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Eliseo Monfort - One of the best experts on this subject based on the ideXlab platform.
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Beyond the energy balance: Exergy analysis of an industrial roller kiln Firing porcelain tiles
Applied Thermal Engineering, 2019Co-Authors: S. Ferrer, A. Mezquita, Vicente M. Aguilella, Eliseo MonfortAbstract:Abstract The ceramic tile manufacturing process consumes large amounts of energy, mainly in the Firing Stage. Firing usually takes place in natural gas-fuelled continuous roller kilns, the most widely used tile Firing facilities worldwide, which typically exhibit low energy efficiency (generally 5 to 20%). This paper investigates the application of energy and exergy balances to an industrial roller kiln Firing porcelain tiles in order to identify the most critical parameters affecting kiln energy efficiency and propose ways of improving kiln energy performance. The experimental kiln measurements and thermodynamic calculations confirmed the kiln’s low energy performance (15%). Exergy analysis showed that 83% of the total exergy input into the kiln was destroyed, only 10% of the exergy input being kept in the physico-chemical transformations of the ceramic tile composition. The main sources of irreversibilities: natural gas combustion, heat transfer in the fired tile cooling process, and heat transfer through the kiln surfaces, were identified and quantified. The study shows that waste heat (over 61%) recovery could be expected to significantly increase kiln energy performance. Finally, further measures are proposed for optimising kiln energy efficiency.
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Estimation of the heat of reaction in traditional ceramic compositions
Applied Clay Science, 2015Co-Authors: S. Ferrer, A. Mezquita, M.p. Gómez-tena, C. Machi, Eliseo MonfortAbstract:Abstract Most energy studies on the traditional ceramic manufacturing process focus on the Firing Stage because this is the process Stage that consumes the greatest amount of thermal energy. At present in Europe, using typical technologies, about 50% of the energy input in the Firing Stage is still lost through the kiln stacks. A key issue in energy studies is the accurate determination of the energy efficiency of the process, an issue that may become crucial in coming years to enable the energy management of different facilities and products to be compared. To reliably determine energy efficiency, accurate determination is required of the energy needed for the necessary physico-chemical transformations to develop in the material in the Firing Stage. This energy is also the only strictly unrecoverable energy, as the energy contained in other streams could, potentially at least, be partly recoverable. The present study was undertaken to develop an analytical methodology for estimating the heat of reaction of seven different traditional ceramic products, involving a broad spectrum of compositions, with peak Firing temperatures ranging from 850 °C to 1200 °C. The following industrial ceramic compositions were studied: four ceramic tile compositions (red-body stoneware tile, porcelain tile, red-body earthenware wall tile, and white-body earthenware wall tile); two structural ceramic compositions (white brick and roof tile), and a porcelain tableware composition. To estimate the energy involved in the physico-chemical reactions in the Firing Stage, an analytical methodology was developed, based on the mineralogy data of the unfired body composition and on the enthalpy of formation of the minerals in the fired tiles. The methodology was validated by comparing the results with experimental data.
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Cleaner production of porcelain tile powders. Granule and green compact characterization
Ceramics International, 2012Co-Authors: Zhu Shu, Eliseo Monfort, J. Garcia-ten, J.l. Amorós, Jun Zhou, Yongqian WangAbstract:Abstract A new ceramic powder preparation process, the droplet–powder granulation process (DPGP), was recently proposed in pursuit of energy/water conservation and environment protection for sustainable development of the ceramic industry. This study characterizes the DPGP granules and resulting pressed green compacts and compares them with those obtained using traditional spray-drying (hereafter SD) and granulation (hereafter G) processes. Powder and granule properties (granule size distribution, flowability, microstructure, yield pressure, etc.), powder pressing behaviour, and green compact properties (microstructure, bending strength, etc.) were determined. The properties of the DPGP powder and the resulting compacts displayed an intermediate performance between those of the powders and compacts obtained by the SD and G processes, demonstrating the feasibility of the DPGP process in the pre-Firing Stage of porcelain tile manufacture. The study also shows that, in addition to the key spray-mixing step, the subsequent rolling treatment also plays a major role in DPGP granule formation.
Sergio Neves Monteiro - One of the best experts on this subject based on the ideXlab platform.
