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Energies 2020, 13, 6096 Measure Hot air recycling between kilns Hot air recycling as drying air Drying air preheating Phase change material Thermal energy storage (PCM–TES) Water heating and preheating Inertising Use of dry route for raw material preparation Use of concentrated solar thermal energy 11 of 24 Table 5. Description of plant-level technologies and strategies. Main Findings Technical Aspects Similar to the hot air recycling in a kiln, the hot air from the cooling zone of a kiln may be used and mixed as preheated combustion air in other kilns of the plant [117]; the more adequate use for a recovered heat air stream is the one that allows to recover the higher thermal energy from that stream (having the lowest thermal loss: that is the closest matching heating need). The hot air from the cooling zone of kilns may be used as an additional heat source in dryers; commonly implemented when part of the hot air is already recovered to the combustion chamber of kilns and a remaining part is recycled to the dryers [117]; in the case the hot air stream has a sufficient waste heat potential, the operation may be converted to disable the need to consume fuel [117]. Installation of air–gas heat exchangers to heat up an air stream to be used as an additional heat source in a dryer may be alternatively performed instead of direct hot air recycling; this may be performed by either using the exhaust gas streams or hot air streams from the cooling zone of kilns [108]; the heat pipe heat exchanger is a typical air preheater type used for this application, due to its associated high heat transfer capability and economic viability [108]. Implementation of a thermal energy storage-based phase change material unit for the preheating of combustion air at the inlet of a furnace; the air stream is heated in an air–gas heat exchanger followed by the PCM unit. Exhaust gases from stacks of a kiln (either exhaust gas or hot air from the cooling zone) may be used to heat up a water stream in an water–gas heat exchanger, such as the water stream at the inlet of a boiler. Drying stage is eliminated, with energy savings being achieved through the use of dry grinding instead of wet grinding [98]; the inertising operation has a common duration of 10–15 min, using a maximum operation temperature of 900 ◦C and allows the use of raw materials of worse quality [98]. Substitution of the wet route by a dry route for the preparation of raw materials. Concentrated solar power (CSP) technologies include solar dish, parabolic trough, and solar power towers; the solar radiation may be used to produce a valuable heat stream with temperatures up to 70–320 ◦C [155]; the CSP systems may be integrated or adapted to the existing heating systems [156–158], with the drying processes being pointed for potential application. Ref. Energy and Economic Aspects From 15 to 30% in fuel savings [126]; payback time is negligible [117]. [117,126,129] About 110 dam3/year fuel savings [108]; payback time of 2 years [108]. Fuel savings of 570 MWh/year [132]. Fuel savings of 3.1 MWh/year; payback time less than a year [74]. Overall energy savings of 40% [97]. 74% water savings; 78% fuel savings; 36% electricity savings [104]. Compensate 10% of industrial energy demand [155]. [78,79,108] [132,133] [74,80,117] [97,98] [104] [155–158]PDF Image | Ceramic Sector Focusing on Waste Heat Recovery
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