IDEAS home Printed from https://ideas.repec.org/a/gam/jeners/v13y2020i22p6096-d448648.html
   My bibliography  Save this article

Review on Energy Efficiency Progresses, Technologies and Strategies in the Ceramic Sector Focusing on Waste Heat Recovery

Author

Listed:
  • Miguel Castro Oliveira

    (Low Carbon & Resource Efficiency, R&Di, Instituto de Soldadura e Qualidade, 4415-491 Grijó, Portugal)

  • Muriel Iten

    (Low Carbon & Resource Efficiency, R&Di, Instituto de Soldadura e Qualidade, 4415-491 Grijó, Portugal)

  • Pedro L. Cruz

    (Low Carbon & Resource Efficiency, R&Di, Instituto de Soldadura e Qualidade, 4415-491 Grijó, Portugal)

  • Helena Monteiro

    (Low Carbon & Resource Efficiency, R&Di, Instituto de Soldadura e Qualidade, 4415-491 Grijó, Portugal)

Abstract

Thermal processes represent a considerable part of the total energy consumption in manufacturing industry, in sectors such as steel, aluminium, cement, ceramic and glass, among others. It can even be the predominant type of energy consumption in some sectors. High thermal energy processes are mostly associated to high thermal losses, (commonly denominated as waste heat), reinforcing the need for waste heat recovery (WHR) strategies. WHR has therefore been identified as a relevant solution to increase energy efficiency in industrial thermal applications, namely in energy intensive consumers. The ceramic sector is a clear example within the manufacturing industry mainly due to the fuel consumption required for the following processes: firing, drying and spray drying. This paper reviews studies on energy efficiency improvement measures including WHR practices applied to the ceramic sector. This focuses on technologies and strategies which have significant potential to promote energy savings and carbon emissions reduction. The measures have been grouped into three main categories: (i) equipment level; (ii) plant level; and (iii) outer plant level. Some examples include: (i) high efficiency burners; (ii) hot air recycling from kilns to other processes and installation of heat exchangers; and (iii) installation of gas turbine for combined heat and power (CHP). It is observed that energy efficiency solutions allow savings up to 50–60% in the case of high efficiency burners; 15% energy savings for hot air recycling solutions and 30% in the when gas turbines are considered for CHP. Limitations to the implementation of some measures have been identified such as the high investment costs associated, for instance, with certain heat exchangers as well as the corrosive nature of certain available exhaust heat.

Suggested Citation

  • 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.
    • Handle: RePEc:gam:jeners:v:13:y:2020:i:22:p:6096-:d:448648
    as

    Download full text from publisher

    File URL: https://www.mdpi.com/1996-1073/13/22/6096/pdf
    Download Restriction: no
    File URL: https://www.mdpi.com/1996-1073/13/22/6096/
    Download Restriction: no
    ---><---