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clay bricks added with effluent sludge from paper industry technical economical and environmental benefits
Applied Clay Science, 2016Co-Authors: Carlos Mauricio Fontes Vieira, Verônica Scarpini Candido, Regina Maria Pinheiro, Ruben Jesus Sanchez Rodriguez, Sergio Neves MonteiroAbstract:Abstract Recently, it was indicated that a feasible industrial alternative to valorize the sludge obtained from the treatment of waste water effluent of paper fabrication in Europe is its use as raw material in the production of clay bricks. The present technical note is an open report, probably first in Americas, on a Brazilian industrial-scaled solution for this kind of sludge. As a novelty, the sludge was added to a mixture of clays for improved technical properties of construction bricks. Both bricks, added with 10 wt% of sludge and conventional pure clay bricks for comparison, were simultaneously fired at a relatively low temperature of 750 °C according to the ceramic fabrication procedure. The technical characterization was performed by linear shrinkage, water absorption and mechanical compression tests as per Brazilian standards. The brick consolidated structure was analyzed by optical microscopy. Environmental impact was evaluated by solution test and atmospheric emission by monitoring the release of SO2, NOx, TOC, CO and particulate material, according to Brazilian standards. The results showed that, owing to its composition and Firing temperature, the addition of paper sludge into clay bricks contributes to a substantial reduction in price associated with a saving of 3% of fuel similar to that reported for Spanish kilns, during the industrial Firing Stage. The paper sludge added clay bricks attended the technical and environmental standards.
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Rewas 2016: Towards Materials Resource Sustainability - Incorporation of Sewage Sludge into Heavy Clay Ceramic Body
REWAS 2016, 2016Co-Authors: Carlos Mauricio Fontes Vieira, Isabela Oliveira Rangel Areias, Sergio Neves MonteiroAbstract:This work has as its objective to evaluate the use of sewage sludge from wastewater treatment plant into heavy clay ceramic body. Compositions were prepared with amounts of 0, 2.5, 10 and 15 wt.% of sludge incorporated into the clay body. Rectangular specimens were obtained by 20 MPa pressure molding and then fired at 850°C in a laboratory furnace. Characterization of the waste was done by X-ray-fluorescence, differential scanning calorimetry and thermogravimetric analysis. Ceramic properties related to the water absorption and compression strength were determined. The results indicated that the incorporation of the sludge into clay bricks must be done in low amounts. In higher amounts the sludge increases the water absorption and reduces the mechanical strength of the ceramic. This is a consequence of the changes caused in the porosity by the relatively elevated weight loss of the waste during the Firing Stage.
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Evaluation of CO and CO 2 Emitted in the Firing of Clay Ceramics Incorporated with Elephant Grass Ash.
Materials Science Forum, 2014Co-Authors: Aline Da Silva, Sergio Neves Monteiro, Roberto Da Trindade Faria, Rosane Toledo, Verônica Scarpini Candido, Carlos Mauricio Fontes VieiraAbstract:Several environmental studies have been dedicated to the correct management of industrial residues. The conventional clay ceramic productive sector became, in past decades, a growing alternative for these residues through their incorporation in products such as bricks and tiles. The Firing temperatures for ceramic sintering usually transform the incorporated residue into an inert microstructural phase. In some cases, the residue may even improve the ceramic properties. However, during the Firing Stage, polluting gases might be emitted causing environmental impact. Therefore, the objective of the present work was to evaluate the gases emitted during sintering of a clay ceramic incorporated with 10 and 20 wt% of elephant grass ashes. The emission was investigated for Firing temperature in the interval from 250 to 1100oC and the gases analyzed by photothermic technique. The ash incorporation promoted a significant increase in the emission of greenhouse gases such as CO and CO2.
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incorporation of sludge waste from water treatment plant into red ceramic
Construction and Building Materials, 2008Co-Authors: Sergio Neves Monteiro, Jonas Alexandre, J I Margem, R Sanchez, Carlos Mauricio Fontes VieiraAbstract:Abstract The influence of the Firing temperature on the technological properties of red ceramics made of a kaolinitic clay incorporated with a sludge from water treatment plant was evaluated. The sludge was initially submitted to characterization tests to determine its particle size distribution, chemical composition, mineralogical composition, thermal behavior and morphological aspects. Mixtures were prepared with amounts of 0, 3, 5 and 10 wt% of sludge incorporated into the clayey body. Rectangular specimens were obtained by 20 MPa pressure molding and then fired at 700, 900 and 1100 °C in a laboratory furnace. Ceramic properties related to the bulk density, linear shrinkage, water absorption and flexural rupture strength were determined. The results indicated that the incorporation of the sludge increase the water absorption and reduce the mechanical strength of the clayey fired ceramic. This is a consequence of the changes caused in the porosity by the relatively elevated weight loss during the Firing Stage.
