Project Description

Decarbonation on the dryer part only: 615 tons of CO2 saved considering an emission rate of 0.168 kgCO2/kWhth consumed and 0.0339 kgCO2/kWhe produced

Energy savings on the dryer part alone: 2,500 MWh saved per year, i.e. 10%.

Location: Valence d’Agen – Tarn et Garonne (82) – Occitanie – France

Client: Villeroy & Boch

Sector : Ceramics

Needs – customer requests:

The feasibility study carried out for this client aims to study:

  • The energy recovery paths identified with regard to the site’s facilities;
  • The solutions identified by Eco-Tech Ceram in order to optimize the energy efficiency of the various installations studied.

This study focused on the renovation of the plant’s dryers, the recovery of waste heat from the compressors and the insulation of the slurry and enameling tanks.

Project issues:

Analyze the available waste heat sources, the energy requirement and the improvement in the efficiency of the equipment listed above.
As a result of this characterization, Eco-Tech Ceram sought the most relevant solutions to satisfy the energy requirement as much as possible and/or improve the energy efficiency of the workstations studied.
Each of the solutions was presented to the client via a complete report respecting Ademe ‘s specifications on the feasibility studies.

Eco-Tech Ceram achievements:

Each waste heat recovery solution has been studied in such a way:

  • Study of the customer’s compressor station, optimization of its operating points
  • Sizing of a 2m3 storage tank
  • Hydraulic study upstream of the balloon to send the cooling water from the various compressors
  • Aeraulic and thermal study downstream of the balloon: water network integrating three unit heaters (heating of premises) and three exchangers (hybridization of boilers). Total power exchanged = 200kW.
  • Solution design
  • Energy and environmental balance
  • Costing of the solution
  • Economic study of the solution and financial arrangement

Each energy efficiency improvement solution has been studied in such a way:

  • Study of dryers in detail and research of heat losses
  • Repair of insulation, defective parts and thermal bridges
  • Approach to possible savings, comparison to conventional ceramic drying
  • Calculation of the solution for each dryer
  • Economic study of the solution and financial arrangement

Description of the proposed solution:

Interdependent achievements in heat recovery and energy performance in the production process (cooking + drying): Replacement of 11 aging dryers with 5 new, more efficient technology dryers powered by waste heat recovery from the tunnel kiln.