Antique Ceramics Case Study

Client: Antique Ceramics 

Product Application: Ceramic Kiln Exhaust to Dryer Air Pre-heater

Location: Morbi, Gujarat, India

Date of Installation: 2008

The Challenge:

Exhaust Inlet:                       316°C

Exhaust Mass Flow:              9800 Kg/h

Recovery Media Inlet:          35°C

Recovery Media Mass Flow: 12000 Kg/h

Fuel Type:                             Gas

The Client:

Much of India’s ceramics industry is located in Morbi, Gujarat; an estimated 75% of all India’s tile output is said to derive from this one region. Antique Ceramics is one of circa 300 local factories operating in a highly competitive sector both nationally in India and globally. Any competitive advantage that can be derived may make the difference between profitability and survival or loss making and potential closure.

Project Circumstances:

The technology used by Antique Ceramics (and many of their competitors) is roller kiln whereby the tiles are pressed as they pass through. The kilns contain multiple burners that generate a known waste heat but is largely considered unusable due to the aggressive dust particulate with high sulphur content. Several attempts had been made with conventional heat exchange technologies but none had been successful prior to the installation of the Econotherm unit.

Why Econotherm Heat Pipe Technology?:

Econotherm  waste heat recovery technology proved ideal for Anrique Ceramic’s needs for a number of reasons:

• Econotherm heat pipe technology was sufficiently robust and reliable to withstand the aggressive particulate in the exhaust
• An automatic cleaning system was incorporated that enabled continuous operation without need for frequent maintenance stoppages
• Avoidance of corrosion due to isothermal properties and heat pipe temperatures higher than dew-point

       The Solution: Carbon Steel Heat Pipes Unit

       Configuration: Cross-Flow

Working Fluid: Distilled water

Access Panels: Yes

Automated Cleaning: Yes

Project Cost: 59,000 GBP

ROI Period: 6 months

       Factors of Success: 

       In addition to the long-term reliability and robustness of the Econotherm unit the ability to clean and maintain the performance of the unit without disrupting the manufacturing process were critical to the clients’ needs and expectations.

       Client / Project Feedback

       Following the installation and commissioning of this unit Econotherm have received a performance certificate from the client  testifying that the Econotherm unit has delivered  on expectations in terms of recovering waste heat energy in extremely challenging circumstances.