CDS GROUPCERAMIC DRYING SYSTEMS

WASTE HEAT RECOVERYAND

HEAT UTILIZATION SYSTEM

“The World Leading Experts on Drying Ceramics.”

Why recover waste heat?In many cases the amount of waste heat recovered from the kilns is

sufficient to satisfy the heat demands of the Ware Dryers and Mould Dryers as well as providing enough energy to heat the workshops via Air Handling Units.

The system can be used for both continuous Tunnel kilns and intermittent Shuttle Kilns

The system can be applied to both existing and new Kilns and then utilized into either new or existing Dryers and equipment.

The system can be installed with virtually no disruption to the factory process.

The return on investment period can be as little as two years, with every Kw of energy saved after than being a direct contribution to profit.

What can CDS offer?Design, consultation and feasibility study concerning

the viability of the project.

Factory survey identifying the potential energy users.

Report of the Investment return period.

Flexibility of contract structure.– Complete equipment supply from the UK or part ‘local’ content.– Supervision of ‘local’ labour or complete installation by CDS.– Selection of control options.

Comprehensive commissioning service.

After sales service from the UK contribution to profit.

Q: Where can the waste heat be claimed from?

A: Waste heat can be reclaimed from all available sources on both Tunnel Kilns and Shuttle Kilns. Depending on the design of Tunnel Kiln, waste heat can be recovered from the ‘cooling’, ‘centre’ and ‘exhaust’. On Shuttle Kilns, heat is recovered during the cooling part of the curve.

Q: What medium is used to convey the recovered energy?

Photos show waste heat being collected from a Tunnel Kiln and distributed into Dryers and a pre-kiln Glaze Dryer with residual used for space heating the factory via Air Handling Units.

A: The heat may either be transferred in the form of ducted ‘hot air’ or alternatively by means of hot water via pipe work. When used to heat dryers, the hot water system is preferable so as not to compromise the humidity balance within the dryers. Also transferring a large mass of energy is usually uneconomical using ductwork.

CDS GROUP

Q: How does the system work?

A: The following diagrams show:-• How the ‘waste’ heat is recovered,• How the ‘waste’ heat is transferred, • How the ‘waste’ heat is utilized.

Factory Network Providing VPN Connection

for Remote Access

Ethernet Switch

Allen BradleyPanel View C600 HMI

Set point and process variable monitoring

PLC

Ware Dryers

RSView SCADA PC

Located ‘remote’ from the users

Mould Dryers Environmental Heat Recovery systems

Ethernet to PLC’s

PLC PLC PLC

Typical Control Architecture

Ware Dryers

Air Handling Units

Mould Dryers

* Waste heat may be used for Mould drying

Pre-Kiln Glaze Dryers

* Waste heat may be used for Pre-Kiln Glaze drying

Heat Recovery DataYEARLY FIGURES (based on 1 x 7 day working week per month)

High Temp Circuit (kw/hr's) Low Temp Circuit (kw/hr's)Month Waste Heat Available Total of Heat Users Surplus Heat Additional Heat

Required Waste Heat Available Total of Heat Users Surplus Heat Additional Heat Required

January 217,710 321,743 5,932 65,821 170,324 340,234 5,644 205,021February 217,710 311,872 7,321 54,993 172,325 310,652 5,644 165,032March 217,710 291,263 11,032 49,321 173,654 245,823 5,644 112,032April 217,710 264,924 16,832 38,112 168,554 158,773 6,435 60,145May 217,710 239,015 20,883 25,734 165,923 125,712 7,432 35,003June 217,710 227,774 22,732 24,987 167,083 105,982 12,732 20,821July 217,710 226,046 23,463 25,832 167,367 116,003 15,943 20,043

August 217,710 233,821 24,632 27,635 166,943 138,664 14,843 35,773September 217,710 239,732 21,772 29,863 165,773 169,663 6,437 43,921October 217,710 262,811 17,663 36,832 168,345 200,735 5,644 77,447November 217,710 290,212 7,322 48,721 173,882 252,994 5,644 133,932December 217,710 311,084 5,232 57,021 171,992 318,643 5,644 183,032TOTALS = 2,612,520 3,220,297 184,816 484,872 2,032,165 2,483,878 97,686 1,092,202

