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PERFORMANCE STUDY OF TUNNEL KILNS

FOR SANITARYWARE PRODUCTION AT BISF

A THESIS
SUBMITTED TO THE DEPARTMENT OF CHEMICAL
ENGINEERING IN PARTIAL FULFILLMENT OF THE
REQUIREMENTS FOR THE DEGREE OF
MASTER OF ENGINEERING (CHEMICAL)

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DEPARTMENT OF CHEMICAL ENGINEERING


BANGLADESHUNIVERSITYOF ENGINEERING ANDTECHNOLOGY,
DHAKA-IOOO.
\

SEPTEMBER, 2002

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BANGLADESH UNIVERSITY OF ENGINEERING & TECHNOLOGY, DHAKA

DEPARTMENT OF CHEMICAL ENGINEERING

CERTIFICATE OF THESIS WORK

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.

(Dr. M. Serajul Islam) Chairman


Associate Professor
Department of Chemical Engineering
BUET,Dhaka

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 is grateful to Engr. Md. Mustafizur Rahman, Assistant Engineer,


BISF, Mirpur, Dhaka, for providing necessary data & information regarding
the thesis work. Thanks are also due to Mr. A B. Siddique, Manager sales of
Greenland Engineers & Tractors Co. Ltd. (GETCO), Syamoli, Dhaka for
providing their stack gas analyzer to carry out this thesis 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 the staff of Chemical Engineering Department, BUET especially


Mr. Shamsur Rahman, Mr. Md. Idris Munsi and Mr. Md. Humayun Kabir
for their help during this 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

Ceramic production is one of the most energy intensive industries,


consequently savings of energy will reduce the production cost significantly.
At Bangladesh Insulator and Sanitaryware Factory Ltd. (BISF), an enterprise
of BCIC, tunnel kilns are used for sanitaryware and insulator production. A
performance study of the tunnel kiln is important for curtailing of
sanitaryware production cost. In the present study an attempt has been made
to estimate the natural gas and electricity consumption in different sections
at BISF which is important for an energy audit of the entire factory.
Recommendations for enhancing the thermal efficiency of the tunnel kilns
include the various steps, which need to be adopted for energy savings
purposes. Furthermore, an overall heat balance as well as determination of
the thermal efficiency of sanitaryware tunnel kiln-l was performed based on
the present operating conditions of the plant. In most of the cases, the
existing operating data are totally different from the design values. The
calculated thermal efficiency was 28.0%. The main reason for this poor
performance is due to outdated kiln technology.

ii
CONTENTS

Page

CHAPTER 1 INTRODUCTION 1

CHAPTER 2 LITERATURE REVIEW 3


2.1 Classification of kilns 3
2.2 General structure of tunnel kiln 4

2.3 Tunnel kiln operating conditions 5


2.4 Types of tunnel kilns and their characteristics 9

2.5 Loading work in the tunnel kiln 10


2.6 Selection criteria of a kiln . 11

2.7 Advantages and disadvantages of tunnel kiln 12

2.8 Energy conservation techniques 14

2.8.1 Promotion of energy conservation techniques in a 14


modem plant

2.8.2 Energy conservation techniques in ceramic industry 16


CHAPTER 3 DESCRIPTION OF THE PLANT UNDER STUDY 20
3.1 General Information 20
3.2 Sanitaryware production process 20
3.3 Description of the sanitaryware tunnel kiln at BISF 22

CHAPTER 4 ENERGY CONSUMPTION SCENARIO AT BISF 25


4.1 An overview 25
4.2 Excess gas consumption 30
4.3 Excess electricity consumption 31

iii
CHAPTER 5 STACK GAS ANALYSIS OF SANITARYWARE 33
TUNNEL KILNS AT BISF

5.1 Method used for stack gas analysis ' 33

5.2 Standard range of stack gas components 35

5.3 Stack gas composition of sanitaryware tunnel kiln-1 35


at BISF

CHAPTER 6 THERMAL ANALYSIS OF SANITARYW ARE 38


TUNNEL KILNS FOR SANIT ARYW ARE
PRODUCTION AT BISF

6.1 Heat balance 38

6.2 Thermal efficiency 51

CHAPTER 7 RESULTS AND DISCUSSIONS 52

CHAPTER 8 CONCLUSIONS AND RECOMMENDATIONS 54

REFERENCES 55

APPENDICES 56

Appendix A: Overall heat balance in pre-heating and firing zones 56

Appendix B: Overall heat balance in cooling zone 57

Appendix C: Total waste heat calculation of sanitaryware tunnel kilns 58


No.1, 2 and insulator kiln.

iv
LIST OF FIGURES

Page

Figure 2.1: Different types of kilns 3

Figure 2.2: Structure of the tunnel kiln (Top view) 4

Figure 2.3: Operating conditions of a tunnel kiln 7

Figure 2.4: Types of tunnel kilns according to firing systems 9

Figure 3.2: Block diagram for sanitaryware production at BISF 21

Figure 3.3: Measured temperature profile of sanitaryware kiln-l 24


atBISF

Figure 4.1: Bar graph showing year wise total natural gas 27
consumption for production of sanitarywares,
insulators and tiles at BISF

