Full Thesis PDF
Full Thesis PDF
Full Thesis PDF
A THESIS
SUBMITTED TO THE DEPARTMENT OF CHEMICAL
ENGINEERING IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE OF
MASTER OF ENGINEERING (CHEMICAL)
111111111111111111111~llllllflr[
#97207# I
----_._--~
SEPTEMBER, 2002
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. ,
BANGLADESH UNIVERSITY OF ENGINEERING & TECHNOLOGY, DHAKA
We, the undersigned, certify that Md. Rahis Uddin, candidate for the Degree
of Master of Engineering (Chemical), has presented his thesis on the subject
"PERFORMANCE STUDY OF TUNNEL KILNS FOR SANITARYWARE
PRODUCTION AT BISF". The thesis is acceptable in form and content, and
the student demonstrated a satisfactory knowledge of the field covered by
th
this thesis in the oral examination held on the 29 September, 2002.
J~ Q.v~i5IL.
(Dr. A.K.M.A. Quader) Member
Professor
Department of Chemical Engineering
BUET, Dhaka
.&~db.
(Dr. Edmond Gomes) Member
Professor
Department of Petroleum & Mineral Resource Engineering
BUET,Dhaka
ACKNOWLEDGEMENT
The author acknowledges with thanks and gratitude the encouraging advice
and helpful guidance he received from Dr. M. Serajul Islam, Associate
Professor, Department of Chemical Engineering, Bangladesh University of
Engineering & Technology (BUET) under whose supervision the thesis
work has been carried out. Thanks are also due to Dr. AK.M.A Quader,
Professor of Chemical Engineering Department, BUET for his help and co-
operation during this work.
The author extends his thanks to Dr. Edmond Gomes, Professor of PMRE
Department, BUET for his valuable advice in this work.
The author also extends his gratitude to his colleagues especially Engr.
Nirupam Chanda & Engr.Humayun Kabir of Sangu Operations, Brown &
Root Bangladesh Ltd., Chittagong for their co-operation throughout the
thesis work.
Thanks to Mr. M.A. Mobin for his patience and care m typing the
manuscript.
The author is thankful to his wife, Dr. Tahmina Rahman for her co-operation
and encouraging advice throughout the thesis work.
_c
ABSTRACT
ii
CONTENTS
Page
CHAPTER 1 INTRODUCTION 1
iii
CHAPTER 5 STACK GAS ANALYSIS OF SANITARYWARE 33
TUNNEL KILNS AT BISF
REFERENCES 55
APPENDICES 56
iv
LIST OF FIGURES
Page
Figure 4.1: Bar graph showing year wise total natural gas 27
consumption for production of sanitarywares,
insulators and tiles at BISF
v
LIST OF TABLES
Page
vi
CHAPTER-l
INTRODUCTION
1
.'0'
<~<~.
.. '\
1. An overview of the natural gas and electricity consumption in the
different sections of the factory.
2. Stack gas analysis of the tunnel kilns.
3. Heat balance for the tunnel kilns.
4. Determination of thermal efficiency of the tunnel kilns.
5. Recommendations for enhancing the thermal efficiency of the tunnel
kilns.
2
CHAPTER-2
.•-\-.
Periodic Semi conti- Continuous
.._t.•
_.
Horizontal Up-draft Down draft
•
Direct Firing •
Muffle
kiln nuous kiln kiln Draft kiln kiln kiln kiln kiln
4. Classified by 5. Classified by
kinds of fuel the aim
Wood firing +
B lscmt f"mng +fi' +
Gl ost Irmg DecoratlOn
kiln kiln kiln firing kiln
6. Classified by
shape
3
2.2 General Structure of Tunnel Kiln
In 1900, Faugeron in France built the modern tunnel kiln. The tunnel kiln is,
as the name indicates, a nan-ow and long tunnel having the rails in both sides
at the bottom. The wares loaded on the kiln cars are charged through the
entrance of the tunnel and run continuously through the pre-heating, firing
and cooling zones, and then discharged from the exit as shown in Figure 2.2.
