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Energies 2020, 13, 6096 Measure Controlled dehumidification Hot air recycling as combustion air in the kiln Exhaust air recirculation in spray dryers Use of alternative fuels Improvements at ceramic slip and design 9 of 24 Table 4. Cont. Main Findings Technical Aspects The water that condenses within the chamber releases its latent heat to be supplied to the drying process; this system is completely closed, and thus, highly energy-efficient [128]. The hot air from the cooling zone of a kiln may be used as preheated combustion air in the kiln’s combustion chamber; thermal shock caused by high temperature airflow may be reduced by the mixture of hot air and air at ambient temperature [30]. The exhaust air of a spray dryer may be recycled to the process as drying air [124]. An air preheater may be installed in the recirculation process to further use the waste heat from the exhaust air stream [125]; within the recirculation process, the exhaust air stream is divided into a recirculated air stream and a vent air stream (which is purged), with the recirculated air stream being then mixed with ambient air in order to achieve the required drying air moisture content. Fossil fuels (such as natural gas) may be substituted by alternative fuels which supply the same amount of heat; alternate fuels include biogas [136–141] and hydrogen (pure, mixed or syngas) [142–149]; for hydrogen, its injection is feasible in existing gas networks [150–153] and it is the best choice for at-scale decarbonisation, being produced at high grade heat [154]. New ceramic materials and product design have been developed in recent years to reduce ceramic weight, energy consumption and production cost; such materials are developed considering: product design that require less raw material and firing times, new material compositions incorporating pore-forming agents (such as carbon nanotubes) and incorporating residues to produce thermal energy [164,165]; additives such as incineration ashes, waste glass and low sintering clays contribute to lower sintering temperatures or lighter ceramics with identical mechanical properties [165]. Energy and Economic Aspects Typical energy savings of 80%. From 15 to 30% fuel savings [126]; payback time is negligible [117]. From 50 to 61% in energy savings [125]. A 30% supply of energy input in a process (biogas) [142];and 80–100% supply of energy input in a process (hydrogen) [154]. A 15% increase in material porosity leading to increased water absorption and decreasing compressive strength, and thus considerable energy savings in the drying phase [164]. Reference [128] [24,30,117,122,123,126] [124,125] [136–154] [164,165]PDF Image | Ceramic Sector Focusing on Waste Heat Recovery
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