Study of HP&D exhaust kiln heat conversion and use for drying bricks and tiles

该项目的目标是通过减少天然气和电力消耗，以及在可能的情况下减少整个干燥周期，提高Hinton Perry&DavenHill有限公司砖瓦干燥机的能效。Hinton Perry&DavenHill Ltd总部设在西米德兰兹郡的达德利，成立于1805年，生产凯特利砖和无畏屋顶瓦。这些都是寿命长的产品，具有超过100年的使用寿命。与项目合作伙伴陶瓷干燥系统公司合作，该项目旨在充分研究利用主要热处理热交换器的方案的要求，该热交换器将在广泛的高温下收集所有窑炉废气，并将热量吸收到热油中，将其转移到烘干室，在那里，热油经过另一系列热交换器，将热油中包含的热量释放回烘干机再循环气流中，供整个烘干周期使用。这种工艺变化将允许移除燃气燃烧器、一次风机和废热供应风扇，从而大大降低了我们生产过程中这一关键部分的能源消耗。我们估计，这将节省约900吨二氧化碳排放(超过我们二氧化碳排放量的10%)，并减少12%的气体消耗。该项目将详细研究将从窑排出的废气转移到烘干机的热量，整个周期和产品范围内烘干机的基准能耗，以及烘干机内处理通过热交换器传递的热量的需求。我们会探讨系统容量和系统设计的要求，以便评估这项节能建议的技术、商业和工程方面，并探讨计划的长处和弱点，找出部署热交换解决方案所需的资源，并确定其商业和技术上的可行性。结果将在一份报告中公布，该报告将分发给砖瓦行业，并向公众公布。如果可行性研究成功，下一步可能是申请IETF第二阶段资金，以支持该解决方案的部署。

The objective of the project is to improve energy efficiency within the Brick and Tile dryers at Hinton Perry & Davenhill Ltd, by reducing gas and electricity consumption, and where possible the overall drying cycles. Hinton Perry & Davenhill Ltd is based in Dudley in the West Midlands and was established in 1805 and manufactures Ketley Bricks and Dreadnought roof tiles. These are long life products with a demonstrated useful life of over 100 years.With the project partners, Ceramic Drying Systems the project aims to fully study the requirements for a scheme to utilise a major thermal processing heat exchanger, that will collect all of the kiln exhaust flue gases at a wide range of high temperatures and absorb the heat into hot oil, transferring it to the drying chambers where it then passes through a further series of heat exchangers, that will release the heat contained within the hot oil back into the dryer recirculation air stream to be used throughout the drying cycle.This process change would allow for the removal of gas burners, primary air fans and waste heat supply fan, thus significantly reducing the energy consumption for this key part of our production process. We estimate that this would save around 900 tonnes of CO2 emissions, (over 10% of our CO2 emissions) and reduce our gas consumption by 12%.The project will study in detail the amount of heat available from the kiln exhausts to be transferred to dryers, the baseline energy consumption in the dryers across the cycles and product range and the requirements within the dryers to handle heat delivered via heat exchangers. The system capacity will be explored together with the requirements of the system design to enable the assessment of the technical, commercial and engineering aspects of this energy saving proposal and to explore the strengths and weaknesses of the project, identifying the resources needed for the deployment of the heat exchange solution and confirm its commercial and technical feasibility.The results will be published in a report which will be disseminated to the bricks and tile industry and made publicly available.If the feasibility study is successful, the likely next steps would be an application for phase 2 IETF funding to support the deployment of the solution.