Heating System for Ceramic Tile Factory using Furnace Oil or Gas · 2014-03-19 · • Furnace oil...
Transcript of Heating System for Ceramic Tile Factory using Furnace Oil or Gas · 2014-03-19 · • Furnace oil...
HEATING SYSTEM FOR CERAMIC
TILE FACTORY IN VIETNAM
USING FURNACE OIL
Devon Guile
Jean-Marc Guindon
Andreas Hart
Emerson Hawkins
Alex Higgs
Jono Horne
OUTLINE
• Background
• Process Flow
• Engineering
• Plant layout
• Economics
• Conclusion
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Roller Hearth Kiln. (February 2014). Retrieved from http://www.ngk.co.jp/english/products/ceramic/heating/
INTRO
• Vietnam has a very successful tiling industry
• In 2013 a total of 199 million m2 of tile was manufactured
• That’s a 27% share of the global market output
• Runs 24 hours per day
• Regenerative heating
• Fuel Oil
• Proper design of tiles factories maximized the profit/output
• This factory is capable of outputting 25,700 tiles per hour
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BACKGROUND
• Process followed for manufacture
• Raw materials are crushed
• Wet milled into a paste
• Mixed, formed and dried into 12” by 12” by 1/2 “ blocks
• Glazed to add color and protective coating
• Fired in a continuous kiln to save time
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Ceramic material properties. (2014, February). Retrieved from http://www.engineeringtoolbox.com/ceramics-properties-d_1227.html
PROCESS FLOW
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ENGINEERING ANALYSIS
The following factory properties were assumed during the design stage:
• The factory will operate 24 hours per day, 365 days per year.
• The material will be formed into 12” x 12” x 1/2” floor tiles.
• The average temperature of the kiln will be 2500 °F [3].
• The total firing time will be 60 minutes.
• The factory will produce 2000 tons of tiles per day [3].
• To fire 1 kg of ceramic tiles, 1000 kCal of energy is required [3].
• Typical efficiencies of ceramic tile kilns are approximately 50% [3].
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KILN DESIGN
Based on the previous assumptions, the kiln was designed yielding the following results:
• 8.4 GJ/day energy requirement.
• This energy will be supplied by burning furnace oil number 4.
• Furnace oil number 4 is often used in industrial boilers; with a heating value of 34.4 MJ/l [9].
• The total fuel flow required to fire the tiles is then calculated as 2.82 l/s.
• Due to the 50% efficiency, the total fuel flow rate required is increased to 5.64 l/s.
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KILN DETAILS
To determine the dimensions of the kiln, the following assumptions were used:
• The density of ceramic tile is 2900 kg/m3 [5].
• The horizontal and vertical distance between the tiles in the kiln is ½”.
The kiln details are then given as:
• The number of tiles manufactured is 25,700/hr.
• The overall size of the kiln will be 10.4’ wide, 2’ tall and 104’ long.
• Tiles arranged 10 horizontally and 24 vertically.
• Require using racks to transport the tiles from one end of the kiln to the other.
• Ceramic rollers will be driven by an electric motor at 1.73 ft/min.
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REGENERATIVE AIR HEATER
• Used to capture the waste heat in the exhaust from the kiln.
• Heat exchanger that uses the flue gas from the kiln to preheat metal plates.
• These metal plates then transfer the heat to incoming kiln air.
• Require less fuel to achieve an average kiln temperature of 2500 °F.
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Preheated combustion air. (2007, November). Retrieved from http://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/et_preheated.pdf
AIR HEATER DESIGN
Several assumptions were made to perform the air heater design:
• All heat transfer takes place between the flue gas and the entering air.
• The mass flow rate of the inlet air is the same as the mass flow rate of the flue gas.
• cp of flue gas = 0.96 kJ/kg [2] and cp of air = 1.05 kJ/kg[1].
• Flue gas entrance temperature is 2500 °F and outlet temperature is 1500 °F.
• Inlet air temperature to the heat exchanger is 86 °F.
• Outlet air temperature of the heat exchanger can be calculated as 1000 °F.
• This level of heat transfer is possible with most modern regenerative air heaters.
• Estimated 38% fuel savings can be achieved [10].
