is therefore required for framing the most recent technological developments for energy efficiency improvement within the operation of ceramic industry plants, namely improvements at the equipment level, plant level and outer plant level for energy valorisation and cleaner thermal processes. This paper aimed to review the most prominent energy efficiency technologies and strategies in the ceramic sector, focusing on waste heat recovery (WHR) and performing an analysis of improvements at the equipment level, plant level and outer plant level. This was set to establish a benchmark for the analysis of thermal processes in the ceramic industry, the assessment of energy efficiency improvement potential and the selection of the most favourable strategies for the distribution of waste heat within the plant processes attending to each process energy requirements. 2. Description of the Ceramic Sector According to data from the European ceramic industry association, Ceramie-Unie (C-U) [18], the ceramic industry is an overall export-oriented sector (the EU exports 30% of its total production), it encompasses around 2000 companies, and it has an annual production value of EUR 30 billion. As an energy intensive sector, its competitiveness is highly dependent on fuel prices. Therefore, cost effective strategies that increase energy efficiency and reduce carbon emissions will highly improve both the environment and ceramic production costs. The ceramic sector is categorised into several subsectors. A classification considered in the BAT reference document [12] considers the following subsectors: tiles (including roof and wall and floor); refractories; abrasives; household: technical and sanitaryware. There are also other subsectors with minor sales turnover and energy consumption (including vitrified clay pipes and expanded clay aggregates). The ceramic industry may also be characterised regarding sales turnover and energy consumption. Figure 1 presents the distribution of sales turnover for each subsector of the ceramic industry.

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