AIR
'EXHAUST FAN COM8USTllN GAS
4
2.3 Tunnel Kiln Operating Conditions
The tunnel kiln consists of three zones; pre-heating, firing and cooling zone
as shown in Figure 2.3. The firing zone is sub-divided into three zones;
oxidizing, reducing and neutral flame zones. The temperature, pressure and
atmosphere in each zone should be kept constant.
The combustion gas and air always flow from the kiln exit to the entrance
such that the adjustment of one firebox affects not only the firing zone but
also the pre-heating zone. Especially at reducing firing, the adjustment
requires the most care and experience considering various factors; the border
of oxidizing and reducing zones and that of reducing and neutral zones, the
effect of cooling air to firing zone, the relation between the temperature and
atmosphere in reducing zones, etc.
For instance, in order to raise the temperature m the last burner of the
reducing zone, anyone of the following operations may be selected:
The ratio of fuel consumption in each zone varies widely but the rough idea
is given below:
5
The kiln pressure also varies according to the ware to be fired. For firing
sanitaryware, tableware and wall tiles, the pressure is usually kept near about
atmospheric. For firing porcelain insulators, usually greater than
atmospheric pressure is kept.
6
Waste heat
to stack Cooling air
Hot air
f to dryer
(0C)
1200
1000
800
400
200
(%) Atmosphere
21
a
(mmHg)
Kiln Pressure
+1
j;0
-1
Kiln Length
7
The firing zone is placed in the middle of the kiln. There are a large number
of burners on both sides of the firing zones. The burners are set
symmetrically. The combustion gas, which is produced by the burner, heats
the ware on the kiln car and is drawn to the pre-heating zone. In this pre-
heating zone, the green ware is heated up gradually by the combustion gas
coming from the firing zone and the organic substances in the clay is burnt
out and the moisture is vapourized. In the pre-heating zone, the heat capacity
of the car-top is large, so that the difference of temperature between the
upper and lower portions of the kiln is rather high. In order to decrease the
temperature difference various measures are taken. For instance, the inclined
wall is adopted as the lower half of the kiln wall is expanded, the
combustion gas can lower easily. The gas re-circulation method is also
adopted, a high heat metal fan is used which agitates the combustion gas
inside the kiln.
In the cooling zone, the fired wares are cooled gradually by the blast air
coming from the fan near the exit. After cooling the wares, the cooling air
gets hot itself and drawn into the firing zone. A part of the cooling air, which
is heated up, is drawn outside the kiln and used for the drier, and the other
part is used as combustion air.
The kiln car is made of cast-iron or steel, and on both sides of the car the
sand seal plates are fixed. The car top is made of refractories in firebrick and
heat insulation bricks.
8
2.4 Types of Tunnel Kilns and Their Characteristics
There are various types of tunnel kilns. According to the firing system the
tunnel kilns may be classified into the following categories as shown in
Figure 2.4.
Tunnel kilns
Horizontal Down-draft
draft type type
The most important point in kiln design is how to keep the temperature
uniform. So, the direct-flame type of kiln has been designed to have an
inclined wall so as to enable the combustion gas to pass through easily.
Some times the downdraft method is applied for the same purpose.
In the indirect-flame type of kiln, the combustion gas passes through the
combustion pipes, which are provided, on both sides of the kiln. In this type
of kiln, the loading on the kiln cars without sager is applicable. However, as
it is rather difficult to obtain reducing flame, this kiln is mainly used for
firing sanitarywares and tiles which are fired in oxidizing flame.
(I
9
~~ . ~
2.5 Loading Work in the Tunnel Kiln
The wares to be fired in the tunnel kiln are loaded in the kiln furniture. The
idea is not only to load as many wares as possible, but also to acquire the
proper arrangement of loading. It is very important to select suitable kiln
furniture in order to obtain good quality products and high productivity.