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Effect of grog addition on the properties and microstructure of a red ceramic body for brick production
Construction and Building Materials, 2007Co-Authors: Carlos Mauricio Fontes Vieira, Sergio Neves MonteiroAbstract:Abstract In the present paper crushed fired brick waste, known as grog, was used in mixtures with clayey body to make typical red ceramics for bricks. The effect of the grog addition up to 20 wt% on the extrusion Stage as well as on properties and microstructure of bricks fired at 700 °C was evaluated. The results indicate that the extrusion of the unfired clayey body was not impaired by the grog addition. Additions above 5 wt% decreased the mechanical strength of both the dry body and the fired ceramic pieces. This is associated with the increase in porosity during the Firing Stage due to the grog behavior.
Carlos Mauricio Fontes Vieira - One of the best experts on this subject based on the ideXlab platform.
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clay bricks added with effluent sludge from paper industry technical economical and environmental benefits
Applied Clay Science, 2016Co-Authors: Carlos Mauricio Fontes Vieira, Verônica Scarpini Candido, Regina Maria Pinheiro, Ruben Jesus Sanchez Rodriguez, Sergio Neves MonteiroAbstract:Abstract Recently, it was indicated that a feasible industrial alternative to valorize the sludge obtained from the treatment of waste water effluent of paper fabrication in Europe is its use as raw material in the production of clay bricks. The present technical note is an open report, probably first in Americas, on a Brazilian industrial-scaled solution for this kind of sludge. As a novelty, the sludge was added to a mixture of clays for improved technical properties of construction bricks. Both bricks, added with 10 wt% of sludge and conventional pure clay bricks for comparison, were simultaneously fired at a relatively low temperature of 750 °C according to the ceramic fabrication procedure. The technical characterization was performed by linear shrinkage, water absorption and mechanical compression tests as per Brazilian standards. The brick consolidated structure was analyzed by optical microscopy. Environmental impact was evaluated by solution test and atmospheric emission by monitoring the release of SO2, NOx, TOC, CO and particulate material, according to Brazilian standards. The results showed that, owing to its composition and Firing temperature, the addition of paper sludge into clay bricks contributes to a substantial reduction in price associated with a saving of 3% of fuel similar to that reported for Spanish kilns, during the industrial Firing Stage. The paper sludge added clay bricks attended the technical and environmental standards.
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Rewas 2016: Towards Materials Resource Sustainability - Incorporation of Sewage Sludge into Heavy Clay Ceramic Body
REWAS 2016, 2016Co-Authors: Carlos Mauricio Fontes Vieira, Isabela Oliveira Rangel Areias, Sergio Neves MonteiroAbstract:This work has as its objective to evaluate the use of sewage sludge from wastewater treatment plant into heavy clay ceramic body. Compositions were prepared with amounts of 0, 2.5, 10 and 15 wt.% of sludge incorporated into the clay body. Rectangular specimens were obtained by 20 MPa pressure molding and then fired at 850°C in a laboratory furnace. Characterization of the waste was done by X-ray-fluorescence, differential scanning calorimetry and thermogravimetric analysis. Ceramic properties related to the water absorption and compression strength were determined. The results indicated that the incorporation of the sludge into clay bricks must be done in low amounts. In higher amounts the sludge increases the water absorption and reduces the mechanical strength of the ceramic. This is a consequence of the changes caused in the porosity by the relatively elevated weight loss of the waste during the Firing Stage.
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Evaluation of CO and CO 2 Emitted in the Firing of Clay Ceramics Incorporated with Elephant Grass Ash.