Figure 6.1: Simplified PFD of sanitaryware tunnel kiln-l at 41


BISF

Figure 6.1: Heat balances at different zones of sanitaryware 42


tunnel kiln-l at BISF

Figure 8.0: Heat distribution of sanitaryware tunnel kilns at 54


BISF (Proposed)

v
LIST OF TABLES

Page

Table 3.3 Measured temperature data in sanitaryware tunnel 23


kiln-l at BISF

Table 4.IA Total natural gas consumption for production of 26


sanitarywares, insulators and tiles from 1986-87 to
2001-02 at BISF

Table 4.1B Electricity consumption from 1986-87 to 2001-02 at 29


BISF

Table 4.2: % Excess gas energy consumption for sanitaryware 30


production from 1986-87 to 2001-02

Table 4.3: % Excess electrical energy consumption for 32


sanitaryware production from 1986-87 to 2001-02

Table 5.2: Standard ranges of stack gas components 35

Table 5.3: Stack gas composition of sanitaryware tunnel kiln-l 36


at BISF

Table A: Overall heat balance in preheating and firing zones of 56


sanitaryware tunnel kiln-l at BISF

Table B: Overall heat balance in cooling zone of sanitaryware 57


tunnel kiln-l at BISF

vi
CHAPTER-l

INTRODUCTION

Background and Present Status of the Problem

Ceramic production is one of the most energy intensive industries as the


solid-solid reaction occurs at a high temperature (1). Two types of energy
are used in the ceramic industry; electric energy and thermal energy. The
percentage of the energy cost in the total ceramics production cost is up to
20 percent. Reduction of energy cost will contribute to reducing the
production cost and increasing the profit. The drying and firing processes in
ceramic production use much energy. Of these processes, the firing process
is the greater energy consumer (3). At Bangladesh Insulator and
Sanitaryware Factory Ltd. (BISF), tunnel kilns are used for the firing of
sanitaryware and insulator. These are continuous type kilns and use natural
gas as a fuel. The natural gas consumption cost is about Tk. 2 million per
month, which is about 14% of the total production cost (2). Presently, the
consumption of gas in the tunnel kilns is higher than the design value. There
is a meter to measure the gas input to the kilns but no information is
available about stack gas flow rate and its composition. The amount of
excess air used for combustion is also unknown. There is a control system
for the kilns but it is not working properly (2).

Present study is concerned with the performance evaluation of tunnel kilns


for sanitary ware production at BISF. The objectives of the study include:

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

LITERA TURE REVIEW

2.1 Classification of kilns

The kiln is to be classified according to various factors. Usually one typical


name will be given to each kiln as shown in Figure 2.1.

1. Classified by 2. Classified by the 3. Classified by the


operation method direction of flame mode of flame

.•-\-.
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

Round Rectangular Ring Tunnel Roller hearth MireD


kiln kiln kiln kiln kiln kiln

Figure 2.1: Different types of kilns

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.

FIRING ZONE COOLING ZOkE

AIR
'EXHAUST FAN COM8USTllN GAS

DIRECTION OF I((lN CAR

Figure 2.2: Structure of the tunnel kiln (Top view)

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:

a) Increase its air


b) Decrease its air
c) Open the damps of exhaust fan
d) Open the damper of cooling fan
e) Adjust the relief port to decrease the inducing volume of waste heat air
f) Increase the air volume of neutral zones burner.

The ratio of fuel consumption in each zone varies widely but the rough idea
is given below:

Oxidizing zone: reducing zone: neutral zone = 3: 5.5:1.5

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

14 Pre-F..iring Zone -I.-


Firing Zone Cooling Zone

(0C)

1200

1000

800

600 Heat Curve

400

200

(%) Atmosphere

21

a
(mmHg)
Kiln Pressure
+1

j;0

-1

Kiln Length

Figure 2.3: Operating conditions of tunnel kiln

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

Figure 2.4: Types of tunnel kilns according to firing systems.

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:

- The loading capacity is increased by 40 to 90% more than sager setting


method.

- By eliminating the handling of sagers, loading and unloading work


becomes very easy, resulting in the saving oflabour cost.

- Though initial cost of silicon carbide slabs and pillars is high the total
cost can be reduced considering its life more than 200 cycles.

- Since the weight of kiln furniture is considerably decreased than the


sager setting and furthermore the heat conductivity of silicon carbide is
high, the heat efficiency is much increased.

2.6 Selection Criteria of a Kiln

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:

- . Kind of product to be fired

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.

2.7 Advantages and Disadvantages of Tunnel Kiln

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:

A. Advantages of Tunnel Kiln

Good heat efficiency: Consumption of fuel is half compared to that of the


periodic kilns because of (i) the heat of firing zone is utilized in pre-heating
zone, (ii) the cooling air which is heated up by the ware is utilized for pre-
heating zone and for dryer, (iii) the heat loss from the kiln wall is smaller
than that of the periodic kiln etc.

