Decarbonization: 158 tonnes of CO2 saved, based on an emission rate of 0.241 kg of CO2/kWh consumed.
Energy savings: 654 MWh saved per year, i.e. 20%.
Productivity gain: Estimated by the customer at 5%.
Location : Meymac (19) – New Aquitaine – France
Céramiques et développement – Tegulys
Sector : Ceramics
Needs – customer requests :
The feasibility study carried out for the
Céramiques et Développement – Tegulys
site in Meymac was to study the recovery of high-temperature waste heat from a kiln. The idea was to recycle it to the plant’s dryer. Eco-Tech Ceram decided to implement a storage solution.
The study took into account a potential gain in productivity by studying in a second time the implementation of a pre-cooking chamber fed exclusively by the available waste heat. As a result, the firing cycle would be reduced, allowing more kiln cycles per year.
This part will be refined in a second study, the results presented take into account the current production and a complete recovery of the waste heat towards the dryer.
Project progress :
- Analysis of the fatal heat source of the baking oven via a measurement campaign
- Analysis of the energy needs of the dryer via the operation of its burner
Following this characterization, Eco-Tech Ceram sought the most relevant solutions to satisfy energy needs as much as possible. As this is out of phase with the heat source, a storage solution was chosen. In view of temperature levels (>500°C),
the Eco-Stock® solution
solution was chosen.
Two solutions with or without taking into account the customer’s productivity gain were presented to the customer via a complete report.
Eco-Tech Ceram achievements :
- Identification of cooking cycle periods where the fatal heat is greater than 500°C
- Sizing of an Eco-Stock® solution : storage capacity of 1300 kWh
- Aeraulic study on the smoke system network: sizing of the fans
- Thermal study on the smoke system network: validation of calculations with insulator specialists
- Study of the energy repercussions on the various stations of the factory following an increase in production
- Plant-wide energy and environmental balance sheet
- Economic study of the solution and financial arrangement
- Design of the solution and implementation of the proposed solution
- Site supervision, commissioning and performance monitoring
Description of the proposed solution:
The chosen solution is to recover the waste heat contained in the fumes from the 8m3 furnace, using Eco-Stock® technology to offset the time lag between the source and the need. The need served here is the drying of clay products before the firing process, which no longer requires fossil energy to be realized. In addition, the dry heat produced by theEco-Stock® increases productivity by enabling products to be dried more quickly.
Feedback after 36 months of use:
We note a positive difference of 2% between what was forecast in the feasibility study and the actual situation in 2022.
These results will surely be improved with the implementation of the pre-cooking oven, but the study has not yet been conducted.