Materials Science Forum, 2014Co-Authors: Aline Da Silva, Sergio Neves Monteiro, Roberto Da Trindade Faria, Rosane Toledo, Verônica Scarpini Candido, Carlos Mauricio Fontes VieiraAbstract:Several environmental studies have been dedicated to the correct management of industrial residues. The conventional clay ceramic productive sector became, in past decades, a growing alternative for these residues through their incorporation in products such as bricks and tiles. The Firing temperatures for ceramic sintering usually transform the incorporated residue into an inert microstructural phase. In some cases, the residue may even improve the ceramic properties. However, during the Firing Stage, polluting gases might be emitted causing environmental impact. Therefore, the objective of the present work was to evaluate the gases emitted during sintering of a clay ceramic incorporated with 10 and 20 wt% of elephant grass ashes. The emission was investigated for Firing temperature in the interval from 250 to 1100oC and the gases analyzed by photothermic technique. The ash incorporation promoted a significant increase in the emission of greenhouse gases such as CO and CO2.
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incorporation of sludge waste from water treatment plant into red ceramic
Construction and Building Materials, 2008Co-Authors: Sergio Neves Monteiro, Jonas Alexandre, J I Margem, R Sanchez, Carlos Mauricio Fontes VieiraAbstract:Abstract The influence of the Firing temperature on the technological properties of red ceramics made of a kaolinitic clay incorporated with a sludge from water treatment plant was evaluated. The sludge was initially submitted to characterization tests to determine its particle size distribution, chemical composition, mineralogical composition, thermal behavior and morphological aspects. Mixtures were prepared with amounts of 0, 3, 5 and 10 wt% of sludge incorporated into the clayey body. Rectangular specimens were obtained by 20 MPa pressure molding and then fired at 700, 900 and 1100 °C in a laboratory furnace. Ceramic properties related to the bulk density, linear shrinkage, water absorption and flexural rupture strength were determined. The results indicated that the incorporation of the sludge increase the water absorption and reduce the mechanical strength of the clayey fired ceramic. This is a consequence of the changes caused in the porosity by the relatively elevated weight loss during the Firing Stage.
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Effect of grog addition on the properties and microstructure of a red ceramic body for brick production
Construction and Building Materials, 2007Co-Authors: Carlos Mauricio Fontes Vieira, Sergio Neves MonteiroAbstract:Abstract In the present paper crushed fired brick waste, known as grog, was used in mixtures with clayey body to make typical red ceramics for bricks. The effect of the grog addition up to 20 wt% on the extrusion Stage as well as on properties and microstructure of bricks fired at 700 °C was evaluated. The results indicate that the extrusion of the unfired clayey body was not impaired by the grog addition. Additions above 5 wt% decreased the mechanical strength of both the dry body and the fired ceramic pieces. This is associated with the increase in porosity during the Firing Stage due to the grog behavior.
A. Mezquita - One of the best experts on this subject based on the ideXlab platform.
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Beyond the energy balance: Exergy analysis of an industrial roller kiln Firing porcelain tiles
Applied Thermal Engineering, 2019Co-Authors: S. Ferrer, A. Mezquita, Vicente M. Aguilella, Eliseo MonfortAbstract:Abstract The ceramic tile manufacturing process consumes large amounts of energy, mainly in the Firing Stage. Firing usually takes place in natural gas-fuelled continuous roller kilns, the most widely used tile Firing facilities worldwide, which typically exhibit low energy efficiency (generally 5 to 20%). This paper investigates the application of energy and exergy balances to an industrial roller kiln Firing porcelain tiles in order to identify the most critical parameters affecting kiln energy efficiency and propose ways of improving kiln energy performance. The experimental kiln measurements and thermodynamic calculations confirmed the kiln’s low energy performance (15%). Exergy analysis showed that 83% of the total exergy input into the kiln was destroyed, only 10% of the exergy input being kept in the physico-chemical transformations of the ceramic tile composition. The main sources of irreversibilities: natural gas combustion, heat transfer in the fired tile cooling process, and heat transfer through the kiln surfaces, were identified and quantified. The study shows that waste heat (over 61%) recovery could be expected to significantly increase kiln energy performance. Finally, further measures are proposed for optimising kiln energy efficiency.
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Estimation of the heat of reaction in traditional ceramic compositions
Applied Clay Science, 2015Co-Authors: S. Ferrer, A. Mezquita, M.p. Gómez-tena, C. Machi, Eliseo MonfortAbstract:