Using heat recovery systems in ceramic production plants is an environmentally responsible approach to manufacturing processes that we actively support alongside our customers. As well as supplying dryers, we focus strongly on providing energy efficiency services to help make the ceramic industry more sustainable.
Drying technology and energy recovery
For a customer producing sanitary ceramics in Southeast Asia, we recently developed a strategy that combines the supply of a complete dryer line with a structured heat recovery plan.
This project was developed in response to the customer’s requirement to expand their facility by introducing a new production line. Progetti was entrusted with supplying a full range of dryers for sanitaryware. These custom-made systems are perfectly calibrated to the company’s production needs and product specifications:
- A pre-dryer, where the pieces are stabilized at a medium-low temperature before entering the drying phase. Pre-drying is crucial in order to reduce the risk of breakage after casting. Using dedicated pre-dryers, instead of allowing the pieces to dry in uncontrolled open-air environments, helps shorten pre-drying times and ensures temperature and humidity control. This improves final product quality, reduces waste and increases overall productivity.
- A multi-chamber static dryer, for the complete drying of the pieces.
- A continuous dryer with automatic car loading, for drying glazed pieces before the kiln firing stage.
However, our work doesn’t stop at supplying perfectly customized systems. As mentioned earlier, energy efficiency is a key aspect of the project.
The first identified action was to implement new dryers that run entirely on recovered heat from the kilns. This allows the customer to reduce energy consumption and lower their environmental impact.
The chosen solution also enables optimized heat recovery for use in additional stages of the ceramic production process.
An energy recovery system serving the entire ceramic production process
The energy efficiency plan developed for our customer’s production line involves installing six heat exchangers: two for each tunnel kiln.
This system ensures that hot air, which would normally be wasted, is recovered from the kiln cooling zones and used to heat water, rather than being fed directly to the dryers.
Using water as a heat transfer medium offers multiple advantages, particularly with regard to precise and differentiated heat distribution at various stages of the sanitaryware production process.
The heated water will primarily be used to warm the air inside the dryers, but also to:
- power high-pressure casting machines,
- supply air handling units for climate control in the casting room.
As with any energy efficiency project, monitoring is essential. For this reason, the project includes the integration of energy monitoring software on each machine. This will enable savings to be assessed and ensure all systems operate optimally.