    References listed on IDEAS

    as
    1. Hongcheng Li & Haidong Yang & Bixia Yang & Chengjiu Zhu & Sihua Yin, 2018. "Modelling and simulation of energy consumption of ceramic production chains with mixed flows using hybrid Petri nets," International Journal of Production Research, Taylor & Francis Journals, vol. 56(8), pages 3007-3024, April.
    2. Wang, Chaojun & He, Boshu & Sun, Shaoyang & Wu, Ying & Yan, Na & Yan, Linbo & Pei, Xiaohui, 2012. "Application of a low pressure economizer for waste heat recovery from the exhaust flue gas in a 600 MW power plant," Energy, Elsevier, vol. 48(1), pages 196-202.
    3. Royo, Patricia & Acevedo, Luis & Ferreira, Victor J. & García-Armingol, Tatiana & López-Sabirón, Ana M. & Ferreira, Germán, 2019. "High-temperature PCM-based thermal energy storage for industrial furnaces installed in energy-intensive industries," Energy, Elsevier, vol. 173(C), pages 1030-1040.
    4. Brückner, Sarah & Liu, Selina & Miró, Laia & Radspieler, Michael & Cabeza, Luisa F. & Lävemann, Eberhard, 2015. "Industrial waste heat recovery technologies: An economic analysis of heat transformation technologies," Applied Energy, Elsevier, vol. 151(C), pages 157-167.
    5. Manrique, Raiza & Vásquez, Daniela & Vallejo, Gabriel & Chejne, Farid & Amell, Andrés A. & Herrera, Bernardo, 2018. "Analysis of barriers to the implementation of energy efficiency actions in the production of ceramics in Colombia," Energy, Elsevier, vol. 143(C), pages 575-584.
    6. Gómez, Henar Olmedo & Calleja, Miguel Castaños & Fernández, Luis Aldea & Kiedrzyńska, Aleksandra & Lewtak, Robert, 2019. "Application of the CFD simulation to the evaluation of natural gas replacement by syngas in burners of the ceramic sector," Energy, Elsevier, vol. 185(C), pages 15-27.
    7. Ricardo S. Gomez & Túlio R. N. Porto & Hortência L. F. Magalhães & Gicelia Moreira & Anastácia M. M. C. N. André & Ruth B. F. Melo & Antonio G. B. Lima, 2019. "Natural Gas Intermittent Kiln for the Ceramic Industry: A Transient Thermal Analysis," Energies, MDPI, vol. 12(8), pages 1-29, April.
    8. Krzysztof Kosowski & Karol Tucki & Marian Piwowarski & Robert Stępień & Olga Orynycz & Wojciech Włodarski, 2019. "Thermodynamic Cycle Concepts for High-Efficiency Power Plants. Part B: Prosumer and Distributed Power Industry," Sustainability, MDPI, vol. 11(9), pages 1-13, May.
    9. Angela Neves & Radu Godina & Susana G. Azevedo & Carina Pimentel & João C.O. Matias, 2019. "The Potential of Industrial Symbiosis: Case Analysis and Main Drivers and Barriers to Its Implementation," Sustainability, MDPI, vol. 11(24), pages 1-68, December.
    10. Yamada, Noboru & Tominaga, Yoshihito & Yoshida, Takanori, 2014. "Demonstration of 10-Wp micro organic Rankine cycle generator for low-grade heat recovery," Energy, Elsevier, vol. 78(C), pages 806-813.
    11. Peris, Bernardo & Navarro-Esbrí, Joaquín & Molés, Francisco & Mota-Babiloni, Adrián, 2015. "Experimental study of an ORC (organic Rankine cycle) for low grade waste heat recovery in a ceramic industry," Energy, Elsevier, vol. 85(C), pages 534-542.
    12. Chao Zhang & Jinglun Fu & Pengfei Yuan & Jianjun Liu, 2018. "Guidelines for Optimal Selection of Subcritical Low-Temperature Geothermal Organic Rankine Cycle Configuration Considering Reinjection Temperature Limits," Energies, MDPI, vol. 11(11), pages 1-18, October.
    13. Saidur, R., 2010. "A review on electrical motors energy use and energy savings," Renewable and Sustainable Energy Reviews, Elsevier, vol. 14(3), pages 877-898, April.
    14. Li, Jing & Pei, Gang & Li, Yunzhu & Wang, Dongyue & Ji, Jie, 2012. "Energetic and exergetic investigation of an organic Rankine cycle at different heat source temperatures," Energy, Elsevier, vol. 38(1), pages 85-95.
    15. Hammond, G.P. & Norman, J.B., 2014. "Heat recovery opportunities in UK industry," Applied Energy, Elsevier, vol. 116(C), pages 387-397.
    16. Simeoni, Patrizia & Ciotti, Gellio & Cottes, Mattia & Meneghetti, Antonella, 2019. "Integrating industrial waste heat recovery into sustainable smart energy systems," Energy, Elsevier, vol. 175(C), pages 941-951.
    17. 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.
    18. Kaya, Sinem & Mançuhan, Ebru & Küçükada, Kurtul, 2009. "Modelling and optimization of the firing zone of a tunnel kiln to predict the optimal feed locations and mass fluxes of the fuel and secondary air," Applied Energy, Elsevier, vol. 86(3), pages 325-332, March.
    19. Quoilin, Sylvain & Broek, Martijn Van Den & Declaye, Sébastien & Dewallef, Pierre & Lemort, Vincent, 2013. "Techno-economic survey of Organic Rankine Cycle (ORC) systems," Renewable and Sustainable Energy Reviews, Elsevier, vol. 22(C), pages 168-186.
    20. Ma, Q. & Luo, L. & Wang, R.Z. & Sauce, G., 2009. "A review on transportation of heat energy over long distance: Exploratory development," Renewable and Sustainable Energy Reviews, Elsevier, vol. 13(6-7), pages 1532-1540, August.
    21. Yali Wang & Haidong Yang & Kangkang Xu, 2020. "Thermal Performance Combined with Cooling System Parameters Study for a Roller Kiln Based on Energy-Exergy Analysis," Energies, MDPI, vol. 13(15), pages 1-31, July.
    22. Delpech, Bertrand & Axcell, Brian & Jouhara, Hussam, 2019. "Experimental investigation of a radiative heat pipe for waste heat recovery in a ceramics kiln," Energy, Elsevier, vol. 170(C), pages 636-651.
    Full references (including those not matched with items on IDEAS)