Many kinds of kiln furniture are used for ceramic production among them
"sager" is widely used. The sager is the vessel made of refractory clay or
silicon carbide. It is used to cover and protect the wares from severe flame
and also from contamination by flying ash. There are many shapes in sager;
round, oval, rectangular and odd shapes. The sequences of loading work in
the tunnel kiln are as follows:
1) Sager setting: Before starting the loading work, the following measures
are to be taken:
- Check if there were any cracks on the kiln wall, repairs firebox and baffle
wall, if necessary.
- Clean the draft port.
- Adjust the size of the draft port and the height of the opening of the
baffle wall.
- Check the previous firing data.
- Check the cracks in sager. Remove the clay dust. Spread alumina powder
on the contacting point of each sager. Paint the dilute glaze to the under
side of the bottom of each sager, which will prevent the fall of chips from
the sager and protect the ware underneath.
- Prepare the clay setter, clay sheet and silica or alumina powder
10
. (' .-
- Prepare the sager cone.
Above all, the height of the sager bulk should be checked by the gauge. If
the sager bulk falls down inside the kiln, a fatal accident may happen.
Special care in checking the crack of each sager and inclination of sager bulk
should be taken.
2) Shelf setting: The shelf is assembled with the slabs and pillars on the kiln
car, and the wares are set on the shelf. Advantages of shelf setting are as
follows:
- Though initial cost of silicon carbide slabs and pillars is high the total
cost can be reduced considering its life more than 200 cycles.
Utmost care should be taken to select the kiln because it is the heart of
ceramic production and the biggest investment for any factory. The factors
to be considered are as follows:
11
- Quantity to be produced
- Quality to be produced
- Firing temperature
- Firing time
- Atmosphere of flame
- Kind of fuel
- Balance of the capacity of forming section and that of the kiln
- Location and infrastructure
- Condition of land etc.
At present the numbers of tunnel kiln and the like is very few. However,
there is a sign of boom on constructing the brick making plant and peoples
are fumbling for the possibility of installing the tunnel kiln. Advantages and
disadvantages of tunnel kiln is enumerated as follows:
12
Shortening of firing hours: In the periodic kiln, quick pre-heating or rapid
cooling is impossible due to big kiln volume, where as it is in the tunnel kiln
due to its small volume.
Saving in labour cost: As the loading and unloading work can be done at a
fixed place, the labour cost per unit of product is much less than that of a
periodic kiln.
Longer life of kiln furniture: The life of kiln furniture of tunnel kilns is
longer than any other kilns.
High productivity per unit area: When the total production quantity is
considered, the area required for a plant having a tunnel kiln is smaller than
that of the periodic kiln.
Limited variety of Products: The tunnel kiln is run under constant firing
condition. For instance, porcelain tableware and sanitaryware cannot be fired
simultaneously. Even with the same quality of products varieties in size and
shape will preferably be minimised. When there are varieties, utmost care is
required to obtain uniform loading style.
13
Kind of fuel is limited: The fuel used for tunnel kiln is oil, kerosene, heavy
oil or gas (natural gas, LPG or producer gas). Solid fuel (coal or wood) is not
suitable for the tunnel kiln.
High construction cost: Besides the refractories, kiln cars, rails, fans and
longer ducting, piping and wiring works other than the unit kiln are required.
The construction period is also longer, resulting into the higher construction
cost.
14
Step 1 - Good housekeeping
15
2.8.2 Energy conservation techniques in ceramic industry for
sanitaryware production
Table 2.1 shows the energy conservation techniques in the ceramic industry
in the case of sanitary ware production. Two major processes in which
energy conservation is applicable are the drying and firing processes.
In the third step of above Table 2.1, it is recommended to replace the tunnel
kiln with the roller hearth kiln. As the roller hearth kiln represents the kiln
16
with reduced height so the temperature difference between top and bottom
surraces remains within a minimum range which is very useful for rapid
firing and quality product as well as improved yield. Another advantage is
instead of kiln car, the roller hearth kiln is adopted the rollers which are
made of stainless steel and belt conveyor made of steel mesh for higher
temperature, which is very easy for maintenance. Besides, the roller hearth
kiln permits quick temperature rise, shut-down, cooling and easy change of
the temperature and pressure as the temperature control is automatic so
firing and shut down can be perrormed by the one-touch operation.
