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TANGRAM
TECHNOLOGY
Energy efficiency in ceramics processing
CONTENTS
Fact Sheet 1 - Reducing energy costs - the first steps ...............3
Fact Sheet 2 - The rewards ...........................................................4
Fact Sheet 3 - Raw material preparation ......................................5
Fact Sheet 4 - Drying .....................................................................6
Fact Sheet 5 - Firing ......................................................................7
Fact Sheet 6 - Motors and drives ..................................................8
Fact Sheet 7 - Compressed air .....................................................9
Fact Sheet 8 - Buildings ................................................................10
Free Action Energy publications for the ceramics sector ..........11
2
Energy efficiency in ceramics processing
to 1.
Load Factor is a measure of the
Base Load (kWh) hours per day that the user draws
from the supply. Reduce the cost by:
Running for greater than a single
tonnes shift.
Carrying out some operations
Using production information to find the SEC and the Base Load outside the main shift pattern.
3
Energy efficiency in ceramics processing
The rewards the implemented energy policy should motors, and to create the largest load
be promoted within the company and when they are used.
Energy efficiency measures can
used to create a favourable climate for Is the thermal insulation on all the
improve your profits significantly for
investment treatment of other energy machines in good condition? If there is
minimum effort and costs. For a
saving programmes. inadequate or no insulation, then why
ceramics company with an annual
Energy efficiency is a competitive not?
turnover of 10 million and a net profit
of 1 million, the average electricity bill
advantage in any market and an initial Are there any good reasons why
site survey is the start of gaining the machines need to be kept idling to be
will be approximately 200,000
advantage for your company. This Fact ready for the next production run or
(between 1% and 3% of turnover).
Sheet explains how to carry out an when not in production? These include
Simple no-cost or low-cost energy
initial site energy survey the starting conveyors, water pumps, vacuum
efficiency practices can reduce this by
point for all improvement plans. pumps, motors, granulators, fans,
up to 20% and increase profits by up to
4%. This is the equivalent of adding machine heaters, etc.
sales of 400,000 to turnover and is a Why are the motors the size they are
worthwhile investment by any An initial site survey is a key and would a smaller motor be more
standards. starting point for energy efficient?
saving Is the airflow from fans being throttled
back with dampers and could variable
speed drives be used instead?
Low cost energy efficiency The initial site energy survey Are there leaks in water, air or steam
measures can improve The objective of the initial energy lines?
profits significantly survey is to gain an overview of the Where can you hear steam and
general site energy use. It is a walk compressed air leaks? The hissing
around the site with an energy noise you hear from leaks is costing
Raising energy awareness managers hat on. This will identify real money. If no production is being
The cost savings possible from energy some rapid no-cost or low-cost carried out, then why is the
efficiency will only be achieved if there improvements that can be made to compressed air system still running?
is management commitment to actually save money. Is compressed air being used for
carry out the work necessary. This is The survey should be carried out as applications where other cheaper
best ensured by having an energy soon as possible if energy is being methods can be used, e.g. cleaning or
policy that is as much a part of overall wasted now, it is costing money now. drying?
company operations as its quality How do you carry out a site Does the compressed air pressure
policy. The energy policy should ideally survey? need to be so high or the vacuum so
be part of a broader company Take an unannounced walk around the low?
environmental policy and, at the very site at around mid-shift. If there is no Is the lighting dirty or broken?
least, should be formally adopted with night shift it can also be worthwhile to What simple maintenance measures
top-level management commitment. take a walk around the factory when could be adopted to reduce energy
The policy should be the responsibility there is no production to look for base use?
of a designated energy manager who load energy uses such as compressors Are accepted practices wasting
has clear responsibility for energy and other services plant. energy? Can they be modified at no
matters. There needs to be regular cost at all?
The questions to ask (and answer)
communication with major users who Are there clear setting instructions for
are held accountable for their energy Which areas have the largest
electrical load? Look for the largest all machines and are they
use, which should be monitored and implemented when a machine is set
targeted. The quantified savings from machines they are most likely to
have the largest heating demand and up?