YEARLY FIGURES (based on 338 days per annum)High Temp Circuit (kw/hr's) Low Temp Circuit (kw/hr's)

Month Waste Heat Available Total of Heat Users Surplus Heat Additional Heat Required Waste Heat Available Total of Heat Users Surplus Heat Additional Heat

RequiredJanuary 876,024 1,294,633 23,869 264,851 685,351 1,369,037 22,710 824,965February 876,024 1,254,914 29,458 221,281 693,403 1,250,004 22,710 664,057March 876,024 1,171,987 44,391 198,458 698,751 989,145 22,710 450,795April 876,024 1,066,004 67,729 153,355 678,229 638,872 25,893 242,012May 876,024 961,751 84,029 103,549 667,643 505,841 29,905 140,845June 876,024 916,519 91,469 100,543 672,310 426,451 51,231 83,780July 876,024 909,566 94,411 103,943 673,453 466,774 64,152 80,649

August 876,024 940,851 99,114 111,198 671,747 557,958 59,725 143,944September 876,024 964,636 87,606 120,163 667,039 682,692 25,901 176,730October 876,024 1,057,501 71,073 148,205 677,388 807,719 22,710 311,632November 876,024 1,167,758 29,462 196,044 699,668 1,018,000 22,710 538,917December 876,024 1,251,743 21,053 229,442 692,063 1,282,159 22,710 736,486TOTALS = 10,512,283 12,957,862 743,664 1,951,033 8,177,045 9,994,652 393,070 4,394,813

Total Combined Waste Heat Available = 18,689,328 kw/hr's

HT Waste Heat Utilised = 9,768,618 kw/hr's LT Waste Heat Utilised = 7,783,975 kw/hr's%age HT Waste Heat Utilised = 92.93% %age LT Waste Heat Utilised = 95.19%

HT Additional Energy Req'd = 1,951,033 kw/hr's LT Additional Energy Req'd = 4,394,813 kw/hr's

MAXIMUM AVAILABLE HEAT RECOVERY PER YEAR = 18,689,328 kw/hr'sCOMBINED USAGE OF HEAT RECOVERY PER YEAR = 17,552,594 kw/hr's%age WASTE HEAT UTLISATION IN THE DRYERS = 93.92%

SURPLUS ENERGY PER YEAR = 1,136,734 kw/hr'sADDITIONAL ENERGY REQUIRED PER YEAR = 6,345,845 kw/hr's

Note: The surplus 6.08% heat can be used for ancillary heating such as canteen, office space, warehouse etc...

Heat Recovery Data

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

JanuaryFebruaryMarch April May June July AugustSeptemberOctoberNovemberDecember

Kw

/Hr's

per

mon

th

High Temperature Circuit

Waste Heat Available Total of Heat Users

Surplus Heat Additonal Heat Required

0

200,000

400,000

600,000

800,000

1,000,000

1,200,000

1,400,000

JanuaryFebruaryMarch April May June July AugustSeptemberOctoberNovemberDecember

Kw

/Hr's

per

mon

th

Low Temperature Circuit

Waste Heat Available Total of Heat Users

Surplus Heat Additonal Heat Required

Payback Period• Maximum available heat recovery per annum = 18,689,328 kw/hr’s• Combined usage of heat recovery per annum = 17,552,594 kw/hr’s• Percentage waste heat utilisation in the factory = 93.92%• The remaining 6.08% waste heat can be used in the warehouse,

canteen, offices etc…• Surplus energy per annum = 1,136,734 kw/hr’s• Additional energy required per annum = 6,345,845 kw/hr’s• Assumed cost of natural gas per kw = $0.033

• Estimated annual fuel cost saving = $579,236• Investment cost for waste heat system = $1,500,000

• Return on investment period = 2.59 years

CDS GROUPThere can be NO

COMPROMISE when it comes to QUALITY &

RELIABILITY.