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
Roller Hearth Kiln. (February 2014). Retrieved from
http://www.ngk.co.jp/english/products/ceramic/heating/
2
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
3
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
Ceramic material properties. (2014,
February). Retrieved from
http://www.engineeringtoolbox.com/ce
ramics-properties-d_1227.html
4
PROCESS FLOW
5
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].
6
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.
7
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.
8
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.
9
Preheated combustion air. (2007, November). Retrieved from
http://www1.eere.energy.gov/manufacturing/tech_assistance/pdfs/et_pr
eheated.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.
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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
12
PLANT LAYOUT
13
ECONOMIC ANALYSIS
INITIAL COST
Item
Kiln[17]
Burners
Retail Price
Air-Air Heat Exchanger[11]
Property[18]
Land rate in Vietnam
Infrastructure[18]
Contingency
Total Capital Expense
Qty.
178,000.00
40
160.00
50,000.00
1800
5.37
220,000.00
10
488,472.60
Units
$
units
$/unit
$
m2
$/m2
$
%
$
• All figures are in USD
• Equipment:
• Kiln, burners, heat exchanger
• Install & commission
• Property
• Infrastructure:
• Facilities, utilities
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ECONOMIC ANALYSIS
REVENUE & EXPENSES
• Operations Cost = 4 x Fuel Cost
• Max revenue based on individual tile sales
Item
PERFORMANCE PARAMETER:
• Net Present Value
• 8%, 10 years
• NPV of +452.7 million USD
Fuel
Market Price [7,8]
Total
Raw Clay
Market Price[15]
Total
Operations
Estimated Total
Total Expenses
Item
Retail price
Tiles manufactured
Total Revenue
Qty.
3.5
1.03
30,022,272.00
2000
40.00
29,200,000.00
4*Fuel Cost
120,089,088.00
149,289,088.00
Units
litre/s
$/US gallon
$/yr
tons/day
$/ton
$/yr
$/yr
$/yr
Qty.
Units
$/ft2
0.929
25700 units/hr
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
http://myatlantaflooring.com/wp-content/uploads/2011/03/Atlanta-Ceramic-TileFlooring-1.jpg
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REFERENCES
1.
2.
Air properties. (2014, February). Retrieved from http://www.engineeringtoolbox.com/air-properties-d_156.html
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.pdf
5. Ceramic material properties. (2014, February). Retrieved from http://www.engineeringtoolbox.com/ceramics-propertiesd_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-combustionvalues-d_509.html
10. 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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