Turning a survey into savings
A site energy survey is only worthwhile
Services and buildings energy needs if action is taken as a result of the
findings. Use the survey to estimate
the sites excess energy use. Arrange
Energy Energy Energy for an electrician to measure the
factorys electrical load and then
Materials Transport Form Dry
calculate the costs involved. Use the
survey to identify operating practices
that cost money and need to be
changed.
The results of the survey should be
distributed with full recommendations
for improvements and costs for
carrying them out.
Product Transport Post-Process Fire
4
Energy efficiency in ceramics processing
Raw materials Tip: Fit interlocks or sensors to reduce costs. The extrusion of
conveyors or link them to machine ceramics products uses electricity to
Ceramics processors often overlook
start-up/shutdown switches so that run the extruder and this can use large
the treatment of raw materials when
they only operate when the machines amounts of energy.
considering energy efficiency. The
are operating. Tip: Set the extruder to run at its most
increased use of mechanisation in
Size reduction efficient speed (usually the maximum
processing means that energy use in
Particle size is an important factor in all design speed) and control the screw
this area is increasing and there are
ceramics processing and it is speed to give an extrusion rate as
opportunities for cost savings.
sometimes necessary to grind or mill close to the maximum as possible
raw materials to achieve both the while still producing good product.
The preparation and Motors run most efficiently close to
transport of raw materials correct absolute particle size and
particle size distribution. Size reduction their design output a large motor at
uses significant quantities of of any type uses large motors and part load is less efficient than a small
energy but is often heavy equipment. Even if the machine one at full load.
Tip: Size and control the electric
overlooked in energy is not processing materials, the energy
load will be high. motor to match the torque needed by
efficiency efforts the screw
Tip: Fit time delay switches to all
grinding and milling machines to turn Tip: Other forming processes also
Purchasing and storage use significant amounts of energy and
Purchasing should always be made to them off if no material is being
processed need to be considered.
a comprehensive purchase
Tip: If processing small amounts of Material recipes
specification that gives details of the
acceptable limits of possible raw materials, it can often be profitable Material recipes are largely fixed in the
contaminants and the size range of the to save grinding until the night shift to ceramics industry by product and
material feedstock (to avoid problems take advantage of lower electricity process needs. Despite this, there are
with bridging or blockages in transport tariffs and to reduce daytime maximum some areas (e.g. brick manufacture)
systems). demand charges. But be aware of where bulk additives are added to the
Tip: Purchasing the right materials
possible noise restrictions. mix. These fall into two categories:
can reduce costs and energy use by Tip: Large motors with high use on Those that have no combustible
getting the right materials delivered grinders and mills will benefit from material, but can act as fillers and may
rather than having to treat them in the being replaced by high efficiency contain fluxes to reduce the firing
factory. motors (see Fact Sheet 6). temperature, e.g. pulverised flue ash
Storing any material costs money and Mixing (PFA) and glass cullet
uses energy in some way. Even bulk Mixing of raw materials is carried out Those that are combustible and can
outside storage costs money in terms by a variety of methods (e.g. in ball act as a source of energy in the firing
of the inventory cost; it is estimated mills or slurries) and wet compounds process, e.g. carbonaceous additives.
that inventory costs in the ceramics normally need to be dewatered in a Processors should examine their
industry are approximately 30% of the filter press before forming and firing. material recipes closely to see if there
total value of the materials held per These processes all use energy for are opportunities for material changes
year. motors and drives, and care needs to to reduce both the costs of the raw
be taken in motor selection and use. materials and their processing.
Materials transport
Tip: It is always better to change the Tip: Changing materials may be
Materials are inevitably transported extremely cost effective and reduce
from storage areas to processing structure of the operation than to try to
change the habits of the staff. Fit cut- not only raw material costs but also
areas, generally using conveyors. It is processing costs.
common to see conveyors operating outs and interlocks rather than trying to
when no materials are being change behaviour. Reducing materials content
transported. This is clearly a waste of Forming Reducing the amount of material used
energy; machines should operate only The basic forming process also uses in any product leads to both cost and
when doing useful work. energy and should be reviewed to energy benefits (processors neither
pay for the raw material nor do they
pay to process it). It can lead to cost
reductions at all stages of production,
e.g. increasing the perforation content
Storage Mixing of bricks can produce bricks with no
discernible performance reduction but
with cost reductions at all stages of
processing.
