Water and Energy Use in Sanitary-ware Manufacturing: Using Modelling Processes for Water and Energy Accounting and Decarbonisation (Green Energy and Technology)

This book analyses and quantifies how and where energy and water are consumed by the ceramic sanitary-ware industry and provides solutions as to how to reduce this. The whole production process is mapped, including modelling methods. The book begins by providing an introduction to ceramic sanitary-ware production and types of factories casting technology. It then moves on to discuss the process and energy modelling for the production line, analysis of energy and water consumptions and proposals for improvements. The last chapter presents the practical implementation of the selected modelling configuration. This book is of particular interest to water and energy management professionals within the ceramic industry, but the methods are of interest to those in other production industries as well. Preface Contents 1 Introduction to Ceramic Sanitary-Ware Manufacturing 1.1 Environment, Sustainability and Ceramics 1.2 Energy and Water Consumption Relevant to the Sanitary-Ware Industrial Sector 1.3 Sanitary-Ware Manufacturing Worldwide 1.4 Ceramic Sanitary-Ware Manufacturing General Process References 2 Types of Factories by Casting Technology 2.1 Main Technologies for Casting Barbotine 2.1.1 Traditional Technology 2.1.2 Current Technology 2.2 Characterization of Factory Type 2.2.1 Water Consumption Differences 2.2.2 Energy Consumption Differences References 3 Planning for Energy and Water Management 3.1 Characterization of Consumption and Waste 3.2 Quantification of Energy and Water Requirements 3.2.1 Electrical Demand 3.2.2 Thermal Demand 3.2.3 Psychrometric Calculations 3.3 Requirements in Every Section of the Factory 3.3.1 Raw Materials 3.3.2 Slip Preparation 3.3.3 Glaze Preparation 3.3.4 Modeling and Molds 3.3.5 Casting 3.3.6 Heating and Ventilation 3.3.7 Drying 3.3.8 Glazing 3.3.9 Kilns 3.3.10 Sorting 3.3.11 Offices 3.3.12 Ware-House 3.3.13 Facilities 3.4 Existing and Potential Links of Resource and Wastes References 4 Production Line: Process and Energy Modeling 4.1 Raw Materials Section 4.2 Slip Preparation 4.3 Glaze Preparation 4.4 Modeling and Molds 4.4.1 Molds Dryer Model 4.5 Casting 4.5.1 Plaster Mold Factory 4.5.2 Resin Mold Factory 4.6 Heating and Ventilation 4.6.1 Heating and Ventilation Unit Model 4.6.2 Thermal Demand Calculation of a HVU 4.6.3 Climate Conditions 4.7 Drying 4.7.1 Ware Dryer 4.7.2 Thermal Demand Calculation of a Ware Dryer 4.8 Glazing 4.9 Kilns 4.9.1 Tunnel Kiln Model 4.9.2 Shuttle Kiln Model 4.10 Sorting, Offices, Warehouse and Facilities Sections References 5 Analysis of Consumptions 5.1 Electrical Model 5.2 Thermal Models 5.2.1 Molds Dryer Model Results 5.2.2 HVU Model Results 5.2.3 Ware Dryer Model Results 5.2.4 Tunnel Kiln Model Results 5.2.5 Shuttle Kiln Model Results 5.3 Water Consumption Model 5.4 CO2 Emissions Model 5.5 Global Results References 6 Improvement Proposals 6.1 Generalized Proposals 6.1.1 Efficiency of the Motors 6.1.2 Frequency Variation of Electrical Motors 6.1.3 Substitution of Conventional by LED Lighting 6.1.4 Lighting Regulation by Control of Presence and External Lighting Level 6.2 Particularized Actions Per Section 6.3 Raw Materials 6.3.1 Mills 6.3.2 Belts, Sieves, Magnets and Other Equipment 6.4 Slip Preparation 6.4.1 Blungers 6.4.2 Tanks for Stock of Slip 6.4.3 Peristaltic Pumps, Belts, Sieves and Other Equipment 6.5 Modeling and Molds 6.5.1 Mold Dryers 6.5.2 Hygrothermal Regulation of the Dryer Environment 6.5.3 Insulation Improvement 6.5.4 Recovered Heat 6.6 Casting 