In the thermal processing of ceramics, energy input is essential, but energy loss doesn’t have to be. In many production plants, a large share of the energy used for thermal treatment leaves the kiln as waste air. Without targeted recovery strategies, this energy and its potential is lost. At Keramischer OFENBAU, we focus on making every kilojoule count. That’s why waste heat utilisation is a core element of our kiln designs, both in new and retrofit kiln solutions.
Why is this relevant? Depending on the kiln type, firing conditions and product, thermal energy losses via waste air and flue gas can represent one of the largest untapped efficiency reserves in a ceramic production line. In continuous operations especially, recovering this energy can significantly reduce overall consumption and support long-term energy strategies.
Our waste heat recovery concepts are based on proven engineering principles. Depending on product, process, and plant layout, our approaches include:
Integrated use in the preheating zone
Instead of venting hot waste air, we redirect it, increasing overall thermal efficiency and reducing firing energy demand. Energy recovery within the kiln is especially relevant in continuous plants, where we redirect hot air from the firing to the preheating zone where it is used to raise the temperature of incoming ware.
This reduces burner load and above all minimises energy consumption. The concept also bears the highly beneficial side effect of stabilised temperature curves. Ceramic ware, especially large pieces, thus have lower risk of fracturing, leading to higher product quality and ultimately a significantly increased output.
This solution thus includes benefits like:
- lower energy consumption
- stabilised temperature curves
- reduced thermal stress
- improved product quality
- higher throughput
Use of waste heat for drying processes
Drying ceramic products requires considerable thermal energy in the process chain. Reusing hot waste air to support the dryer drastically lowers energy demand and improves plant-wide efficiency.
The result: lower total consumption and better energy balance across the entire plant. The cross-process integration additionally reduces dependency on additional heating systems for dryers.
Read more on LinkedIn: Article WASTE HEAT IS NOT WASTE, IT’S UNTAPPED POTENTIAL