Research On Energy-saving Reconstruction Of The Premixed Post-combustion System Of Ceramic Kilns

Ceramic industry is one of the high energy consumption industries in which there aresome problems such as low comprehensive utilization high energy consumption resourceconsumption and low production efficiency these problems are especially severe in ourcountry. The energy efficiency of ceramic industry in China is only28-30%which is about50%in developed countries. It means the energy efficiency of ceramic industry in China isonly half of it in developed countries. It is a large gap between China and western developedcountries and we have huge energy saving potential. The huge consumption of energyresources and the impact on the environment from ceramic production has severely restrictedthe development of ceramics industry in China so it is significant saving energy andreducing emission for this industry. The mainly process of ceramic industry is raw materialsprocessing compression moulding, drying, sintering and packing. The test results of theenergy consumption for a ceramics factory indicated that more than80%of the energyconsumption was cost in the process of sintering and desiccation of which20%used fordesiccation and60%used for sintering process. Thus the energy-saving transformation for thefiring process (i.e. ceramic kiln) is extremely urgent.Burner reconstruction is an important part of ceramic kiln transformation. It is also thekey factor influencing the ceramic kiln energy consumption. At present, there are two kinds offorms of the ceramics kiln gas burners (promote oxidation by using fan): one is the aftermixed gas burner; the other one is preheating combustion-supporting air after mixed gasburner. The first one is in common use in ceramic industry. The second one s effect is notobvious because as the heating temperature and exhaust temperature rising exhaust heat lossis also increasing.This paper built up a ceramic kiln heat balance calculation model based on the actualoperation condition of a ceramics factory in Guangdong, theoretically calculated the influenceof "premixed secondary combustion system" transformation on ceramic kiln. Throughanalyzing, the ceramics factory took the suggestion of transforming its ceramic kiln burner to"premixed secondary combustion system". An energy efficiency test under actual operationconditions for ceramic kiln burner before and after the transformation was conducted at the same time. The result of the test indicated that the efficiency changes obviously, and achievedgood energy saving effect. It provided a reference for ceramic kiln energy-saving optimizationand transformation.