5
Energy efficiency in ceramics processing
Drying Method of moving the product into as a heat source for drying. Possible
and through the dryer methods include:
Nearly 30% of the 10,700TJ consumed
Mechanical aids to improve drying Heat pumps
by the UK ceramics industry is used for
drying. However, energy for drying is Method of air circulation Recuperators
often used inefficiently and companies Ware support method. Hot air from the kiln cooling zone
could typically save 10% of these costs Energy consumption can also be (optimum operation is not to let any
through improved process reduced by minimising the sensible heat escape from the kiln but use it all
management and good housekeeping. heat load of the structure and in the kiln).
optimising the insulation to reduce heat Questions to ask:
Energy efficient dryers dry loss from the dryer. Does the kiln waste heat or do gases
the product from the inside, Loading contain any contaminants that might
not from the outside Loading density is crucial to affect the dryer?
optimisation; if it is too low, then it may Is the kiln heat always available?
The rate of drying is controlled by: reduce humidity and make it necessary Does the payback justify the
Temperature the higher the to add moisture. additional cost of moving the heat from
temperature, the faster the drying Tip: Match the production schedule to the kiln to the dryer?
Relative humidity the lower the the dryer cycle to improve loading Exhaust air from a dryer will not be
humidity, the faster the drying densities fully saturated, i.e. less water will be
Airflow the higher the airflow, the Tip: Slowing the dryer and filling the removed than is possible and more
faster the drying shelves can significantly reduce the energy will be used than necessary.
Product design features surface SEC. Many dryers can operate at a higher
area and thickness both affect drying. Airflow control exhaust humidity without affecting the
These parameters largely determine A major factor in energy consumption drying rate, and mixing some of the
the size of the dryer and technology is the volume of air used. If there is too exhaust gas with the freshly heated
used. The high latent heat of water much airflow, then energy can be drying air can recycle this heat. The
means that large amounts of energy wasted. However, dryers do not capital cost of this measure is low and
are sometimes used inefficiently in function without adequate air and, if it can be applied to all types of dryers.
drying. Energy efficiency involves the airflow is too low, then temperature Monitoring
process optimisation, monitoring and and humidity will not be distributed Key performance parameters must be
maintenance. evenly. A consistent airflow pattern can monitored regularly to control dryers.
Process optimisation lead to inconsistent drying - These include temperature, humidity,
intermittent airflow is preferred. airflow, final moisture content,
Tip: Redirecting airflows can improve production throughput and yield, cycle
Optimisation is an on-going
consistency and reduce drying time time and energy consumption.
process Tip: Intermittent airflow patterns can Improved measurement and controls
Less than 50% of the energy used in reduce drying time and improve yield. can result in energy savings of 510%.
a conventional dryer is used to heat Kiln effects Tip: Install a monitoring and targeting
the product and evaporate water. The Optimisation of the dryer should (M&T) system
rest is used by the dryer structure, consider the overall production flow Tip: Even the most expensive control
ware supports and exhausted air. and ensure that drying does not system is useless if a sensor is not
Optimisation will improve the process interrupt firing. Firing is the most operating or reading incorrectly.
and reduce costs. energy intensive process and adds the Temperature and relative humidity are
Optimisation aims to find the best most value. The kiln should always be key control measurements. Initial work
heating rate to reach maximum kept working at peak efficiency and to optimise a dryer may necessitate
shrinkage in sufficient time to allow drying should support the kiln firing measurements at several locations,
adequate materials compaction while schedule. but routine control may use a single
minimising energy consumption and Tip: The dryer and the kiln should be measurement as a control point. The
maximising process yield. scheduled together to give the best key step is using the measurements to
Important considerations for energy production output and energy control the product.
efficiency in drying are: efficiency. Tip: Water should not be allowed to
Temperature and pressure levels Using waste heat condense in the dryer, some clays can
Heating method and medium Waste heat from other areas can used reabsorb water and condensation can
cause corrosion of pallets and internal
metal supports.
