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S U C C E S S S T O R YMULTI-KILN SANITARYWARE PROJECT

ENERGY OPTIMIZATION IN INDUSTRIAL KILNS WITH OUR ERS

NEW TECHNOLOGIES FOR OUR

ENERGY RECOVERY SYSTEMS3R D E D I T I O N , F E B R U A R Y 2 0 1 9 C E R A M I C S S P E C I A L

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welcome to our latest e-bulletin. This has received much positive reaction since we started publishing it towards the end of last year. This month you will be able to read in some detail about what we are doing to ensure energy optimization – a crucial part of the picture – and also how our advanced technology and wide expe-rience have ensured product uniformity and excellence in the ceramic sanitaryware sector.

In fact, the Ceramics Business Unit has been extremely busy across a number of product areas, not only sanitaryware but also technical ceramics and steel refrac-tories, for instance. The take-up of technical ceramics has continued to grow at a great rate, opening up more opportunities for our state-of-the-art systems, while raw steel production in 2018 was up 4.6% over 2017 and we benefit from being able to offer specialty kilns at the product end, for continuous casting refractories, slide gates and similar elements.

Many of these projects have been taking place in busy markets in North America, Mexico and Europe; however, we have increasingly been asked to look at new ma-nufacturing facilities and expansions in Asia. Southeast Asia and India, in particular, will be an area on which we are closely focusing this year.

Reading all about our latest developments here provides you with what I might call a ‘taster’, but we would like to meet up with you all as well. Please don’t forget that we will be exhibiting at Thermprocess in Düsseldorf and representatives from our various business units will be on hand to discuss all those points that are important to you as you plan for the future.

I hope you enjoy reading this latest e-bulletin – your feedback is always welcome!

EditorialRODRIGO GONZÁLEZ, VP CERAMICS

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Our industrial kilns are specially desig-ned to optimize energy efficiency by various means, one of the main oppor-tunities being the recuperation of heat normally lost through the exhaust flue during the combustion process.

With the goal of taking this a step forward – increasing the potential for the use and transfer of process heat – we have developed new technologies for our energy recovery systems (ERS).

These system enhancements allow the user to recover waste heat and to reuse it both in the kiln and in other plant processes, instead of simply ex-hausting it to atmosphere.

In the next section, we will talk more about these systems and the advanta-

ges they offer your production proces-ses.

HOW DO OUR KILN ERS SYSTEMS WORK?

The energy that is introduced into the kiln via the burners is typically used to heat the following:

• Heating the kiln walls• Heating the product• Heating the kiln furniture• Heating the kiln cars

The remaining energy is usually lost in what we term ‘loss to atmosphere’.

B Y R O D R I G O G O N Z Á L E Z

In an interview with our VP Ceramics, Rodrigo

González, we talked about the advantages and

benefits of the ERS offered by Nutec Bickley.

ENERGY OPTIMIZATION IN INDUSTRIAL KILNS WITH OUR ENERGY RECOVERY SYSTEMS

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What our heat recuperation systems seek to achieve is the reuse of the energy carried by the gases that nor-mally exit through the flue, in order to reduce gas consumption in a typical industrial heating process.

Example:The temperature of the kiln’s dischar-ge gases is 1000°C (1830°F), while when heat recuperation takes place we see this temperature reduce to 400°C (750°F), demonstrating that in reducing losses to atmosphere we are retaining more heat in the product/process, thereby achieving a more efficient operation.

This is extremely valuable for our custo-mers, since an ERS can generate savings in energy consumption of 25% to 30%.

HEAT RECOVERY SYSTEMS

At Nutec Bickley we offer three types of kiln ERS, each with different capa-cities and costs, tailored to the indivi-dual customer’s requirements:

1. HEAT EXCHANGERS

Typically we install these in the kiln flues, where via an indirect heat exchange we are able to preheat kiln combustion air to temperatures up to 500°C (930°F).

A couple of advantages offered by this system are:

• The preheated air that is injected into the kiln is clean and can be used for the combustion process.• It can be used with all our combustion systems, including IMPS®.

2. SELF-RECUPERATIVE BURNERS

This system achieves higher tempera-tures than preheated air produced via the heat exchanger method, reaching up to 750°C (1380°F).

Unlike the system in which we employ a central heat exchanger, each self-re-cuperative burner has its own heat ex-changer.

The energy savings over a system using a central heat exchanger are anything from 10% to 30%.

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Self-recuperative burners are compa-tible with our IMPS® system.

3. REGENERATIVE BURNERS

These represent the most efficient form of energy recovery in industrial kilns, as they can preheat combus-tion air to temperatures ranging from 900°C to 1000°C (1650°F to 1830°F).

These burners need to be installed in pairs. A limitation, however, on these burners is that they can only be used in applications characterized by high temperature and heat capacity.

BENEFITS OFFERED BY OUR ERS TECHNOLOGY

Nutec Bickley ERS prevents wasted energy and returns large quantities of energy back into the system, offering major advantages to our customers, such as:

• Systems compatible with all types of continuous and shuttle kilns.

