In the ceramic production process, the kiln is an indispensable part. So, how to improve the product quality by improving the operation mode of the kiln while achieving energy saving? Don't worry, let's reveal it to you today!
PART.01
Inner height of kiln
In the ceramic production process, the inner height design of the kiln is a crucial link, which directly affects the firing quality of the product and the energy consumption in the production process. The following will analyze the specific impact of the inner height of the kiln in detail from a professional perspective:
① Increased heat consumption
As the inner height of the kiln increases, the heat consumption of the unit product also increases accordingly. Specifically, when the inner height of the roller kiln increases from 0.2 meters to 1.2 meters, the heat consumption will increase by 4.43%. This is because the increase in the inner height of the kiln leads to more heat loss and a longer heat conduction path.
② Increased heat dissipation of the kiln wall
The increase in the inner height of the kiln will also increase the heat dissipation of the kiln wall. In the case of the above-mentioned kiln height change, the heat dissipation of the kiln wall will increase by 33.2%. This means that the kiln becomes less efficient in terms of heat preservation, resulting in more energy waste.
③ Temperature stratification and temperature difference
The increase in the height of the kiln will cause temperature stratification in the channel, that is, there is a significant difference in the temperature between the upper and lower parts of the kiln. This problem is particularly prominent in kilns such as tunnel kilns. For example, in some preheating zones, the temperature difference between the upper and lower parts may be as high as 300~500℃. This huge temperature difference will seriously affect the uniform firing of the product and even lead to firing failure.
④ Case analysis
There are actual cases showing that excessive kiln height may lead to firing quality problems. For example, a full-fiber sanitary ware roller kiln introduced by a certain company could not successfully fire the product due to the excessively high design of the kiln channel, resulting in a large temperature difference. In the end, this problem was solved by lowering the kiln height. This fully illustrates the importance of reasonably controlling the kiln height to ensure firing quality.
PART.02
Kiln inner width
In ceramic production, the inner width of the kiln is a key design parameter, which has a significant impact on energy consumption, output, thermal efficiency and other aspects in the production process. The following is a professional analysis of increasing the inner width of a ceramic kiln:
① The relationship between the inner width of the kiln and energy consumption
a. Reduction in heat consumption per unit product: As the inner width of the kiln increases, the heat consumption per unit product will decrease accordingly. Specific data show that when the inner width of the roller kiln increases from 1.2 meters to 2.4 meters, the heat consumption per unit product decreases by 2.9%.
b. Reduced heat dissipation from the kiln wall: The increase in the inner width of the kiln will also lead to a decrease in the heat dissipation from the kiln wall. In the case of the above kiln width change, the heat dissipation from the kiln wall is reduced by 25%. This means that less heat is lost to the environment through the kiln wall, thereby improving thermal efficiency.
② The impact of the inner width of the kiln on output
Increase in output: Increasing the inner width of the kiln can significantly increase output. For example, by expanding the inner width of the roller kiln from 2.5 meters to 3.0 meters, the daily output can be increased from 10,000 square meters to 15,000 square meters. This is because a wider kiln can accommodate more ceramic products for simultaneous firing.
③ Relationship between kiln inner width and thermal efficiency
a. Optimization of heat dissipation area: As the inner width of the kiln increases, although the total heat dissipation area of the kiln body will increase, the heat dissipation area of the kiln wall per square meter of brick produced will actually decrease. For example, in the case of the above-mentioned kiln width change, the heat dissipation area of the kiln wall per square meter of brick produced is reduced from 0.1206 square meters to 0.0948 square meters. This helps to reduce the heat dissipation loss of the outer wall of the kiln body and improve thermal efficiency.
b. Case verification: There are actual cases showing that the thermal efficiency of the kiln can be significantly improved by increasing the inner width of the kiln and making corresponding optimization and transformation. For example, in the kiln transformation of a certain enterprise, the energy consumption per unit product was greatly reduced, and the thermal efficiency of the kiln was more than doubled.
④ Development trends and challenges of wide-body kilns
a. Development direction: Increasing the inner width of the kiln within a certain range can improve energy saving rate and production efficiency. Therefore, wide-body kilns are regarded as the direction of future development. However, this also requires solving the problem of cross-section temperature difference to ensure product quality.
b. Technical Challenge: As the kiln width increases, how to maintain the uniformity of the temperature in the kiln and reduce the temperature difference in the cross section becomes a technical challenge. This needs to be achieved through reasonable kiln structure design and advanced firing technology.