To Routine maintenance
increase Operators should carry out routine
drying maintenance but not change the
Increase Reduce Increase
rate process settings.
temperature humidity airflow
Tip: One ceramics manufacturer found
out that operators had changed the
dryer settings and, after the machine
To
had been reset to the original
decrease
conditions, waste was reduced by 3%.
drying
Reduce Increase Decrease However, the problem was only
rate
temperature humidity airflow spotted after five years of inefficient
The effect of various parameters on drying rate and energy use operation and extra cost!
6
Energy efficiency in ceramics processing
7
Energy efficiency in ceramics processing
Motors and drives should include guidelines on: can produce savings of up to 10%.
Repair and replacement based on Tip: VSDs (see below) will allow
Approximately one-third of the energy
lifetime costing motors to run at the required speed to
costs in ceramics processing are the
result of electric motor use. Yet motors Specification of HEMs for all new save energy.
are often overlooked when considering purchases. High efficiency motors
energy use. The motors in the main When new motors are required, the
processing equipment such as material benefits of opting for HEM are obvious.
mixers and compounders, moulders However, the failure of an existing The life cost of a motor is
and extruders are obvious but the motor raises the question of whether often over 100 times the
majority of motors are hidden in other the motor should be repaired or purchase cost
equipment such as compressors, replaced. Repairing a failed motor may
pumps and fans. Given that the energy appear to be cost-effective, but repair
cost of running a motor for 1,000 hours can reduce energy efficiency by up to The cost premium for HEMs is now
can exceed the purchase cost and that 1% (and does so every time a motor is small and easily offset by the energy
the whole life costs are often over 100 rewired) and may not be the most savings that result from their use.
times the purchase cost, then failing to economic long-term action. A motor HEMs achieve efficiency levels of up to
take action with all the motors in a management policy can provide the 3% more than conventional motors
factory is expensive! framework and rules for making the and have a peak efficiency at 75% of
best financial decision even when load, thus reducing both energy costs
urgent answers are required. and oversizing problems. A 3%
The energy cost of a motor Motor sizing efficiency gain may not sound much,
Motors are most efficient when their but a 500 motor uses approximately
can exceed the purchase load equals, or is slightly greater than, 50,000 in energy over a ten-year life
cost in just 1000 hours of use their rated capacity. Motors can be and a 3% saving is worth 1,500
overloaded for short periods provided thats equivalent to three free motors.
that there is a later lower load to allow Variable speed drives
The motor management cooling. If larger than necessary The speed of an alternating current
policy machines are purchased or used, then (ac) motor is fixed by the number of
The greater importance of running the motor will not reach the design poles and the supply frequency. As a
costs than the initial purchase cost load and will never run at optimum result, the fans used in many
means that companies need to change efficiency. Oversized motors are processes are designed to be run at a
the way they look at motors. Decisions inefficient; equipment needs to be fixed and constant speed but are
need to be made on the whole life carefully matched with demand. Even damped down to provide the correct
cost where all purchase, maintenance, steady loads from fans, compressors airflow required by the process. This
repair and operating costs are and pumps fluctuate slightly and the wastes considerable amounts of
considered. basic operating load rarely matches energy.
The energy efficiency improvements that of a standard motor. Another way to meet the varying
available with the development of Tip: Seek expert advice on motor demands is to fit a VSD to the motor. A
varable speed drive (VSD) and high sizing to reduce costs. VSD allows the speed of an ac motor
efficiency motors (HEMs) means that, Tip: Where motors can be accurately to be varied and the fan output can be
to reduce costs, companies must predicted to run at less than 33% of matched to the variable demand. This
develop and implement a motor the rated output, it is possible to simple application of VSD technology
management policy for the purchase reconfigure the motor from delta to star can significantly reduce energy costs.
and operation of motors. This policy connection. This simple low-cost action Other VSD benefits include:
Reduced noise
Lower maintenance costs
Better all-round performance.