• Easy to maintain.• No adverse effects on product qua-

lity.

• Operation with all Nutec Bickley combustion systems.

• Dramatic reduction in energy costs.• Not only for use in new kilns, but

also suitable for refurbishments.• Nutec Bickley’s high-level experti-

se and reliable performance, plus its wide ranging experience in kiln construction.

Here at Nutec Bickley, we are experts in the installation and customization of kiln energy recovery systems. Call us for a quote on a complete solu-tion or for an upgrade of your existing equipment, which will help you make the most out of your kilns and boost your profit.

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IN PLAY A QUICK ROUND-UP OF OUR LATEST PROJECTS

KILN RELINING OF TWO SHUTTLE KILNS

FABRICATION AND INSTALLATION OF 20 PYROLISIS FURNACES

• Location: USA • Industry or segment: Ceramic

Sanitaryware • Replacement of current insulation

system with Nutec Bickley’s new Jointless® Fiber System

• Location: Terre Haute, Indiana, USA• Currently the equipment is being

installed in the customer’s facilities• Normal Temperature: 800°C (1470°F)• Industry or segment: Recycling

Industry• Process: Pyrolysis process for Recy-

cling end-of-life car tires

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Nutec Bickley has continued to consolidate its leading position in the arena of ceramic kilns with the successful completion of a presti-gious contract for a world-renow-ned sanitaryware manufacturer with factories across the globe.

This led to three separate projects across two sites and involved the de-sign, manufacture and installation of two tunnel kilns and three shuttle kilns. As is standard with Nutec Bic-kley, the kilns were preassembled (complete for shuttles, in modules for tunnels) and also fully tested at the company’s Monterrey headquar-ters in Mexico, before transporta-tion, installation and commissioning.

Rodrigo González, Vice President – Ce-ramics, commented: “We have once again proved – with our advanced designs, attention to detail, high per-formance and reliability – that we are

the go-to kiln manufacturer for the world’s ceramic sanitaryware indus-try. We don’t push people down any predetermined design route; we work extremely closely with our customers, we understand all the important para-meters, and our team comes up with state-of-the-art, bespoke solutions. It’s the main reason for our continuing success.”

SHUTTLE KILNS The development of shuttle kilns for this customer has been an evolutio-nary process, with Nutec Bickley ha-ving already supplied to a different design some years ago. In the latest installations, the company was able to demonstrate that a new configuration could achieve at least what previous kilns had done, but at a reduced cost with enhanced temperature and pres-sure control.

S U C C E S S S T O R YSTAYING AT THE CUTTING EDGE

OF SANITARYWARE FIRING

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It is an ROI and performance success. The new design features a three-deck (rather than four-deck) configuration, with a setting area of 9m2, and as a result the total weight of the kiln fur-niture is reduced by 20% and the fuel usage is reduced by 7%. Furthermore, the same amount of pieces per kiln car can be fired as with existing kilns, with a useful loading volume per car of around 17m3. The capital cost of these shuttle kilns is also reduced.

With regard to combustion, the kilns employ Nutec Bickley’s proprietary IMPS® (integrated multi-zone pul-sing system), the benefits of which are lower fuel consumption (25% to 30% less than competitors’ kilns) and great temperature uniformity. The-se nine-car kilns typically have a fuel consumption of 1700-1800 Kcal/kg. Depending on load, configuration and cycle, other Nutec Bickley shuttles can achieve around 1400 Kcal/kg.

IMPS also offers the user a great deal of flexibility. In more conventional sys-tems, commonly used by other manu-facturers, where there is a low firing temperature they simply don’t ignite all the burners, but inevitably this leads to a lack of uniformity. With IMPS, Nu-tec Bickley can control from as low as 90°C (195°F) with all burners switched

on. A further effect of this is that there is a reduction in the use of excess air – excess air is only used when absolutely required.

Additionally, the system emplo-yed here is capable of having diffe-rent levels of internal pressure on every segment of the firing cycle. The pressure is monitored cons-tantly by the system and controlled by the ceramic louver type damper.

The kiln operation is based on three principal modes of heating, and equa-lly three modes of cooling. Secondary air is integrated into the kiln and this results in faster cooling, especially at the end of the cycle. The importance of this factor cannot be underestima-ted. In one other case, this feature has enabled the customer to achieve an additional 25 cycles per annum, equi-valent to an extra month’s produc-tion or, put another way, a production boost of more than 8%.

These kilns make full use of Nutec Bickley’s patented ceramic fibre Joint-less™ insulation modules, which can withstand temperatures up to 1350ºC (2460°F), providing for minimal main-tenance, improved fuel economy and extended service life. This is a one-pie-ce system that eliminates the joints between modules and also the spaces

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which are typically located in the ex-haust ports. It doesn’t need to be cove-red with cordierite which reduces fuel consumption.