6.6.1 Casting Benches 6.6.2 Transformer for Handling Device 6.6.3 Fans to Dry Molds 6.6.4 Local Lighting Lines 6.6.5 Pressure Machines 6.6.6 Tanks for Stock of Slip 6.7 Heating and Ventilation of Casting Hall 6.7.1 Heating and Ventilation Units 6.7.2 Heat Recovery 6.7.3 Hygrothermal Regulation 6.7.4 Enclosure Insulation 6.8 Ware Dryers 6.8.1 Thermal Parameters of Ware Dryer Operation 6.8.2 Insulation of the Enclosure 6.8.3 Regulation of Fresh Air Intake 6.8.4 Heat Recovery 6.9 Kilns 6.9.1 Induced Draught and Pre-Heating of Combustion Air 6.9.2 Pulse Burners 6.9.3 Controlled Regulation of the Kiln 6.9.4 Load Control 6.9.5 Substitution of Cordierite by Silicon Carbide for Refractory Supports 6.9.6 Insulation Increase 6.9.7 Refractory Lining Film 6.10 Facilities 6.10.1 Frequency Variation 6.10.2 Heat Recovery from Compression Cooling 6.10.3 Appropriate Maintenance of the Compressed Air Network 6.10.4 Boilers Fueled by Recovered Heat 6.10.5 Actions on Pumping Systems 6.11 Other General Actions 6.11.1 Alternative Energies (Photovoltaic) 6.11.2 Combined Heat and Power Plant 6.11.3 Organic Rankine Cycles 6.12 Water-Saving Measures 6.12.1 Multi-effect Distillation 6.12.2 Condensation via Absorption Machine 6.13 Optimization 6.13.1 First Stage 6.13.2 Second Stage 6.14 Global Assessment References 7 Proposals Calculation 7.1 Electrical Savings 7.1.1 Efficiency of the Motors 7.1.2 Frequency Variation of Electrical Motors 7.1.3 Substitution of Conventional by LED Lighting 7.1.4 Lighting Regulation by Control of Presence and External Lighting Level 7.1.5 Summary of Electrical Generalized Actions 7.2 Non-exclusive Thermal Savings 7.2.1 Increase of Thermal Insulation of the Mold Dryer 7.2.2 Increase of Thermal Insulation of the Casting Hall 7.2.3 Thermal and Humidity Control of the HVU’s 7.2.4 Increase of Thermal Insulation of the Ware Dryer 7.2.5 Thermal and Humidity Control of the Ware Dryer 7.2.6 Load Lightening by SiC of the Tunnel Kiln 7.2.7 Load Lightening by SiC of the Shuttle Kiln 7.2.8 Heating Recovery from Compressor Refrigeration 7.2.9 Summary of Thermal Non-Exclusive Savings 7.3 Exclusive Thermal Savings 7.3.1 Heating Recovery 7.3.2 Induced Draught for Tunnel Kiln 7.3.3 Primary Air Preheating for Tunnel Kiln 7.3.4 Primary Air Preheating for Shuttle Kiln 7.3.5 Condensation by Absorption Machine 7.3.6 MED Distillation 7.3.7 Photovoltaic Plant 7.3.8 Cogeneration [18] 7.4 Summary of Optimization Results References 8 Energy Supply Versus Energy Demand 8.1 Variability of the Demand 8.2 Cycle Analysis 8.3 Water Condensation Potential and Co2 Emissions 8.4 Recovery Strategy Conclusions References 9 Optimized Factory Versus Conventional Factory 9.1 Optimized Configuration 9.2 Results and Discussion 10 Exergoeconomic Analysis 10.1 Introduction to the Analysis Approach 10.2 Methodology of Calculation 10.3 Results of Exrgoeconomic Analysis 10.4 Major Conclusions of Exergoeconomic Analysis References 11 Practical Implementation of Selected Configurations 11.1 Electrical General Measures 11.1.1 Efficiency of the Electrical Motors 11.1.2 Frequency Variation of the Electrical Motors 11.1.3 Substitution of Conventional Lighting by LED 11.1.4 Lighting Regulation 11.2 General Thermal Measures 11.2.1 Increase of Thermal Insulation 11.2.2 Thermal and Humidity Automatic Control 11.2.3 Load Lightening by SiC 11.2.4 Heating Recovery from Compressor Refrigeration 11.3 Exclusive Measures 11.3.1 Heating Recovery 11.3.2 Induced Draught in Tunnel Kiln 11.3.3 Pre-heating of Kiln Airs 11.3.4 Absorption Machine 11.3.5 MED Distiller 11.3.6 Photovoltaic Plant 11.3.7 Cogeneration Plant 11.4 Summary of Investment References