Uniform firing condition: Uniform quality of products will be obtained due


to the fact that (i) the temperature difference ,at a certain section is less than
any other kiln, (ii) fired under a constant heat curve etc.

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.

Automatic control is easy: As the firing temperature is kept constant, it is


very easy to put the burners under automatic control.

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.

Less maintenance cost: As the temperature in each section of the tunnel


kiln is kept constant hence the life of refractory bricks is much longer than
that of the periodic kiln which is exposed to sampling repeatedly.

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.

B. Disadvantages of Tunnel 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.

Balance with the forming capacity is necessary: If the forming capacity is


less than that of tunnel kiln, slowdown of kiln car schedule is required,
resulting into uneconomical running. If the quantity of green ware is still
less, some kiln car loaded only with sagers has to be sent intermittently,
resulting into unsatisfactory quality due to uneven loading style.

Skill of kiln operator required: In order to control the tunnel kiln


satisfactorily, high level of knowledge and skill are required for the kiln
operators.

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.

2.8 Energy Conservation Techniques

2.8.1 Promotion of energy conservation techniques in a modern ceramic


plant

Energy conservation efforts can be classified into the following


three steps (3):

14
Step 1 - Good housekeeping

Energy conservation efforts are made without much equipment investment,


including elimination of the minor waste, review of the operation standards
in the production line, more effective management, improvement of
employees' cost consciousness, group activities, and improvement of
operation technique.

For example, such efforts include management to prevent unnecessary


lighting of the electric lamps and idle operation of the motors, repair of
steam leakage, as well as reinforcement of heat insulation.

Step 2 - Equipment improvement

This is the phase of improving the energy performance of the equipment by


minor modification of the existing production line to provide the waste heat
and pressure recovery equipment or by introduction of the efficient energy
conservation equipment. For example, energy conservation efforts in this
step include an effective use of the waste heat recovery in combustion
furnaces and construction of the waste pressure recovery device and waste
heat recovery generator in the steel and iron works and cement plant.

Step 3 - Process improvement

Thisis intended to reduce energy consumption by substantial modification


of the production process itself by technological development. Needless to
say, this is accompanied by a large equipment investment. However, this is
linked to modernization of the process aimed at energy conservation, high
quality, higher added value, improved product yield and man power saving.

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.

Table 2.1: Energy conservation techniques in drying and firing processes of


sanitaryware (3)

Dr in rocess Firin rocess


1st step Combustion control • Exhaust gas temperature control
(combustion • Kiln seal
temperature) • Cooling air
• Air ratio
• Firing management (heat curve,
temperature distribution in the kiln,
kiln pressure, atmosphere)
• Loading pattern on the kiln car
• Clearance between the kiln wall and
kiln car
• Sand seal
• Kiln car ushin seed
2° step Heat insulation • Refractories on the kiln car to be light
in weight
• Refractories in the periodic kiln (to be
light in weight)
• Form of the tunnel kiln
• Recovery of the exhaust gas

3' step Conversion from the tunnel kiln to the


roller hearth kiln

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.

Energy Conservation Technique in Drying Process: Electric and gas


energies are used for material adjustment and forming in the ceramic
production process. Especially the greatest amount of energy is consumed to
dry the formed product and by the kiln in the firing process. This is also true
in the case of sanitaryware production at ElSF.

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.

Energy Conservation Technique in Firing Process

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 retained by fuel


Combustion heat = calorific value of fuel x fuel consumption
• Heat carried in by the heated object
Volume of heated object x density x specific heat x temperature
difference

Heat output

• Heat carried away by the heated object


Volume of heated object x density x specific heat x temperature
difference
• Heat carried away as waste heat
Volume of waste heat stream x density x specific heat x temperature
difference
• Heat carried away by exhaust gas generated by combustion

18
Volume of exhaust gas x density x specific heat x temperature difference

• Heat loss by radiation and conduction


Difference between total heat input and total heat output

b. Thermal efficiency: The thermal efficiency is expressed as "effective


heat" divided by "heat input". The effective heat is defined, as the heat
required to fire the heated object; namely, it is the mass of heated object
multiplied by its specific heat by maximum temperature difference.

19
CHAPTER-3

DESCRIPTION OF THE PLANT UNDER STUDY

3.1 General Information

In March 1981, Bangladesh Insulator and Sanitaryware Factory Ltd. (BISF),


was constructed through a bilateral commodity exchange agreement with
MIS Progoinvest of Czechoslovakia on a turnkey basis. The company's total

workforce is approximately 1200.

The annual installed production capacities of BISF for different products


are:

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

3.2 Sanitaryware Production Process

Several steps are involved in sanitaryware production. Among these - mass


body preparation, glaze preparation, mould preparation glazing, loading on
the kiln car, firing in the tunnel kiln, sorting of the fired product, storage of
the finished product etc. are mentionable.

