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Energy efficiency enhancement and waste heat recovery in industrial processes by means of the heat pipe technology: Case of the ceramic industry

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  • Delpech, Bertrand
  • Milani, Massimo
  • Montorsi, Luca
  • Boscardin, Davide
  • Chauhan, Amisha
  • Almahmoud, Sulaiman
  • Axcell, Brian
  • Jouhara, Hussam

Abstract

This paper investigates the application of heat-pipe based heat exchanger for improving the energy efficiency of industrial processes. In particular, the case of the ceramic industry is addressed and the potential heat recovery and reduction of fuel consumption is determined. A theoretical model is constructed based on the established, proven performance characteristics of heat-pipe technologies and the performance of the ceramic process are calculated using numerical simulation. The results of the kiln numerical model are then combined to the theoretical model of the heat-pipe based heat exchanger and the heat recovery potential is evaluated as well as the reduction of fuel consumption. The combined theoretical and numerical approach demonstrates that the application of the heat pipes based heat exchanger to the cooling stack of the ceramic kiln enables to recover more than 863 MWh of thermal energy that can be used for heating up the hot air stream of the pre-kiln dryer. Thus, approximately 110,600 Sm3 per year of natural gas can be saved from the burners powering the dryer and the emission of 164 tonnes per year of carbon dioxide can be avoided. Additionally, the avoided cost due to the fuel consumption reduction amounts to more than 22,000 Euro per year. These figures support the application of the heat pipes based heat recovery to the ceramic process from the viewpoint of the improvement the energy efficiency and environmental impact and also of the economic investment.

Suggested Citation

  • Delpech, Bertrand & Milani, Massimo & Montorsi, Luca & Boscardin, Davide & Chauhan, Amisha & Almahmoud, Sulaiman & Axcell, Brian & Jouhara, Hussam, 2018. "Energy efficiency enhancement and waste heat recovery in industrial processes by means of the heat pipe technology: Case of the ceramic industry," Energy, Elsevier, vol. 158(C), pages 656-665.
    • Handle: RePEc:eee:energy:v:158:y:2018:i:c:p:656-665
    DOI: 10.1016/j.energy.2018.06.041
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    13. Furszyfer Del Rio, Dylan D. & Sovacool, Benjamin K. & Foley, Aoife M. & Griffiths, Steve & Bazilian, Morgan & Kim, Jinsoo & Rooney, David, 2022. "Decarbonizing the ceramics industry: A systematic and critical review of policy options, developments and sociotechnical systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 157(C).
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    15. Miguel Castro Oliveira & Muriel Iten & Pedro L. Cruz & Helena Monteiro, 2020. "Review on Energy Efficiency Progresses, Technologies and Strategies in the Ceramic Sector Focusing on Waste Heat Recovery," Energies, MDPI, vol. 13(22), pages 1-24, November.
    16. Caglayan, Hasan & Caliskan, Hakan, 2021. "Advanced exergy analyses and optimization of a cogeneration system for ceramic industry by considering endogenous, exogenous, avoidable and unavoidable exergies under different environmental condition," Renewable and Sustainable Energy Reviews, Elsevier, vol. 140(C).
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    19. Ruivo, Luís & Russo, Michael & Lourenço, Rúben & Pio, Daniel, 2021. "Energy management in the Portuguese ceramic industry: Analysis of real-world factories," Energy, Elsevier, vol. 237(C).
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