• Total fuel rate required is decreased to 3.5 l/s from 5.64 l/s. 10
BURNERS
• Our design will utilize 40 burners; 20 on each side of the kiln, spaced 5 feet apart.
• The fuel flow rate for each burner is calculated as 0.0875 l/s.
• This flow rate is attainable for a typical industrial burner [4].
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FINAL KILN DESIGN
Parameter Value
Material processed 2000 tons/day
Energy requirement 1000 kCal/kg
Tiles manufactured 25700 tiles/hr
Fuel flow rate 3.5 l/s
Kiln dimensions 10.4’ x 2’ x 104’
Number of burners 40
Conveyor speed 1.73 ft/min
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PLANT LAYOUT
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ECONOMIC ANALYSISINITIAL COST
Item Qty. UnitsKiln[17] 178,000.00 $
Burners 40 units
Retail Price 160.00 $/unit
Air-Air Heat Exchanger[11] 50,000.00 $
Property[18] 1800 m2
Land rate in Vietnam 5.37 $/m2
Infrastructure[18] 220,000.00 $
Contingency 10 %
Total Capital Expense 488,472.60 $
• All figures are in USD• Equipment:
• Kiln, burners, heat exchanger• Install & commission
• Property• Infrastructure:
• Facilities, utilities14
• Operations Cost = 4 x Fuel Cost• Max revenue based on individual tile sales
PERFORMANCE PARAMETER:
• Net Present Value• 8%, 10 years
• NPV of +452.7 million USD
ECONOMIC ANALYSISREVENUE & EXPENSES
Item Qty. UnitsFuel 3.5 litre/s
Market Price [7,8] 1.03 $/US gallon
Total 30,022,272.00 $/yr
Raw Clay 2000 tons/day
Market Price[15] 40.00 $/ton
Total 29,200,000.00 $/yr
Operations 4*Fuel Cost
Estimated Total 120,089,088.00 $/yr
Total Expenses 149,289,088.00 $/yr
Item Qty. UnitsRetail price 0.929 $/ft2
Tiles manufactured 25700 units/hr
Total Revenue 209,147,628.00 $/yr
CONCLUSION
• Ceramic tile factory located in Vietnam
• 2000 tonnes of tiles per day
• 1000 kCal per kilogram of tile
• High Efficiency Kiln
• 40 Burners
• Inlet Air Reheater (38% fuel savings)
• Valued at $450 Million US
• Annual Revenue $209 Million US
• Construction is recommended
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http://myatlantaflooring.com/wp-content/uploads/2011/03/Atlanta-Ceramic-Tile-Flooring-1.jpg
REFERENCES
1. Air properties. (2014, February). Retrieved from http://www.engineeringtoolbox.com/air-properties-d_156.html 2. Assessment of boilers and thermic fluid heaters. (2006, September). Retrieved from
http://www.energyefficiencyasia.org/energyequipment/assessment_boiler_indirectmethod.html 3. Basu, Pabir, Dr. "Kiln Design." Telephone interview. Feb. 2014.4. Bussman, W., Venizelos, D., & Hayes, R. (2003). Fluid flow. Retrieved from
ftp://ftp.demec.ufmg.br/ema867j/Livros%20selecionados/QueimadoresInd/1386_C03.pdf5. Ceramic material properties. (2014, February). Retrieved from http://www.engineeringtoolbox.com/ceramics-properties-
d_1227.html 6. "Fuel Cost." Fuel Cost. Vietnam Online, 2011. Web. 10 Feb. 2014. <http://www.vietnamonline.com/az/fuel-cost.html>.7. “Fuel Cost." In Vietnam. Energypedia, 15 Apr. 2013. Web. 11 Feb. 2014. <http://www.vietnamonline.com/az/fuel-cost.html>.8. "Basu, Pabir, Dr. "Kiln Design." Telephone interview. Feb. 2014.9. Fuel oil and combustion values. (2014, February). Retrieved from http://www.engineeringtoolbox.com/fuel-oil-combustion-
values-d_509.html10. Preheated combustion air. (2007, November). Retrieved from
http://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/et_preheated.pdf
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QUESTIONS?
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