PART.03
Kiln Length
In the ceramic production process, the increase in kiln length has a significant impact on energy saving and output. The following is a detailed analysis of this phenomenon:
① The relationship between kiln length and energy consumption
a. Reduction of unit product heat consumption: Experimental data show that when the kiln length of the roller kiln increases from 50m to 100m, the unit product heat consumption can be reduced by 1%. This means that, under the condition of a certain kiln width and height, increasing the kiln length helps to reduce the heat energy required to produce each unit product.
b. Reduction of heat carried away by kiln head flue gas: Also under the above-mentioned kiln length change, the heat carried away by the kiln head hot flue gas is reduced by 13.9%. The longer the kiln, the longer the flue gas stays in the kiln, and the more efficient the heat transfer to the product, thereby reducing heat waste.
② The relationship between kiln length and output
a. Significant increase in output: With the increase in kiln length, ceramic output also shows a significant growth trend. Specifically, when the length of the roller kiln is less than 100m, the output is about 5000㎡; when the length exceeds 100m, the output can reach 10000㎡; when the length is between 200 and 300m, the output can reach 20000㎡. This data fully illustrates the significant impact of kiln length on output.
b. Development trend of kiln length: With the advancement of technology and the pursuit of energy-saving and efficient production, the length of modern kilns has far exceeded the early limit of tens of meters. At present, the longest roller kiln has reached 450m, and the length of the tunnel kiln has exceeded 140m.
PART.04
Flat roof and arched roof
In the ceramic production process, the design of the kiln roof has an important influence on the temperature distribution, airflow and thermal efficiency in the kiln. Flat roof and arched roof are two common kiln roof designs, each with its own characteristics, and play their own advantages in different situations.
① Characteristics and application of flat roof design
a. Convenient construction: The flat roof design is relatively simple, which is convenient for construction and later maintenance.
b. Smooth airflow: The flat roof design makes the airflow in the kiln smoother, which is conducive to the uniform distribution of gas.
c. Applicable to low temperature section: In the low temperature section, the flat roof structure is conducive to the uniform distribution of temperature and reduces the temperature difference.
However, the flat roof design also has certain limitations, especially when the kiln channel is short (generally 30~50cm), the gas flow resistance is large, and in the high temperature section, due to the reduction of the thickness of the heat radiation layer, the advantages of radiation heat transfer cannot be fully utilized.
② Characteristics and application of arch design
a. Increase the thickness of the radiation layer: The arch structure can increase the thickness of the radiation layer in the middle part of the cross section, thereby increasing the heat transfer capacity. This is conducive to the advantages of radiation heat transfer in the high temperature section and improve thermal efficiency.
b. Conducive to uniform temperature: The heat transfer method of the arch structure is conducive to reducing the temperature difference in the firing zone, making the temperature in the kiln more uniform.
c. Good stability: The arch structure has uniform force distribution, making the kiln more stable and suitable for long-term continuous use.
However, the vault design also has its disadvantages, such as high manufacturing and installation costs, relatively small internal space, and greater difficulty in maintenance and repair.
③ Combination of flat roof and vault
Practical experience has shown that the combination of flat roof and vault structure can be more conducive to the mixing of airflow in the kiln and the uniform distribution of temperature. The vault structure is used in the high temperature section of the wide kiln to increase the thickness of the radiation layer and the heat transfer efficiency, while the flat roof structure is used in the low temperature section to maintain the uniformity of temperature. This combination design can effectively reduce the temperature difference in the kiln and improve the quality and production efficiency of ceramic products.
PART.05
Strengthen kiln sealing and kiln pressure control
In the ceramic production process, strengthening kiln sealing and accurately controlling kiln pressure are of great significance to improving product quality, energy saving and consumption reduction, and stabilizing the production environment. The following is a detailed analysis of this topic:
① The importance of strengthening kiln sealing
a. Reduce temperature difference and improve product quality: Kiln sealing can effectively reduce the outflow of hot gas in the kiln and the infiltration of cold air from the outside, thereby reducing the temperature difference in the kiln. The reduction in temperature difference means that ceramic products are heated more evenly during the firing process, which helps to reduce defects such as product deformation and cracking, and improve the yield rate.
b. Energy saving and consumption reduction: A kiln with good sealing can reduce the loss of heat energy and improve thermal efficiency. This not only helps to reduce production costs, but also conforms to the current production concept of green environmental protection, energy saving and emission reduction.
c. Stabilize the pressure distribution in the kiln: Good sealing performance provides a basis for stabilizing the pressure distribution in the kiln, making the firing process more controllable and conducive to the realization of atmosphere firing.
