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Energies 2020, 13, 6096 Measure High-efficiency burners Microwave assisted firing and drying Kiln cars and furniture with low thermal mass Airless drying Controlled drying air recirculation 8 of 24 Table 4. Description of equipment-level technologies and strategies. Main Findings Reference [42–50,105,118] [51,95,106] [51–53,111] [54,55,107] [96,126] Technical Aspects New high efficient burners designed to allow preheating the combustion air with the exhaust gases (examples include self-recuperative and regenerative burners); these burners can replace old burners in ceramic tunnel kilns [105] and roller kilns [118] improving the fuel consumption. The microwave processing has been studied for the drying and firing (sintering) of some ceramics; microwave applied for sintering of ceramics was identified to be a very interesting alternative achieving finer microstructure, improved mechanical properties, with lower processing times and energy consumption [106]. Use of low thermal mass (LTM) kiln cars to decrease the thermal energy requirement for the heating of supporting refractories; they offer similar strength and stability comparative to traditional construction materials with the advantage of having lower running costs, repairs, downtime and maintenance [52,53]; LTM materials include Si3N4 and SiC [111]. While in a conventional dryer the vapour is lost to the environment with the outlet air stream, in here, it is made use of the steam as the heat transfer medium; the steam presents a higher specific heat and thermal conductivity relative to air, thus improving heat transfer [107]; this allows improving overheat control, the minimisation of the risk of explosion, avoidance of secondary contamination and an overall improved control system. Use of more advanced ventilation systems, in which the control of the drying parameters is improved; the inlet and outlet air temperatures are maintained, while the drying agent recirculation coefficient increases (lowering the share of new air) by optimising the air flow and convention, and high energy savings are achieved [126]; due to variations in the evaporation rate, investment costs are highly variable. Energy and Economic Aspects Firing efficiency improvement by approximately 10% [45]; fuel savings of 25–30% in self-recuperative burners [47] and 50–60% in regenerative burners [46]. Eight times reduction in firing time leading to fuel savings [51]; 7–30 times reduction in drying time leading to fuel savings [95]. A 70% reduction in thermal mass leading to fuel savings [52]. From 20 to 50% thermal energy savings and reduction in the drying time [107]. Energy savings of 25% [96].PDF Image | Ceramic Sector Focusing on Waste Heat Recovery
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