VSDs can not only be used for fans,
but also for water pumps, air
compressors and any other application
where the load varies considerably
with time. For constant loads, the use
Annual running hours
Repair
Size (kW)
8
Energy efficiency in ceramics processing
Compressed air the generating power is wasted in being generated at a higher pressure
feeding leaks). A 3mm diameter hole in than required
Compressed air is a convenient and
a system at 7 bar will leak about Tip: Switch off compressors during
often essential utility, but it is very
11 litres/sec and cost around 1,000/ non-productive hours. They are often
expensive to produce. In fact, most of
year. This is the cost for just one only feeding leaks or creating them.
the energy used to compress air is
leak with more leaks, the wastage
turned into heat and then lost. At the Tip: Check that compressors are not
will increase significantly.
point of use, compressed air costs idling when not needed they can draw
Simple leak surveys and maintenance
more than ten times the equivalent up to 40% of full power when idling
can produce dramatic cost reductions
quantity of electrical energy, i.e. an Tip: Position air inlets outside if
and, in some cases, leak reporting and
equivalent cost of around 50p/kWh. At possible it is easier to compress cold
repair have enabled companies to shut
this price, it should never be wasted air
down some compressors for all or
and only be used when necessary.
most of their operating time. Tip: If there is a machine or area that
Air also needs to be treated to remove
Tip: Simple and repeated walk- requires compressed air longer than
moisture, oil and dirt. The higher the
around surveys, with leaks tagged and the rest, consider zoning or a
quality required, the greater the energy
repaired as soon as possible, will dedicated compressor so that others
consumed by the treatment system.
significantly reduce leakage rates can be switched off
The chart below shows the cost of
compressor ownership over ten years. Tip: Isolate redundant pipework. This Tip: Investigate electronic sequencing
In a typical 24-hour day, five and a is a common source of leakage. to minimise compressors going on-
half-day week, a 100kW motor will use Tip: Measure losses due to leakage and off-load
energy worth around 30,000/year and target reductions. Tip: Maintain the system missing a
(assuming the cost of electricity to be Reduce use maintenance check increases costs.
4.5p/unit. At these cost levels, an Compressed air is often misused Improve distribution
energy-efficient system is highly cost- because everyone assumes its cheap.
The longer the compressed air
effective, even if it costs slightly more Check every application to see
pipeline, the higher the pressure loss
to install. whether it is essential or simply
over the pipeline and the greater the
The cost of compressed air makes it convenient.
cost of the system.
an expensive resource and the way to Tip: Stop the use of compressed air
achieve the best savings is to minimise Tip: Make sure that pipework is not
for ventilation or cooling fans are
the demand and then to optimise the undersized. This causes resistance to
cheaper and more effective
airflow and pressure drops.
supply. Savings up to 30% can be Tip: Fit high efficiency air nozzles
made by inexpensive good the payback can be as short as four Tip: Use a ring main arrangement in
housekeeping measures such as months each building air can converge from
making end users aware of the cost of two directions. This reduces the
Tip: Consider the use of electric tools
generating compressed air and pressure drop and makes changes to
instead of compressed air tools
enlisting their help in reporting leaks. the system easier.
Tip: Do not use compressed air for
Tip: Avoid sharp corners and elbows
conveying granules or products.
Compressed air is an in pipework as these cause turbulence
Optimise the supply and thus increase pressure drops.
expensive resource.
Reduce generation costs Reduce treatment costs
Minimise the demand and The higher the compressed air Tip: Treat the bulk of air to the
then optimise the supply. pressure, the more expensive it is to minimum quality necessary, e.g. 40 m
provide the air. Twice the pressure filters are usually sufficient. Specifying
Minimise demand means four times the energy cost. The 5 m will increase filter purchase cost,
real needs may be lower than you are replacement frequency and pressure
Reduce leakage supplying. In some cases, the machine drop.
A significant amount of energy is rating is for a 7 bar supply but pressure Tip: Test filters regularly to make sure
wasted through leakage. Typically, reducers are fitted inside the machine. the pressure drop does not exceed
leak rates are up to 40% (i.e. 40% of Tip: Check that compressed air is not 0.4 bar. Replace the filters if the
pressure drop is higher than 0.4 bar;
the cost of power to overcome this
drop is usually greater than the cost of
a filter.