② The criticality of kiln pressure control
a. Necessary conditions for atmosphere firing: In specific processes such as reducing atmosphere firing, precise control of kiln pressure is a key factor in ensuring the stability of the firing atmosphere. By adjusting the frequency of the exhaust fan and controlling the flue gas discharge, precise control of the kiln pressure can be achieved.
b. Improve product performance: Stable control of kiln pressure helps ceramic materials to fully react during the firing process, thereby improving the physical properties and chemical stability of the product.
③ Implementation measures
a. Optimize kiln design: Fully consider the sealing performance in the kiln design stage, adopt advanced sealing materials and structural design to ensure that the kiln has good sealing during use.
b. Introduce intelligent control system: By introducing an automated and intelligent control system, real-time monitoring of parameters such as pressure and temperature in the kiln, and automatic adjustment according to the preset curve, to achieve precise control of kiln pressure.
c. Regular maintenance and overhaul: Regularly maintain and overhaul the kiln to ensure that key components such as seals are intact, so as to maintain the sealing performance of the kiln and the control accuracy of kiln pressure.
PART.06
Lightweighting of kiln cars and kiln furniture
In the ceramic production process, the lightweighting of kiln cars and kiln furniture is of great significance for energy saving and improving production efficiency. The following is a professional analysis of this phenomenon:
① The impact of lightweighting on kiln cars
Reduce heat loss: The heat loss of kiln cars in tunnel kilns accounts for a large proportion of the total energy consumption, about 10% to 15%. By adopting lightweight materials and technologies, the weight of the new low-heat storage kiln car can be reduced to 1/3 of that of the traditional kiln car, and the heat storage is also reduced to 2/7. This improvement significantly reduces heat loss and can achieve energy saving effects of up to 17%.
② Application of lightweight in kiln tools
a. Reduce the weight of kiln tools: In tunnel kilns for firing daily-use porcelain, the weight of traditional kiln tools is often more than 2 times that of the product, and can even reach up to 5.4 times. By selecting lightweight materials to make kiln tools, their weight can be greatly reduced, thereby increasing the loading capacity and production efficiency of the kiln.
b. Optimize the pad design: Taking the exterior wall tile pad as an example, by reducing its thickness from 10.5mm to 7.3mm (the thinnest can reach 6.5mm), the weight of each pad is reduced from 4kg to 2.3kg. This lightweight design not only saves material costs, but also achieves an energy saving effect of 18.7%.
③ Comprehensive benefits brought by lightweighting
a. Improve energy-saving effect: In addition to the above-mentioned optimization of kiln cars and pads, some manufacturers have achieved the purpose of eliminating pads for firing by improving the roller bars and spacing settings of roller kilns, thereby achieving energy-saving effects of up to 60%.
b. Promote kiln transformation: The successful practice of lightweighting has provided valuable experience for the ceramic industry. When firing sanitary porcelain, daily porcelain, arts and crafts porcelain and other products, it is possible to consider transforming traditional shuttle kilns into tunnel kilns or roller kilns for firing. This transformation not only helps to improve production efficiency, but also greatly saves energy consumption.
PART.07
The choice of kiln type is critical
In the ceramic production process, the choice of kiln type has a vital impact on product quality, production efficiency and energy consumption. The following is a professional analysis of the importance of kiln type selection:
① Energy efficiency:
Take the roller kiln as an example, it performs well in the rapid high-temperature reduction firing of daily porcelain and has significant energy-saving characteristics. The unit consumption of the roller kiln is only 0.294tce/t porcelain, which means that the energy consumed for producing each ton of ceramic products is much lower than other kiln types. In contrast, the firing heat consumption of the tunnel kiln is 1.71tce/t porcelain, which is much higher than that of the roller kiln. Therefore, when choosing a kiln type, its energy efficiency should be fully considered to reduce production costs and reduce environmental impact.
② Kiln thermal efficiency:
Kiln thermal efficiency is one of the important indicators for measuring kiln performance. The kiln thermal efficiency of the roller kiln is as high as 68.8%, which shows that it can effectively utilize thermal energy and reduce energy waste. High thermal efficiency means that more ceramic products can be produced under the same energy consumption, thereby improving production efficiency and reducing energy consumption per unit product.
③ Matching production needs with kiln types:
Different ceramic products may require different kiln types to achieve the best production effect. For example, for daily-use porcelain that requires rapid high-temperature reduction firing, the roller kiln is an ideal choice. Therefore, when choosing a kiln type, it should be matched according to specific production needs and product characteristics to ensure production efficiency and product quality.
In short,
By taking the above measures to improve the quality of ceramic products and save energy, we can effectively improve the quality of ceramic products and reduce energy consumption. What other measures do you have to improve the quality of ceramic products and save energy? Welcome to leave a message in the comment area to discuss!
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