Different steps of sanitaryware production are shown 10 Figure 3.2.

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

Scrap De-dusting Glazing


and Finishing Dry Green

Ready for Sale Storage Sorting

Figure 3.2: Block diagram for sanitaryware production at BISF (2)

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:

i) Capacity of kiln: 2000 x 2 = 4000 MT/year


ii) Type of kiln: Tunnel kiln (directly fired).
iii) Length of the kiln: 99 m
iv) Max. construction width: 3.69 m
v) Max. construction height: 2.5 m
vi) No. of burners: 48 (equal number on both sides)
vii) No. of thermocouples: 18
viii) No. of kiln car inside the kiln: 46
ix) Firing condition: Oxidation firing
x) Firing temperature: 12800 C (12700 :t 10 0 C) maximum
xi) No. of car for operation: 120
xii) Firing cycle: 26 hours (optimum)
xiii) Tunnel kiln characteristics: Three firing zones

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.

Table 3.3: Measured temperature data in sanitaryware tunnel kiln-l at BISF


(February 03,2002 at 11:00am.)

Location of the Name of the zone Measured


thermocouple temperature (0 C)
Tj Pre-heating 180
T2 Pre-heating 355
T3 Pre-heating 450
T4 Pre-heating 480
Ts Pre-heating 765
T6 Firing zone 940
T7 Firing zone 1090
Ts Firing zone 1180
Tg Firing zone 1185
TID Firing zone 1065
Tll Cooling zone 940
TI2 Cooling zone 780
Tl3 Cooling zone 700
TI4 Cooling zone 605
TIS Cooling zone 465
TI6 Cooling zone 440
Tl7 Cooling zone 255
TIS Cooling zone 115

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

ENERGY CONSUMPTION SCENARIO AT BISF

4.1 An Overview

BISF spends approximately Tk. 2 million/month for natural gas, which is


approximately 14% of the total production cost. Therefore, even a few
percentage of energy conservation will yield significant savings in
production cost that will increase the profit. With this view in mind, the
excess energy consumption of BISF has been studied in this project.

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)

Gas consumption Production (MT)


Year ( 103m3) Sanitaryware Insulator Tiles
1986-87 3179 1545 663 280
1987-88 3362 1945 501 237
1988-89 3863 2209 635 310
1989-90 4457 2301 605 850
1990-91 4193 2036 429 1006
1991-92 4318 2324 324 1058
1992-93 4402 2389 129 1113
1993-94 4512 2422 715 1186
1994-95 4809 2958 755 941
1995-96 5039 3119 544 1179
1996-97 5295 3174 527 813
1997-98 5279 3078 529 972
1998-99 4564 3013 568 989
1999-00 5767 2950 579 1012
2000-2001 5137 2812 612 1028
2001-2002 4448 2918 658 1112

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.

Table 4.IB: Electricity consumption from 1986-87 to 2001-02 at BISF (2)

Year Electricity Production (MT)


consumption
Sanitaryware Insulator Tiles
(103 Kwh)
1986-87 2346 1545 663 280
1987-88 2266 1945 501 237
1988-89 2498 2209 635 310
1989-90 2852 2301 605 850
1990-91 2884 2036 429 1006
1991-92 2719 2324 324 1058
1992-93 2810 2389 129 1113
1993-94 .3422 2422 715 1186
1994-95 4348 2958 755 941
1995-96 4391 3119 544 1179
1996-97 4391 3174 527 813
1997-98 4391 3078 529 972
1998-99 4391 3013 568 989
1999-00' 4648 2950 579 1012
2000-01 4698 2812 612 1028
2001-02 4507 2918 658 1112

• 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

The breakdown of total gas consumption for production purposes at BISF is


- sanitaryware 62.77%, insulator 22.81 % and tiles 14.42% (2). So, year wise
gas consumption for sanitaryware product is calculated from Table 4.1A.
From this, gas energy consumption rate per kg sanitaryware product is also
calculated. According to Czechoslovakian expert's design; the standard gas
energy consumption per kg sanitaryware product is 3659 Kcal. Comparing
with design value year wise excess gas energy consumption for sanitary ware
production is presented in Table 4.2.

TABLE 4.2: % Excess gas energy consumption for sanitaryware production


from 1986-87 to 2001-02 at BISF (2)

Production Gas Gas Gas energy Excess energy


Of consumption consumption consumption per consumption
Year Sanitaryware per kg product kg product Dercenta"e
MT IOJ mJ mJ/kg Kcallkg If standard energy is
3659 Kcal/kg
1986-87 1545 1996 1.29 10,885 197 %
1987-88 1945 2110 1.08 9,113 149 %
1988-89 2209 2425 1.09 9,197 151 %
1989-90 2301 2797 1.21 10,210 179 %
1990-91 2036 2632 1.29 10,885 197 %.
1991-92 2324 2710 1.17 9,872 170 %
1992-93 2389 2763 1.16 9,788 168 %
1993-94 2422 2832 1.17 9,872 170 %
1994-95 2958 3019 1.02 8,607 135%
1995-96 3119 3163 1.01 8,522 133 %
1996-97 3174 3324 1.05 8,860 142 %
1997-98 3078 3314 1.08 9,113 149 %
1998-99 3013 2865 0.95 8,016 119%
1999-00 2950 3620 1.23 10,379 184 %
2000-2001 2812 3224 1.15 9,704 165 %
2001-2002 2918 2792 0.96 8,100 121 %

