Absorption Heat Pump for Ceramic Firing Energy Recovery
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Solution Overview
Problem
The ceramics industry faces significant energy losses due to thermal energy being wasted as moist, heated exhaust air in dryers and as waste heat in furnaces, particularly in times of increasing energy costs and environmental concerns.
Innovation Solution
Implementing an absorption heat pump system that recycles thermal energy from dryer exhaust air and waste heat from furnaces by thermally coupling the dryer, furnace, and heat pump components, allowing for independent control of temperature and humidity in the drying process.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Productivity
If open convection dryers are used to dry blanks with hot air, then drying effectiveness is improved, but thermal energy is lost as moist heated exhaust air
Solution Approach 1:
The patent recovers thermal energy from dryer exhaust air by directing it through a heat exchanger to preheat incoming fresh air before it enters the dryer. This recovers the thermal energy that would otherwise be discarded with the moist exhaust air, reducing the fuel required for heating while maintaining drying effectiveness.
Solution Approach 2:
The patent introduces a heat exchanger as an intermediary device between the exhaust air system and the fresh air supply. This heat exchanger mediates the thermal energy transfer from the warm exhaust air to the cooler incoming air, enabling energy recovery without direct mixing of air streams.
2Productivity
If cooling air is supplied to the furnace to cool burned blanks, then cooling effectiveness is improved, but thermal energy is lost as hot exhaust air
Solution Approach 1:
The patent recovers waste heat from the furnace cooling air by directing it through a heat exchanger to preheat the cooling air before it enters the furnace. This recovers thermal energy that would otherwise be lost with the hot exhaust air, reducing fuel consumption while maintaining cooling effectiveness.
Solution Approach 2:
The patent introduces a heat exchanger as an intermediary between the furnace cooling air system and the incoming cooling air supply. This device mediates heat transfer from the warm exhaust air to the cooler incoming air, enabling energy recovery without direct contact between air streams.
3Productivity
If fuel is used to heat the dryer, then drying process is maintained, but CO2 emissions increase
Solution Approach 1:
The patent recovers thermal energy from exhaust air streams (both dryer and furnace) and redirects it through heat exchangers to preheat incoming air. This reduces the amount of fuel required to heat the air for drying and cooling processes, thereby reducing CO2 emissions while maintaining drying process effectiveness.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
This approach reduces the fuel required for heating, decreases CO2 emissions, and enhances energy efficiency by reusing thermal energy, making the process more environmentally friendly and cost-effective.
Implementation Method 1
an absorption heat pump (4) with an evaporator (5), a condenser (6) and an expeller (7) has that the evaporator (5) and an exhaust air system of the dryer (2) are thermally coupled, that the condenser (6) and a heat supply of the dryer (2) are thermally coupled and that the expeller (7) and the oven (3) are thermally coupled
Implementation Method 2
the evaporator (5) and an exhaust air system of the dryer (2) are thermally coupled, that the condenser (6) and a heat supply of the dryer (2) are thermally coupled and that the expeller (7) and the oven (3) are thermally coupled
Implementation Method 3
the evaporator (5) and an exhaust air system of the dryer (2) are thermally coupled
Implementation Method 4
the condenser (6) and a heat supply of the dryer (2) are thermally coupled
Implementation Method 5
the expeller (7) and the oven (3) are thermally coupled
Data Source
Figure 1
AI summary
In a method for operating a plant (1) for firing ceramic blanks comprising a dryer (2), a kiln (3) and an absorption heat pump (4) with an evaporator (5), a condenser (6) and a desorber (7), wherein blanks are dried in the dryer (2) and dried blanks are fired in the kiln (3), it is proposed that heat energy from an exhaust air system of the dryer (2) is supplied to the evaporator (5), that heat energy from the condenser (6) is supplied to the dryer (2), and that waste heat from the kiln (3) is supplied to the desorber (7).