    Citations

    Citations are extracted by the CitEc Project, subscribe to its RSS feed for this item.
    as


    Cited by:

    1. Davide Di Battista & Roberto Cipollone, 2023. "Waste Energy Recovery and Valorization in Internal Combustion Engines for Transportation," Energies, MDPI, vol. 16(8), pages 1-28, April.
    2. Andrei, Mariana & Thollander, Patrik & Sannö, Anna, 2022. "Knowledge demands for energy management in manufacturing industry - A systematic literature review," Renewable and Sustainable Energy Reviews, Elsevier, vol. 159(C).
    3. Miguel Castro Oliveira & Muriel Iten & Henrique A. Matos, 2022. "Review of Thermochemical Technologies for Water and Energy Integration Systems: Energy Storage and Recovery," Sustainability, MDPI, vol. 14(12), pages 1-17, June.
    4. 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).
    5. 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).
    6. Zare Banadkouki, Mohammad Reza, 2023. "Selection of strategies to improve energy efficiency in industry: A hybrid approach using entropy weight method and fuzzy TOPSIS," Energy, Elsevier, vol. 279(C).
    7. Teresa Annunziata Branca & Barbara Fornai & Valentina Colla & Maria Ilaria Pistelli & Eros Luciano Faraci & Filippo Cirilli & Antonius Johannes Schröder, 2021. "Industrial Symbiosis and Energy Efficiency in European Process Industries: A Review," Sustainability, MDPI, vol. 13(16), pages 1-37, August.
    8. Miguel Castro Oliveira & Muriel Iten & Henrique A. Matos, 2022. "Review on Water and Energy Integration in Process Industry: Water-Heat Nexus," Sustainability, MDPI, vol. 14(13), pages 1-24, June.
    9. Pradeep, N. & Reddy, K.S., 2022. "Design and investigation of solar cogeneration system with packed bed thermal energy storage for ceramic industry," Renewable Energy, Elsevier, vol. 192(C), pages 243-263.
    10. Patricia Royo & Luis Acevedo & Álvaro J. Arnal & Maryori Diaz-Ramírez & Tatiana García-Armingol & Victor J. Ferreira & Germán Ferreira & Ana M. López-Sabirón, 2021. "Decision Support System of Innovative High-Temperature Latent Heat Storage for Waste Heat Recovery in the Energy-Intensive Industry," Energies, MDPI, vol. 14(2), pages 1-13, January.