TUNNEL KILNS

The sanitaryware tunnel kilns are around 120 metres long and are approximately 3.5 metres wide. They feature integrated car handling sys-tems, including automatic car weighing and therefore optimised load manage-ment. Product weight is approaching 250kg per car and the fuel consump-tion is in the 800-1000 Kcal/kg range. As with the shuttles, by using the di-fferent IMPS modes of operation, it is possible to achieve very good tempera-ture distribution throughout the whole firing cycle.

There is the option of recovering waste energy from the tunnel kiln ware cool exhaust, whereby the hot, cleanair coming from the tunnel kiln is used as preheated combustion air in the kiln burners. The pre-heated air canbe used on all heating segments whi-le the kiln is operating above 300°C (570°F). On a typical firing cycle, thiscan result in substantial fuel cost sa-vings.

Further enhancing efficiencies is the use of Nutec Bickley cordierite baffle

designs. This allows for a baffle tobe hung with a refractory hanging crank that can be exposed to elevated temperatures. In this way, thermalshock on the baffles and the danger of premature failure is avoided. On tun-nel kiln pre-heat zones and on thetransition between heating and coo-ling, cordierite baffles are installed to force the gases through the load,enhancing efficiency and temperature uniformity.

The sanitaryware tunnel kilns – equi-pped as they are with SCADA and ad-vanced control and monitoringsoftware – demonstrate high levels of functionality, added to which is the fact that they incorporate industrialcameras to record images of kiln cars that are planned to be loaded to a pre-defined limit. This real-time visualrecorder helps kiln operators to easi-ly identify cars that have been under-loaded.

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WE HOPE YOU’LL JOIN US AT ONE OF THESE EVENTS

Ceramics Expo 30 April - 1 May - Booth 518

Cast Expo 27-30 April

International Exposition Center (I-X Center) East Entrance, One I-X Center Drive Cleveland, Ohio 44135

Georgia World Congress Center Atlanta, Georgia

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Nutec Bickley will once again participate in the Thermprocess exhibition, taking place in Düssel-

dorf, Germany from 25-29 June 2019. This massively important event takes place just once every

four years and is part of an interlinked international trade fair quartet that also comprises GIFA,

METEC and NEWCAST.

Thermprocess is the platform for meetings and business for manufacturers in areas that are

central to Nutec Bickley’s activities. International buyers, users, experts and decision makers

from the metallurgy, heat technology and foundry industries come together in this bustling te-

chnology forum.

Some of the lead themes identified by the organisers include lowering energy costs in produc-

tion and reducing fuel costs through effective waste heat recovery systems. Nutec Bickley is an

expert voice in these departments and we look forward to discussing our advanced systems

with producers from all around the world.

There are a number of trends that we note with interest. The most recent Thermprocess news-

letter spoke about how aluminum is displacing steel in certain areas. It is lighter – making it

popular in the automotive sector, for instance, where we have substantial experience – while

the finished components can be cheaper due to advanced manufacturing methods and state-of-

the-art machinery. Nutec Bickley is very much part of the aluminum success story and we look

forward to showing visitors how our furnaces offer the very best options in the industry.

Nutec Bickley will exhibit at Thermprocess in Hall 10 on Stand A50. If you would like to

prearrange a meeting with our team, then please just e-mail us at jorgepina@nutecbic-

kley.com and state which day and what time would suit you.

THERMPROCESS25-29 JUNE

DÜSSELDORF, GERMANY

MAKE AN APPOINTMENT

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In December, as is our tradition at the end of each year,

Nutec Group organized its Bazar Nutec, where we start with

our employees gathering any objects from the home that they

no longer need or want to keep. Then, we carefully select

all those objects that might attract a bid and are in a good

enough condition for selling on.

The charity auction itself was carried out online, with a live

video link between Fibratec, Bickley and our headquarters.

Employees made their bids for objects that caught their eye

and the highest bids won out. This time around we donated

the proceeds to the Mater Filius center in Monterrey.

The Mater Filius centers offer assistance to pregnant women

in distress and so once again we benefited a very worthwhile

cause.

CHARITY AUCTION A SUCCESS ONCE AGAIN

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CHALLENGE

I N S T R U C T I O N S :

‘The first word you find reveals

what your 2019 will be like’

A U T O M O T I V E W H E E L M A R K E T C O U L D B E W O R T H $ 1 0 0 B I L L I O N B Y 2 0 2 4

The automotive wheel market is expected to grow from

USD 82 billion in 2017 to USD 100 billion by 2024, ac-

cording to a 2019 Global Market Insights, Inc. report.

Increasing vehicle sales coupled with shifting consu-

mer preference toward comfort and improved driving

experience will enhance the industry demand. Growing

popularity of corrosion resistant, lightweight, and high

strength parts are prominent product attributes that

will fuel the automotive wheels market growth through

the forecast period.

Source: Global Market Insights, Inc.

DID YOU KNOW?

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TQPMNALOER

SBEWTHDRGR

SLOPPIOIVO

THQJEEJALN

RJAHLAUMOS

WWANENPMAM

AULOVEQILL

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DO YOU NEED A QUOTE FOR ANY OF THESE SOLUTIONS?

Contact us and describe your project so that we can respond effectively. bulletin@nutec.com We look forward to hearing from you.