Heat recovered during the cooling of the product in the kiln is generally used
as the heat source for drying the formed products in the ceramic production
process. However, this heat alone is not sufficient, so the heat regenerator
(boiler, hot air generator) is used to make up for this insufficiency.
The structure of the drier is so designed that the outer wall is provided with
the heat insulation board and wool in order to prevent heat dissipation.
a. Heat balance: The tunnel kiln consumes the greatest amount of energy
in the firing process. The following describes the energy conservation for
the tunnel kiln.
17
The first step in promoting the energy conservation activities is to have a
correct understanding of the current situation. Namely, correct
information on how, where and how much the energy is used and wasted
will make it possible to determine the target of reducing the energy loss
and to initiate the improvement efforts. Such accounting of the heat is
known as "heat balance". Heat balance defines the quantitative
relationship between the heat supplied to the thermal equipment (heat
input) and the consumed heat (heat output). In all cases, the total heat
input is perfectly equal to the total heat output. The degree of economic
use of heat in thermal equipment depends on distribution of various types
of heat constituting the heat output with respect to heat input.
Heat input
Heat output
18
Volume of exhaust gas x density x specific heat x temperature difference
19
CHAPTER-3
Name of the product Type of kiln used No. of kiln Production capacity
Sanitaryware Tunnel kiln 2 2 x 2000 MT
Insulator Tunnel kiln 1 2400MT
Tiles Roller hearth kiln 1 110000 sq meter
Muffle kiln 2
20
Body Preparation I Glaze Preparation I MouldShop
Broken Body
Quartz
Feldspar
Dolomite
Zirconium Silicate
China Clay
Lime Stone
Color Stains
Water Cobalt Sulphate
Bijoypur Clay
Rajmahal Clay
Ball Clay
Green Sanitaryware
Magnetic Separator
Slip
Glaze
21
3.3 Description of the Sanitaryware Tunnel Kiln at BISF
BISF has three tunnel kilns - one insulator kiln and two sanitaryware kilns.
A detailed specification for the sanitaryware tunnel kiln is given below:
Preheating zone
Firing zone
Cooling zone.
22
Measured temperature profile: Temperatures of different thermocouples
located in different zones of sanitaryware tunnel kiln-l were measured
manually, shown in Table 3.3 and prepared a temperature profile at present
operating conditions of the kiln, Figure 3.3.
23
Measured temperature versus thermocouple location profile of tunnel kiln-l
is shown in Figure 3.3.
1400
12l)-
11XXl- ,,
() !
Cl
Gl
'tl8X)
l!!
::l
~
8.a:xJ
E
~
400
0,
1 2 3 4 5 6 7 8 9 10 11 12 13 14 15 16 17 18
11 leiII ux:x.pe 1000000s
24
CHAPTER-4
4.1 An Overview
There are two types of energy used for production purposes at BISF - gas
and electricity. Year wise total gas consumption for the production of
sanitarywares, insulators and tiles is shown in Table 4.1A. A bar chart
showing year wise gas consumption for total production is also shown in
Figure 4.1A.
25
Table 4.1A: Total natural gas consumption for production of sanitarywares,
insulators and tiles from 1986-87 to 2001-02 at BISF (2)
26
Figure 4.1A: Bar graph showing year wise total natural gas consumption for production
of sanitarywares, insulators and tiles at BISF.
7000 ...."",....."
6000
5000
ME
M
0
~
C 4000.
0
:;::
Co
E
:l
en
C
3000
0
U
VI
'"
Cl 2000 .
1000 .
o .
1986--87 1987--88 1988.89 1989-90 1990-91 1991-92 1992-93 1993-94 1994-95 1995-96 1996-97 1997-98 1998-99 1999-00 2000-01 2001-02
Year
27
Year WIse total electricity consumption for sanitarywares,
insulators, and tiles production is shown in Table 4.1B.
