Energy Efficient Tunnel Kilns With Superlative Firing Atmosphere For Ceramic Industries

Abstract

Khurja is a pottery cluster having around 500 manufacturing units in the state of Uttar Pradesh (India). These units manufacture whitewares i.e. table ware ceramics (Bone china & Stoneware), artistic items, chemical porcelain, tiles, sanitary ware and porcelain insulators etc. In Khurja, about 110 units are firing their product in oil fired tunnel kilns. Due to low fuel efficient kilns, large quantity of fuel is used for firing of white ware ceramics. A study was carried out on the firing atmosphere in oil fired tunnel kilns being used for the firing of ceramics. These kilns do not have much engineering design inputs. Large fuel consumption is the biggest challenge due to poor designs. The aim was to reduce fuel consumption by various technological interventions like increasing firing zone length and chimney height and diameter, redefining the ratio of CO, O2 and excess air etc results in the reduction in firing cycle hours, improvements in products loading density, improvement in product quality and reduced emission of Green House Gases(GHG). A number of kilns were chosen for the study. The appropriate ranges of CO, O2 and excess air in the flue gas were optimized for oil fired Kilns which resulted in increased kiln efficiency. Proper kiln insulation resulted decrease in the skin temperature. The control of excess air resulted in better product quality.