HEATING SYSTEM FOR CERAMIC TILE FACTORY IN VIETNAM

Transcription

1 HEATING SYSTEM FOR CERAMIC TILE FACTORY IN VIETNAM USING FURNACE OIL Devon Guile Jean-Marc Guindon Andreas Hart Emerson Hawkins Alex Higgs Jono Horne

2 OUTLINE Background Process Flow Engineering Plant layout Economics Conclusion Roller Hearth Kiln. (February 2014). Retrieved from 2

3 INTRO Vietnam has a very successful tiling industry In 2013 a total of 199 million m 2 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

4 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 ramics-properties-d_1227.html 4

5 PROCESS FLOW 5

6 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

7 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

8 KILN DETAILS To determine the dimensions of the kiln, the following assumptions were used: The density of ceramic tile is 2900 kg/m 3 [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

9 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 eheated.pdf

10 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. c p of flue gas = 0.96 kj/kg [2] and c p 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. 10

11 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 l/s. This flow rate is attainable for a typical industrial burner [4]. 11

12 FINAL KILN DESIGN Parameter Material processed Energy requirement Tiles manufactured Fuel flow rate Value 2000 tons/day 1000 kcal/kg tiles/hr 3.5 l/s Kiln dimensions 10.4 x 2 x 104 Number of burners 40 Conveyor speed 1.73 ft/min 12

13 PLANT LAYOUT 13

14 ECONOMIC ANALYSIS INITIAL COST Item Qty. Units Kiln [17] 178, $ Burners 40 units Retail Price $/unit Air-Air Heat Exchanger [11] 50, $ Property [18] 1800 m 2 Land rate in Vietnam 5.37 $/m 2 Infrastructure [18] 220, $ Contingency 10 % Total Capital Expense 488, $ All figures are in USD Equipment: Kiln, burners, heat exchanger Install & commission Property Infrastructure: Facilities, utilities 14

15 ECONOMIC ANALYSIS REVENUE & EXPENSES Operations Cost = 4 x Fuel Cost Max revenue based on individual tile sales PERFORMANCE PARAMETER: Net Present Value 8%, 10 years NPV of million USD Item Qty. Units Fuel 3.5 litre/s Market Price [7,8] 1.03 $/US gallon Total 30,022, $/yr Raw Clay 2000 tons/day Market Price [15] $/ton Total 29,200, $/yr Operations 4*Fuel Cost Estimated Total 120,089, $/yr Total Expenses 149,289, $/yr Item Qty. Units Retail price $/ft 2 Tiles manufactured units/hr Total Revenue 209,147, $/yr

16 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 Flooring-1.jpg 16

17 REFERENCES 1. Air properties. (2014, February). Retrieved from 2. Assessment of boilers and thermic fluid heaters. (2006, September). Retrieved from 3. Basu, Pabir, Dr. "Kiln Design." Telephone interview. Feb 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 6. "Fuel Cost." Fuel Cost. Vietnam Online, Web. 10 Feb < 7. Fuel Cost." In Vietnam. Energypedia, 15 Apr Web. 11 Feb < 8. "Basu, Pabir, Dr. "Kiln Design." Telephone interview. Feb Fuel oil and combustion values. (2014, February). Retrieved from Preheated combustion air. (2007, November). Retrieved from 17

18 QUESTIONS? 18