• From the starting of 1999-2000 year 0.6 MW Gas Electric Generator has
been installed to ensure un-interrupted electricity supply for the six kilns
only. The generator is operating with an average load of 400 Kwh in parallel
of PDB power supply.
29
4.2 Excess Gas Consumption
30
4.3 Excess Electricity Consumption
31
,
Excess energy
Production Electricity Electricity consumption if
Year consumption consumption standard energy
(MT) 103 Kwh (KwhlKg) is 0.137 Kwh/kg
product
From the above descriptions and tables it is clear that at BISF a large amount
of excess energy is consumed per kg sanitaryware produced. This excess
energy utilization can be minimized in the existing plant in two ways:
32
CHAPTER-5
33
b. Main features: A single analysis unit provides continuous, highly
accurate monitoring of NO" SOz, CO, COz, and Oz.
34
Table 5.2: Standard ranges of stack gas components
CO 200-5,000 ppm
O2 10-25 vol%
35
Table 5.3: Stack gas composition of sanitaryware tunnel kiln-l at ElSF.
Result found
Component
1st run 2nd run 3rd run Average
From the above Table 5.3, it can be assumed that the composition of stack
gas on dry basis at BISF is as follows:
CO2 = 7.7 %
O2=7.3%
For 7.7 mol of CO2 production, H20 produced is (2 x 7.7) mol = 15.4 mol
36
Total amount of Nz present in the product is [22.~;79 J mol
= 85.4 mol
=47%
From the above result it is clear that at present operating conditions, BISF
uses 47% of excess air for sanitaryware tunnel kiln-I.
37
CHAPTER-6
The main objective of this study was to performance study of tunnel kilns
for sanitaryware production at BISF. Performance of any thermal equipment
is determined by thermal analysis. For thermal analysis, at first heat balance,
which means accounting of heat input and heat output, must be done.
Secondly, thermal efficiency is calculated from effective heat/heat input
relationship. At BISF both tunnel kilns for sanitaryware production are
identical. So for thermal analysis, sanitaryware tunnel kiln-l is considered.
There are two sections for thermal analysis of sanitaryware tunnel kiln-l
outlined as - 'Heat Balance' and 'Thermal Efficiency'. Details of every
section is described in below:
1. Present production rate is 224 Kg/hr (as per January, 2002 data) although
it should be 238 Kg/hr as per design.
3
2. Net heating value of natural gas is 8438 KcallNm
38
:-'o\;
3. Gas consumption rate for sanitaryware kiln-l IS 129 Nm3/hr as per
January, 2002 data.
4. Maximum moisture content of the sanitaryware finished product is 1.1%.
. 0 8438Kcall29Nm3
Total heat mput,input = 3 h
Nm r
39
.
Average weIght . [560kg 38'
0f re f ractory part IS lear 60minJ
h = 8 84 kg /hr
ear mm r
Total heat associated with kiln car, 01= (283764 + 43229) Kcal/hr
= 326993 Kcal/hr
40
t" t.,
Waste heat to
Stack Gas Dryer, T=115°C
T=165°C
Cooling Air
T=300C
+-+-+-+-+-+-+-
tPre-Heating Zone Firing Zone I~ Cooling Zone
•
Average Temp. =1100°C T Average Temp. = 600° C
t+-+-+- +- +- +---
o
Kiln Car Out
Kiln Car In
T=30°C
i NG
T=115° C
Figure 6.1: Simplified process flow diagram of sanitaryware tunnel kiln-l at BISF
. \. 41
Stack Gas Waste heat to Dryer
T=165°C T=115°C
Q7=Q5+Q6
• Cooling Air
Q5 J. Q6 T=30°C
Figure 6.2: Heat balances at different zones of sanitaryware tunnel kiln-l at BISF (Schematic diagram)
't 42
Flue gas analysis
43
Flue Gas Product
COz: 15.22%
HzO: 12.30%
Nz: 72.47%
= 959 kg-mol
44
Theoretical amount of combustion air = 9.59 m3 air/Nm3 of NO
From the stack gas analysis it was found that 47% excess air is used for
tunnel kiln of sanitaryware production so,
This 2095 kg/hr air is mixed with NO in burner during combustion. As per
the operating manual another 5250 kg/hr false air is infected on product as a
false air for cooling purpose. The stack gas is the combination of the flue gas
and air.