    Most related items

    These are the items that most often cite the same works as this one and are cited by the same works as this one.
    1. 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).
    2. 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).
    3. Landelle, Arnaud & Tauveron, Nicolas & Haberschill, Philippe & Revellin, Rémi & Colasson, Stéphane, 2017. "Organic Rankine cycle design and performance comparison based on experimental database," Applied Energy, Elsevier, vol. 204(C), pages 1172-1187.
    4. Peris, Bernardo & Navarro-Esbrí, Joaquín & Molés, Francisco & González, Manuel & Mota-Babiloni, Adrián, 2015. "Experimental characterization of an ORC (organic Rankine cycle) for power and CHP (combined heat and power) applications from low grade heat sources," Energy, Elsevier, vol. 82(C), pages 269-276.
    5. Fabian Bühler & Stefan Petrović & Torben Ommen & Fridolin Müller Holm & Henrik Pieper & Brian Elmegaard, 2018. "Identification and Evaluation of Cases for Excess Heat Utilisation Using GIS," Energies, MDPI, vol. 11(4), pages 1-24, March.
    6. Peris, Bernardo & Navarro-Esbrí, Joaquín & Molés, Francisco & Mota-Babiloni, Adrián, 2015. "Experimental study of an ORC (organic Rankine cycle) for low grade waste heat recovery in a ceramic industry," Energy, Elsevier, vol. 85(C), pages 534-542.
    7. Pili, R. & García Martínez, L. & Wieland, C. & Spliethoff, H., 2020. "Techno-economic potential of waste heat recovery from German energy-intensive industry with Organic Rankine Cycle technology," Renewable and Sustainable Energy Reviews, Elsevier, vol. 134(C).
    8. Jouhara, Hussam & Bertrand, Delpech & Axcell, Brian & Montorsi, Luca & Venturelli, Matteo & Almahmoud, Sulaiman & Milani, Massimo & Ahmad, Lujean & Chauhan, Amisha, 2021. "Investigation on a full-scale heat pipe heat exchanger in the ceramics industry for waste heat recovery," Energy, Elsevier, vol. 223(C).
    9. Oluleye, Gbemi & Smith, Robin, 2016. "A mixed integer linear programming model for integrating thermodynamic cycles for waste heat exploitation in process sites," Applied Energy, Elsevier, vol. 178(C), pages 434-453.
    10. Miguel Castro Oliveira & Muriel Iten & Henrique A. Matos, 2022. "Review on Water and Energy Integration in Process Industry: Water-Heat Nexus," Sustainability, MDPI, vol. 14(13), pages 1-24, June.
    11. Du, Kun & Calautit, John & Eames, Philip & Wu, Yupeng, 2021. "A state-of-the-art review of the application of phase change materials (PCM) in Mobilized-Thermal Energy Storage (M-TES) for recovering low-temperature industrial waste heat (IWH) for distributed heat," Renewable Energy, Elsevier, vol. 168(C), pages 1040-1057.
    12. Václav Kočí & Lenka Scheinherrová & Jiří Maděra & Martin Keppert & Zbigniew Suchorab & Grzegorz Łagód & Robert Černý, 2020. "Experimental and Computational Study of Thermal Processes in Red Clays Exposed to High Temperatures," Energies, MDPI, vol. 13(9), pages 1-15, May.
    13. Gábor Györke & Axel Groniewsky & Attila R. Imre, 2019. "A Simple Method of Finding New Dry and Isentropic Working Fluids for Organic Rankine Cycle," Energies, MDPI, vol. 12(3), pages 1-11, February.
    14. Campana, Claudio & Cioccolanti, Luca & Renzi, Massimiliano & Caresana, Flavio, 2019. "Experimental analysis of a small-scale scroll expander for low-temperature waste heat recovery in Organic Rankine Cycle," Energy, Elsevier, vol. 187(C).
    15. Oluleye, Gbemi & Jobson, Megan & Smith, Robin, 2015. "A hierarchical approach for evaluating and selecting waste heat utilization opportunities," Energy, Elsevier, vol. 90(P1), pages 5-23.
    16. Bühler, Fabian & Petrović, Stefan & Karlsson, Kenneth & Elmegaard, Brian, 2017. "Industrial excess heat for district heating in Denmark," Applied Energy, Elsevier, vol. 205(C), pages 991-1001.
    17. Alizadeh, Araz & Ghadamian, Hossein & Aminy, Mohammad & Hoseinzadeh, Siamak & Khodayar Sahebi, Hamed & Sohani, Ali, 2022. "An experimental investigation on using heat pipe heat exchanger to improve energy performance in gas city gate station," Energy, Elsevier, vol. 252(C).
    18. Wang, Chaojun & He, Boshu & Yan, Linbo & Pei, Xiaohui & Chen, Shinan, 2014. "Thermodynamic analysis of a low-pressure economizer based waste heat recovery system for a coal-fired power plant," Energy, Elsevier, vol. 65(C), pages 80-90.
    19. Kavvadias, Konstantinos C. & Quoilin, Sylvain, 2018. "Exploiting waste heat potential by long distance heat transmission: Design considerations and techno-economic assessment," Applied Energy, Elsevier, vol. 216(C), pages 452-465.
    20. Lin, Yuancheng & Chong, Chin Hao & Ma, Linwei & Li, Zheng & Ni, Weidou, 2022. "Quantification of waste heat potential in China: A top-down Societal Waste Heat Accounting Model," Energy, Elsevier, vol. 261(PB).

    Corrections

    All material on this site has been provided by the respective publishers and authors. You can help correct errors and omissions. When requesting a correction, please mention this item's handle: RePEc:gam:jeners:v:13:y:2020:i:22:p:6096-:d:448648. See general information about how to correct material in RePEc.

    If you have authored this item and are not yet registered with RePEc, we encourage you to do it here. This allows to link your profile to this item. It also allows you to accept potential citations to this item that we are uncertain about.

    If CitEc recognized a bibliographic reference but did not link an item in RePEc to it, you can help with this form .

    If you know of missing items citing this one, you can help us creating those links by adding the relevant references in the same way as above, for each refering item. If you are a registered author of this item, you may also want to check the "citations" tab in your RePEc Author Service profile, as there may be some citations waiting for confirmation.

    For technical questions regarding this item, or to correct its authors, title, abstract, bibliographic or download information, contact: MDPI Indexing Manager (email available below). General contact details of provider: https://www.mdpi.com .

    Please note that corrections may take a couple of weeks to filter through the various RePEc services.

    IDEAS is a RePEc service. RePEc uses bibliographic data supplied by the respective publishers.