30
4.3 Excess Electricity Consumption

The break down of electricity consumption for different products at BISF is


- sanitaryware 61 %, insulator 15% and tiles 24% (2). So, year wise
electricity consumption for sanitaryware production is calculated from Table
4.1B. From this electricity consumption per kg sanitaryware product is also
calculated. As per the installed capacity total electrical energy required for
sanitaryware tunnel kiln-l is 32.5 Kw. The total annual production capacity
of sanitaryware tunnel kiln-l is 2000 MT. So, the standard electrical energy
consumption per kg sanitaryware product is 0.137 Kwh. Comparing with
this standard value, year wise excess electrical energy consumption is shown
in Table 4.3.

31
,

Table 4.3: % Excess electrical energy consumption for sanitaryware


production from 1986-87 to 2001-02 at BISF

Excess energy
Production Electricity Electricity consumption if
Year consumption consumption standard energy
(MT) 103 Kwh (KwhlKg) is 0.137 Kwh/kg
product

1986-87 1545 1431 0.93 579 %


1987-88 1945 1382 0.71 418 %
1988-89 2209 1524 0.69 404%
1989-90 2301 1739 0.75 447 %
1990-91 2036 1759 0.86 528 %
1991-92 2324 2719 1.17 754%
1992-93 2389 2810 1.18 761 %
1993-94 2422 2087 0.86 528 % %
1994-95 2958 2652 0.90 557 %
1995-96 3119 2678 0.86 528 %
1996-97 3174 2678 0.84 513 %
1997-98 3078 4391 1.43 944%
1998-99 3013 4391 1.46 966 %
1999-2000 2950 2836 0.96 600%
2000-01 2812 2866 1.02 644%
2001-02 2918 2749 0.94 586 %

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:

• Increasing production rate, that is, reducing down time.


• Utilization of waste heat from tunnel kilns.

32
CHAPTER-5

STACK GAS ANALYSIS OF SANITARYWARE


TUNNEL KILNS AT BISF

5.1 Method Used for Stack Gas Analysis

An attempt was taken to measure the stack gas components by usmg


"ECOM-AC Plus" (4) multi-components gas analyzer which was collected
from Greenland Engineers & Tractors Co. Ltd. (GETCO), Shyamoli, Dhaka.
Actually it is a lineup of analyzers for the highly sensitive and accurate
measurement of NOx, SOz, CO, COz, and Oz stack gases emitted from
combustion furnaces, engines and the boilers of thermoelectric power plants.
The units are capable of the simultaneous and continuous measurement of
five different components using only one analysis device. The economical,
space-saving, low-maintenance units offer stable monitoring over the long
term and are equipped with such standard functions as automatic calibration,
calculation, moving average, external confirmation direct output, and self-
diagnosis. Offering superior operability and minimal maintenance, the
sampling systems have been standardized into six types, including those for
monitoring boiler gases, waste incineration, mining, and processing, thereby
providing users with a choice of systems that meet the demands of a variety
of fields and uses.

a. Measuring method: For measuring NOx, SOz, COz and CO Cross-


modulation non-dispersive infrared absorption method is used. Where as
for measuring Oz, magneto-pneumatic method is used.

33
b. Main features: A single analysis unit provides continuous, highly
accurate monitoring of NO" SOz, CO, COz, and Oz.

A NOx/COz interferant element sensor provides continuous compensation


and accurate NOx monitoring limits the influence of COz ..

The units are equipped with an automatic seven-day calibration function


(standard) and can be equipped with a 1-9 day calibration function.

A purge controller automatically purges clogs due to dust on a set cycle.


The units are equipped with a reagent gas probe that is easy to insert and
remove. An independent humidity mechanism minimizes damage due to
liquefaction (units for use at waste incinerators, electric power plants, and
glass furnaces).

There is no alteration to any reagent gas composition, and a dust catcher


completely removes S03.The NOx analysis unit is a low temperature type
converter that uses a proprietary carbon fiber catalyst, achieving stable
reduction from NOz to NO.

5.2 Standard Range of Stack Gas Components

As there is no available standard range of stack gases in Bangladesh so it


was collected from the Internet (14). The standard range of stack gas
components, which is followed in Japan, is shown in Table 5.2.