Mass flow rate of air through stack is (2095 + 5250) kg/hr = 7345 kg/hr
To calculate maximum moisture content of the stack gas let us consider the
rainy season when relative humidity is 100%.
. [20
. /h'r, mOlsture content is g 7345hkg air kg3 ]
In 7345 k g-arr k'
galr r 10 g
= 147.0 kg/hr
Amount of dry air is (7345 - 147) kg/hr = 7198 kg/hr
= 5521 kg/hr
In 7198 kg/hr dry air Oz content is (7198 - 5521) kg/hr = 1677 kg/hr
45
Amount of moisture released from product is
= 2.5 kg/hr
Total moisture in stack gas: 207.6 + 147.0 + 2.5 = 357 kg/hI.
Latent heat of evaporation of moisture = 540 Kcal/kg
Cp of moisture = 0.45 Kcal/ kg. DC
= 31.5 Kcal/kg
After evaporation sensible heat of moisture to rise its temperature from 100
to 165 DC is 0.45 x (165 - 100) = 29.3 Kcal/kg [This sensible heat is a part
of stack gas heat].
= 601 Kcallkg
Total heat of evaporation during one hour operation due to chemically and
mechanically bound moisture, Q} = 357 kg/hr x 601 Kcal/kg
= 214557 Kcal/hr
46
Heat associated with stack gas
O2: 18%
Heat losses through pre-heating & firing zones wall and ceilings
47
Kiln height = 2.5 m
Kiln width = 3.69 m
Length of firing zone = 32 m
Length of preheating zone = 18 m
Ceiling area of firing zone = 118 m2
Total (Right + Left side) wall area offiring zone = 2 x 32 x 2.5 = 160 m 2
2
Total (Right + Left side) wall of pre-heating zone = 2 x 18 x 2.5 = 90 m
2
Ceiling area of pre-heating zone = 66 m
48
Total heat released through wall & ceiling of the pre-heating and firing
zones, 07 = Qs + Q6 = (39960 + 96120) Kcal/hr = 136080 Kcal/hr
Heat losses through metallic part is {632 x 0.12 x (300 - 115)} Kcal/hr
= 14030 Kcal/hr
Heat losses through kiln car at exit, 09 = (128622 + 14030) Kcal/hr
= 142652 Kcal/hr
49
Heat losses through ceiling & side walls,
Total heat carried out by cooling air to raise it's temperature from 30 to 115
°C (kiln outlet temperature 115°C)
m = 3345 kg/hr of air can be heated by the waste heat of cooling zone.
50
HEAT BALANCE ASSOCIATED WITH SANITARYWARE KILN-l
Total heat losses = Losses in the stack + losses in the pre-heating & firing
zone +losses in the cooling zone +losses in the de-sulphurizer
= Q4 + Q7 + QIl + Q12
= (341045 + 136080 + 245142 + 65000) Kcal/hr
= 787267 Kcal/hr
Effective heat
-----xl00%
Thennal efficiency = Heat input
301235
---xlOO%
Thermal efficiency = 1088502
= 28.0 %
51
CHAPTER-7
(l) The specific heat of exhaust gas depends on the temperature. So, the
temperature difference of exhaust gas should be kept as low as
possible. Sealing the small clearance of the kiln with fibbers or similar
materials will reduce the temperature difference causing much heat
recovery.
52
(2) Heat losses by radiation is related to the surface area of the kiln.