Tip: Manual condensate traps are
Maintenance Cost
often left open and act as leaks.
Energy Cost 15% Consider replacing them with
electronic traps.
75% Tip: Compressed air is not free and
10% you can save at least 30% of the costs
of compressed air by simple
Capital Cost management systems and
maintenance. Start now by contacting
the Action Energy helpline on
0800 58 57 94 for free information on
how to reduce your costs.
Whole life costs for compressors (10 year life cycle)
9
Energy efficiency in ceramics processing
10
Free Action Energy publications for the ceramics sector
See The Essentials: Ceramics for full details of these publications.
Ceramics specific information
GPG164 Energy efficient operation of kilns in the ceramics industries
GPG244 The use of low thermal mass materials and systems in the ceramic industry
GPG252 Burners and their controls
GPG253 A manager's guide to optimising furnace performance
GPG013 Waste heat recovery from high temperature gas streams
GPG248 Energy efficient operation of dryers in the ceramics industry
ECG061 Energy consumption in the ceramics industry
GPCS345 Energy management techniques in the pottery industry
General
GIR063 Energy management pathfinder
EMMA98 The Energy ManageMent Advisor
FOCUS The managers guide to reducing energy bills
GPG316 Undertaking an industrial energy survey
Motors and drives
GPG002 Reducing energy consumption of electric motors and drives
GIL056 Energy savings from motor management policies
GIR079 QUICKSTART your fast track to energy savings in electric motor systems
GPG014 Retrofitting ac variable speed drives
GPG249 Energy savings in industrial water pumping systems
GPCS088 Variable speed drives on water pumps
GPCS170 Variable speed drives on process plant
GPCS222 Purchasing policy for higher efficiency motors
GPCS232 Variable speed drives on fans
GPCS270 Variable speed drives on a cooling tower induced draught fan
Compressed air
GPG126 Compressing air costs
GPG216 Energy saving in the filtration and drying of compressed air
GPG238 Heat recovery from air compressors
GPG241 Energy savings in the selection control and maintenance of air compressors
ECG040 Compressing air costs generation
ECG041 Compressing air costs leakage
ECG042 Compressing air costs treatment
GPCS136 Cost and energy savings achieved by improvements to a compressed air system
GPCS346 Compressed air savings through leakage reduction and the use of high efficiency air nozzles
GPCS369 Compressed air leakage reduction through the use of electric condensate drain traps
GPCS380 The use of variable speed drives in the ceramics industry
Buildings
GPG158 Energy efficiency in lighting for industrial buildings a guide for building managers
GPG160 Electric lighting controls
GPG182 Heating system option appraisal a managers guide
GPG303 The designers guide to energy-efficient buildings for industry
GPG304 The purchasers guide to energy-efficient buildings for industry
ECG019 Energy use in offices
ECG081 Benchmarking tool for industrial buildings heating and internal lighting
GPCS157 Lighting in warehouses
GPCS158 Lighting in factories
GPCS295 Energy efficiency in refurbishment of industrial buildings
GPCS307 Energy efficient lighting in a high precision components factory
GPCS309 Energy efficient lighting in industrial buildings
GIR047 Controlling energy use in buildings
Policy and management
GPG067 Energy champions
GPG069 Investment appraisal for industrial energy efficiency
GPG075 Financial aspects of energy management in buildings a summary
GPG084 Managing and motivating staff to save energy
GPG085 Energy efficiency training and development
GPG133 Energy efficiency in the workplace a guide for managers and staff
GPG172 Marketing energy efficiency - raising staff awareness
GPG186 Developing an effective energy policy
GPG235 Managing people, managing energy
GPG251 Maintaining the momentum: sustaining energy management
GPCS214 Energy saved by raising employees awareness
GPCS289 Team building and energy saving
To obtain copies of these publications, call the Helpline on 0800 58 57 94 or visit www.actionenergy.org.uk.