34
Table 5.2: Standard ranges of stack gas components

Component of stack gas Standard range

NOx 200-5,000 ppm

S02 200-5,000 ppm

CO 200-5,000 ppm

CO2 5-50 vol%

O2 10-25 vol%

5.3 Stack Gas Composition of Sanitaryware Tunnel Kiln-! at BISF

The stack gas composition of sanitaryware tunnel kiln-l at BISF IS

determined by "ECOM-AC PLUS" analyzer. As there is no portable stack


gas analyzer available in BUET so this analyzer was borrowed from
GETCO. The analysis was performed at the first sample point of stack gas
(near about the location of thermocouple No.2). There are three runs of
stack gases were taken at the same point but at different time intervals. The
average values of three runs were determined for the calculations as shown
in Table 5.3.

35
Table 5.3: Stack gas composition of sanitaryware tunnel kiln-l at ElSF.

Result found
Component
1st run 2nd run 3rd run Average

NO, 50 ppm 52 ppm 51 ppm 51 ppm

502 Nil Nil Nil Nil

CO 42 ppm 45 ppm 43 ppm 43 ppm

CO2 7.3 vol. % 7.9 vol. % 7.8 vol. % 7.7 vol. %

O2 7.9 vol. % 6.9 vol. % 7.0 vol. % 7.3 vol. %

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%

:. N2 = 100 % - (7.7 % + 7.3 %) = 85.0 %


CH4 + 202 = CO2 + 2H20

Basis: .100 mol of stack gas produced.

For 7.7 mol of CO2 production, H20 produced is (2 x 7.7) mol = 15.4 mol

:. Total amount of theoretical O2 required is 15.4 mol

So, Total amount of O2 supplied is (15.4 + 7.3) mol = 22.7 mol

36
Total amount of Nz present in the product is [22.~;79 J mol
= 85.4 mol

.. Excess Oz used is [ 7.3 XlOO%J


15.4

=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

THERMAL ANALYSIS OF THE TUNNEL KILNS


FOR SANITARYWARE PRODUCTION AT BISF

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:

6.1 Heat Balance

Heat balance of different zones of sanitaryware tunnel kiln-l at BISF is done


by the method which has already been discussed in section 2.8.2.Details of
heat balance around the kiln shown in Figure 6.1 and 6.2. Calculations are
also done based on the following assumptions:

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%.

Heat input through 129 Nm3/hr natural gas

Net heating value of NG (Titas gas) = 8438 Kcal/Nm3 .

. 0 8438Kcall29Nm3
Total heat mput,input = 3 h
Nm r

Qinput= 1088502 Kcal/hr

Heat associated with the firing of product Ql

Mp = Average mass flow rate of sanitaryware product = 224 kg/hr


Tf = Average temperature of the firing zone in the kiln = 1100 DC
Ambient air temperature, T a = 30DC

Cp = Average specific heat of sanitaryware product = 0.25 Kcal/kg. C

Ql = Il1p Cp (Tf- Ta) Kcal/hr


= 224 x 0.25 x (1100 - 30) = 59,920 Kcal/hr

Heat associated with kiln car to go through 1100 DC, Q2:

Car pushing rate = 38 min/car

Average weight of refractory part of one car = 560 kg

39
.
Average weIght . [560kg 38'
0f re f ractory part IS lear 60minJ
h = 8 84 kg /hr
ear mm r

Average sp. heat of refractory part = 0.3 Kcal/kg. °C

Average weight of welded steel frame including wheels on anti-friction


bearings of one car = 400 kg

. . [400k g lear 60minJ


Average weIght of welded steel frame IS ear 38min lhr = 632 kg/hr

Average sp. heat of metal part = 0.12 Kcal/kg. °c

Heat associated by refractory part is {884 x 0.30 x (1100 - 30)} Kcal/hr.


= 283764 Kcal/hr.

Heat associated by metal part is {632 x 0.12 x (600 - 30)} Kcal/hr


= 43229 Kcal/hr. [As the bottom temperature
. of the kiln is lower so it was assumed 600°C]

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

I Average temp. _ 600°C ~


Average temp. = 1100 °c Ql+QZ Cooling Zone
QS+Q9
Pre -heating zone Firing zone
rrln ~
ut
T=30°
,
QIO
Qinput

Figure 6.2: Heat balances at different zones of sanitaryware tunnel kiln-l at BISF (Schematic diagram)

't 42
Flue gas analysis

Composition of NG (Titas gas)

Component Composition (mole %)


CH4 96.8%
C2H6 1.7%
C3Hs 004%
Others 1.10%
100.0%

Reactions occurred while burning of Natural gas with air:

CH4 + 202 = CO2 + 2H20 (v)


C2H6 + 7/202 = 2C02 + 3H20(v)
C3Hs + 502 = 3C02 + 4H20(v)

Basis: 100 Kg-mol Natural gas burning

CH4: 96.8 Kg-mol


C2H6: 1.7 Kg-mol
C3Hs: 004 Kg-mol

CO2 Produced: (l x 96.8) + (2 x 1.7) + (3 x 004) = lOlA Kg-mol


H20 Produced: (2 x 96.8) + (3 x 1.7) +(4 x 004 = 200.3 Kg-mol

Theoretical O2 required for complete combustion:


(2 x 96.8) + (7/2 x 1.7) +(5 x 004) = 201.6 Kg-mol

Theoretical N2 required is {201.6X( ;~) }kg-mol = 758040 kg-mol

43
Flue Gas Product

COz: 101.4 kg-mol = 4461.6 kg COz


HzO: 200.3 kg-mol = 3605.4 kg HzO
Nz: 758.40 kg-mol = 21,235.2 kg Nz

Mass Composition of Flue Gas

COz: 15.22%
HzO: 12.30%
Nz: 72.47%

For 100 kg-mol of NO burning theoretical flue gas production = 29302.2 kg


For 1 kg-mol of NO burning flue gas production = 293.022 kg

Now, 22.4 Nm3 of NO burning flue gas production = 293.022 kg

S0, 129 Nm 3 0 fNO b urnmg


. flue gas pro d"uctlOn IS [293.022X129]
----- kg
22.4
= 1687.50 kg
Amount of Flue Gases

COz: 256.8 kg/hr


HzO: 207.6 kg/hr
Nz : 1223.0 kg/hr

Excess air for combustion of NG

Theoretical air required for combustion of 100 kg-mol NO


= 201.60 kg-mol Oz + 758.40 kg-mol Nz

= 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,

Total air required is (129 X 9.59 x 1.47) m3/hr


= 1819 m3/hr
3
= 2095 kg/hr [Density of air at 30°C = 1.152 kg/m ]

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%.

Air at 30 ° C and 100% RH, Dew point or wet bulb temperature = 30 ° C

From psychometric chart we get,


Specific humidity = 20 g/kg-air

. [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

In 7198 kg/hr dry air Nz content is ( 7198xO.79x28 ]kg/hr


0.79x28+0.21x32

= 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

224kg product O.Ollkg mOisturej .: Finished produt contains]


[ hr kg product [ 1.1% moisture

= 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

Sensible heat of moisture for rising it's temperature from 30 DC to 100 DC

= 0.45 x (100 - 30) Kcallkg

= 31.5 Kcal/kg

Then boiling and evaporation of moisture at 100 DC occurs.

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].

Total heat content of moisture for evaporation

= (540 + 31.5 + 29.3) Kcal/kg

= 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

Stack gas components:


H20: 357.0 kg/hr
CO2: 256.80 kg/hr
N2: 1223.0 + 5521 = 6744 kg/hr
O2: 1677 kg/hr
Mass composition of stack gas:
CO2: 3%
H20: 4%
N2 : 75%

O2: 18%

Stack gas temperature = 165°C

Cp of H20 = 0.52 Kcal/kg. °C


Cp of CO2 = 0.26 Kcal/kg .oC
Cp ofN2 = 0.275 Kcal/kg.oC
Cp of O2 = 0.25 Kca1/kg.oC

Heat losses through stack gases

Q4= (357.0xO.52+256.8xO.26+6744xO.275+1677xO.25)(l65 - 30) Kcal/hr


= 341045 Kcal/hr

Heat losses through pre-heating & firing zones wall and ceilings

Temperature of different walls and ceilings determined by portable


thermometer and others data obtained from the kiln section are as follows:

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

Temperatures of pre-heating zone

Average wall temperature 50°C


Average ceiling temperature 70°C
2
Overall heat transfer co-efficient of the wall = 9 KcaVhr.m .oC (6) .

Heat released through pre-heating zone (ceiling + wall),

Q2 = 9 x 90 x (50 - 30) + 9 x 66 x (70 - 30) KcaVhr = 39960 KcaVhr

Temperatures of firing zone

Bottom wall temperature 55°C


Top wall temperature 70°C
Middle wall temperature 120°C
Average wall temperature 82°C
Average ceiling temperature 50°C

Heat released through firing zone (wall + ceiling),


Q!j = 9 x 160 x (82 - 30) + 9 x 118 x(50 - 30) = 96120 KcaVhr

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 wall and ceiling of cooling zone

i) Heat input = product + kiln car = QI + Q2 = (59920 + 326993) Kcal/hr


= 386913 Kcal/hr

Average temperature inside the cooling zone is 600°C


Outlet temperature of cooling zone is 115 °c

Heat losses through product, 08 = {224 x 0.25 x (600 - lIS)} Kcal/hr


= 27160 Kcal/hr

Heat losses through refractory is {884 x 0.30 x (600 - lIS)} Kcal/hr


= 128622 Kcal/hr

Assuming inlet temperature of metallic part is 300 ° C

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

Cooling zone length = 49 m


2
Wall area = 2 x 49 x 2.5 = 245 m

Ceiling area = 3.69 x 49 = 181 m2


Average wall temperature of cooling zone 42°C
Ceiling temperature 60 °c

49
Heat losses through ceiling & side walls,

QIO = 9 x 245 x (42 - 30) + 9 x 181 x (60 - 30) = 75330 Kcal/hr

Total heat losses in cooling zone, Ql! = Qs + Q9 + QIO

= (27160 +142652 + 75330) Kcal/hr


= 245142 Kcallhr

Heat losses through de-sulfurizer and others

Q12 = 65,000 Kcal/hr (2)

Total heat carried out by cooling air to raise it's temperature from 30 to 115
°C (kiln outlet temperature 115°C)

= 386913 - 245142 - 65000 Kcallhr


= 76771 Kcal/hr

Specific heat of air = 0.27 Kcal/kg. °C

m x 0.27 x (115 - 30) = 76771

m = 3345 kg/hr of air can be heated by the waste heat of cooling zone.