Reduction of the surface area to a half by adopting roller hearth kiln
instead of tunnel kiln, will reduce the rate of heat radiation to a half,
resulting in substantial fuel saving. Conduction heat losses may be
minimized by proper insulation around the kiln.
(4) Heat loss by kiln car depends on- the weight of the car per unit time,
specific heat of the car refractory and temperature difference. High-
speed firing and use of the heat insulation bricks or ceramic fibers will
reduce the weight of the car per unit time, which will reduce heat loss.
53
•
CHAPTER-8
Exhaust Gas
~
;;
-5 Blower
><
~
Air Curtain
Blow Waste Heat Air eu tain
Combustion Air
54
REFERENCES
1. Akter, S., Utilization of flue gas heat for space heating in a ceramic
industry, M.Sc. Thesis, BUET, ChE Dept., 1993.
2. BISF- Annual Reports and Data from Kiln & Electrical Section.
3. Energy Conservation in Ceramic Industry, UNIDO & Energy
Monitoring and Conservation center, Dhaka (1994), pp. 1-31.
4. ECOM-AC, Portable Emission Analyzer, Available:
http://www.ecomusa.com/products/serviceMaintiecomAC/contentsEcomAC.htm
(retrieved on 4th October, 2002).
5. Holman, J.P., Heat Transfer, Sixth edition, McGraw-Hill, Singapore
(1986), pp. 536-538.
6. Kern, D.Q., Process Heat Transfer, First edition, McGraw-Hill,
Singapore (1950), pp. 19-22.
7. Kirk-Othmer, Encyclopedia of Chemical Technology, Third edition,
Vol. 5 (1979), pp. 261-262.
8. Kyotani, K., Ceramic Kiln, Second edition, JICA Pakistan (1995), pp.
30-38,57-58,91,101-108.
9. Norton, F.H., Refractories, Fourth edition, Mc-Graw Hill (1968), pp.
206,210,218.
10. Perry, R.H. & Green, W. Don, Perry's Chemical Engineers
Handbook, Sixth edition, McGraw-Hill, Singapore (1984), pp. 5.18.
11. Reading Materials of International Training Program on "Practical
Training for Energy Managers from Industry (Phase - II: case study
on BISF), Center for Energy Studies, BUET, Dhaka (2002).
12. Singer, F. and Sonja, S. Singer, Industrial Ceramics, First edition,
Chapman and Hall, London (1963), pp. 502-611, 854.
13. Shreve's Chemical Process Industries, Fifth edition, McGraw-Hill,
Singapore, pp. 149-169.
14. Technology of Air Pollution Continuous Monitoring in Japan,
Available: http://nett21.unep.or.jp/CTTDATAl AMON/CHAP5lhtml/Amon-
149 l.html (retrieved on 20th September, 2002).
55
1
r
J
- .'
(. APPEND X-A
II
,,
Table A: Overall heat balance in preheating and firing zones of
sanitaryware tunnel kiln-1 at BISF.
Parameter Amount of
heat (Kcal/hr)
Heat input, Qinput 1088502
56
",'
C
APPENDIX-B
Parameter Amount of
heat (Kcal/hr)
Gain components:
Loss components:
QIO
57
...
. ,
APPENDIX-C
Designed volumetric flue gas flow rate of insulator kiln, sanitaryware kiln
no. 1 & sanitaryw~e kiln no. 2 =3.5 m3 Is each. About 85% ofthe dampers
remain at open condition. Hence actual volumetric flow rate of these three
kilns=2.975 m3 Is. =10710 m3 Is.
3
Density of the stack gas = 0.84 kg/m
Mass flow rate =8996 kg/hr.
For both the kiln the exit flue gas temperature = 165 ° C
Cpo of gas at 165 ° C = 0.275 kcallkgO C
Heat obtained from each the kiln flue gas = 8996 x 0.275 x (165-30)
= 333976 kcal/hr.
So, total waste heat obtained from three kilns flue gases
= 403020 + 333976 + 333976 = 1070972 kcal/hr.
/~~i"t~f<
If.:' .~,-"" ~,-. ~~.
58
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