energy saving and energy efficiency

ENERGY SAVING AND
ENERGY EFFICIENCY
ENERGY SAVING AND ENERGY EFFICIENCY
Since the outset, ITC has conducted R&D and technology consulting activities on energy issues in the ceramic and related
industries. In 2006, given the sector’s growing interest in energy saving and energy efficiency, ITC set up a specific work
group, the Energy Unit, devoted to this line of action.
The Unit provides technological consulting on energy saving in the ceramic manufacturing process. In addition, the Unit
is participating in the performance of R&D&I projects on the optimisation and diversification of energy consumption at the
companies, as well as in customised training activities.
ITC, in general, and the Energy Unit, in particular, are aware of the importance of energy saving in industry, not only with
a view to enhancing company competitiveness but also to helping achieve certain common sustainable development and
social commitment policies.
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The Instituto de Tecnología Cerámica (ITC) is a concerted mixed Institute, established by agreement between the Ceramic Industry Research Association (AICE) and Universitat Jaume I of Castellón, which originated in 1969 in response to the needs of companies from the
Spanish ceramic cluster. In its long track record, ITC has articulated a successful university–business cooperation system that has contributed significantly to the development of the Spanish ceramic tile manufacturing industry.
ITC’s mission is to provide solid support for Spanish ceramic companies in the defence and enhancement of their strategic positioning in
the current global context, principally through innovation-enabling research and development actions, but also through whatever activities
may serve to foster the competitiveness and growth of the sector, always based on sustainability criteria and commitment to the well-being
of society.
ITC’s vision is focused on spearheading technology innovation and design processes in the Spanish ceramic sector, anticipating market
and consumer needs regarding the uses and applications of ceramic materials, through professionalised management of a qualified human
team committed to excellence in the sector.
The Unit’s energy-saving and energy-efficiency services include the following:
• Performance of energy audits
• Studies of energy reuse or recovery in industrial plants
• In a facility: kilns, dryers, spray dryers
• Between facilities: heat recovery
• Optimisation of energy consumption in industrial kilns
• Customised training
The manufacture of ceramic products such as ceramic tiles or structural ceramics (roofing tiles and bricks) requires
a great quantity of thermal energy. Ascertaining which energy-saving actions could be implemented in the manufacturing
process, in order to optimise energy consumption and enhance overall energy efficiency, is of vital interest to ceramics
manufacturers.
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In this regard, some of the tests conducted to study the particular situation of each facility are briefly summarised below:
• Determination of industrial firing cycles
• Determination of static pressure curves in industrial kilns
• Determination of oxygen partial pressure curves in industrial kilns
• Measurement of transverse temperature gradients in single-deck roller kilns
• Analysis of excess air at the burners
• Determination of drying curves in industrial dryers
• Measurement of relative humidity in industrial dryers
• Measurement of gas stream flow rates
• Energy balances of industrial facilities: spray dryers, ceramic tile dryers and kilns, dryers and tunnel kilns for ceramic
ware
• Analysis of heat losses by thermographic images
In addition, the Energy Unit is participating in R&D activities searching for alternatives to the use of natural gas, a fuel of
fossil origin, in the ceramic manufacturing process in order thus to reduce the industry’s environmental impact. The work
being conducted includes:
• Analysis of the use of hydrogen in the ceramic tile manufacturing process
• Study of the application of current CO2 capture and storage techniques in the ceramic sector
At present, the Energy Unit is participating in the Spanish Hydrogen and Fuel Cell Technology Platform (PTE-HPC),
and is currently entering the Spanish Energy Efficiency Technology Platform (PTE-EE).
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AVAILABLE EQUIPMENT
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Discontinuous analyser of combustion gases (O2, CO, NOx, SO2)
On-line CO2 measurement system
Gas flow rate measurement equipment: Pitot tubes, thermocouples, pressure gauges
Thermographic chamber for the obtainment of thermographs and non-contact determination of surface temperature
• Capacitive hygrometer for the determination of moisture content in gas streams
• Device for on-line temperature measurement inside the dryer
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R&D PROJECTS COFINANCED WITH PUBLIC FUNDING
Central Government of Spain
Published articles
FIT-120000-2006-1 – Reduction of corporate energy costs using cogeneration by
hydrogen generation (2006-2007)
Cantavella, V.; Moreno, A.; Mezquita, A.;
Llorens, D.; Barberá, J.; Palanques, A.
Distribución de temperaturas en el interior
de una pieza durante la cocción industrial.
Cerámica Información, 331, 61-68, 2006.
REN2003-09247-C04-04 - Application of
solar energy in ceramic materials processing
(2000-2003).
Autonomous Government of
Valencia
IMIDIC/2007/117 – Environmental Sustainability in the ceramic industry (2007-2008)
IMDITE/2007/13 - Competitive Intelligence
System: Energy and Environment Observatory (2008)
Mallol, G.; Mezquita, A.; Llorens, D.; Jarque,
J.C.; Sahún, J.; Valle, F. Estudio de la
operación de secado de los soportes de las
baldosas cerámicas en secaderos verticales. Técnica Cerámica, 304, 805-817, 2002.
Enrique, J.E.; Mallol, G.; Monfort, E.; Cantavella, V. Racionalización de energía en
hornos de cocción de baldosas cerámicas.
Cerámica y cristal, 124, 21-32, 1998.
Moreno, A; Mallol, G.; Llorens, D.; Enrique,
J.E.; Ferrer, C.; Portolés, J. Estudio de los
gradientes transversales de temperatura en
un horno monoestrato en diferentes condiciones de operación. Cerámica Información,
229, 29-36, 1997.
Ferrando, F.; Llorens, D.;Enrique, J.E.; Moreno, A.; Negre, P. Desarrollo de un equipo
para la determinación de la distribución de
temperaturas en el interior de secaderos de
baldosas. Técnica Cerámica, 244, 418-420,
1996.
Jarque, J.C.; Moreno, A.; Enrique, J.E.;
Barba, A. Optimización de las condiciones
de funcionamiento en hornos monoestrato
(IV). Mecanismos de transmisión de energía
calorífica. Técnica Cerámica, 247, 566-572,
1996.
Enrique, J.E.; Mallol, G.; Páramo, M.; Salvá,
E. Influencia de la evolución tecnológica sobre el consumo energético en la fabricación
de baldosas cerámicas. Cerámica Información, 222, 3-12, 1996.
Enrique, J.E.; Blasco, A.; Monfort, E.; Mallol,
G. Improving energy efficiency in singledeck kilns by optimization of the process
variables. cfi/Ber. DKG, 72(5), 255-260,
1995.
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Ferrer, C.; Llorens, D.; Mallol, G.; Monfort,
E.; Moreno, A. Optimización de las condiciones de funcionamiento en hornos monoestrato (III). Medida de gradientes transversales de temperatura. Técnica Cerámica, 227,
653-662, 1994.
Blasco, A.; Enrique, J.E.; Mallol, G.; Monfort,
E. Optimización de las condiciones de
funcionamiento en hornos monoestrato
(II). Caudal de aire de combustión. Técnica
Cerámica, 218, 716-729, 1993.
Timellini, G.; Blasco, A. Energy Consumptions and carbon Dioxide Emissions in the
Ceramic Tile Sector: Italy and Spain. Ceram.
Acta, 5(1/2), 41-50, 1993
Blasco, A.; Carda, L.; Mallol, G.; Monfort,
E. Optimización de las condiciones de
funcionamiento en hornos monoestrato (I).
Curva de presiones. Técnica Cerámica, 206,
585-593, 1992.