50
HEAT BALANCE ASSOCIATED WITH SANITARYWARE KILN-l

Heat input during firing time

Heat generated by NG = 1088502 Kcal/hr


Total heat input, Q input = 1088502 Kcal/hr

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

6.2 Thermal Efficiency

Effective heat
-----xl00%
Thennal efficiency = Heat input

Here, Effective heat = Heat input - Heat losses


= 1088502 Kcal/hr -787267 Kcal/hr
= 301235 Kcal/hr

301235
---xlOO%
Thermal efficiency = 1088502

= 28.0 %

51
CHAPTER-7

RESULTS AND DISCUSSIONS

It was found that at present operating conditions thermal efficiency of


sanitaryware tunnel kiln-l at BISF is only 28.0 % which is very low. This is
due to back dated technology of MIS Progoinvest of Czechoslovakia.
Another cause of poor thermal efficiency is due to operating the kiln, lower
than atmospheric pressure which admits outer air ingress into the kiln. This
incoming air increases the volume of stack gases and also reduces the
temperature near the entry position. From stack gas analysis it was also
found that BISF uses 47% of excess air for sanitaryware tunnel kiln which
increases the volume of stack gases causing more heat losses. From thermal
analysis it was also found that major energy losses in every sections of
tunnel kiln (Appendix-A, B & C). Investigation found that these losses occur
due to heat losses through kiln walls for improper insulation, kiln cars
carries large amount of heat as the kilns furniture made of firebricks,
sensible heat loss through stack gas, excess rejection of finished products,
lack of proper insulation of steam lines & in-efficient operation of steam
boiler. These heat losses can be minimized as follows:

(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.

(3) At present green sanitaryware bodies are dried in casting shop by


steam-air exchangers. The heat losses from the stack gas are sufficient
to dry the green bodies in the casting shop.

(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

CONCLUSIONS AND RECOMMENDATIONS

As discussed in Chapter - 7, to enhance thermal efficiency of tunnel


kilns for sanitaryware production at BISF, the kilns can use the
fiberboard to minimize the weight of kiln car pushing rate, thereby
improving insulation effect and minimizing the fuel consumption.
Volume of stack gas can be reduced by reducing the percentage of
excess air used. Another step is to utilization of stack gas heat in the
casting shop as well as a substitute of combustion air or as the
secondary air of combustion air as shown in Figure 8.0.

Exhaust Gas

Casting Shop Stack

~
;;
-5 Blower
><
~

Air Curtain
Blow Waste Heat Air eu tain

Kiln Car Kiln Car

Combustion Air

Figure 8.0: Heat distribution of sanitaryware tunnel kilns at BISF (proposed)

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

Heat associated with firing of product, QI 59920

Heat associated with kiln car to go 326993


through 1100 DC, Q2

Heat associated with evaporation of 214557


chemically and mechanically bound
water, Q3

Heat loss through stack gas, Q4 341045


Heat loss through pre-heating zone wall 39960
and ceiling, Qs
Heat loss through firing zone wall and 96120
ceiling, Q6

Unaccountable heat loss =


Qinput - (Ql+Q2+Q3+Q4+QS+Q6)
= 9907 kcal/hr

56

",'
C
APPENDIX-B

Table B: Heat balance in cooling zone of sanitaryware tunnel kiln-l at BISF

Parameter Amount of
heat (Kcal/hr)

Gain components:

Heat from fired product, QI 59920

Heat from kiln car, Qz 326993

Loss components:

Heat loss through product at exit, Qs 27160

Heat loss through kiln car at exit, Q9 142652

Heat loss through ceiling and side walls, 75330

QIO

Unaccountable heat loss through 65000


desulphurizer and others, Q12

Heat carried by cooling air = (QI+ Qz)-


(QS+Q9 +QIO +Q1Z) = 76771 kcal/hr.

57

...
. ,

APPENDIX-C

TOTAL WASTE HEAT CALCULATION OF


SANITARYWARE KILNS NO.1, 2 AND INSULATOR KILN

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.

Heat obtained from insulator kiln flue gas:

Exit flue gas temperature = 190°C


Cpo of gas at 190 ° C = 0.28 kcallkgO C
If atmospheric temperature = 30 ° C
Then calculated heat, Qinsulator = 8996 x .28 x (190 - 30) kcallhr
= 403020 kcallhr
Heat obtained from sanitaryware kiln no. 1 and 2

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.

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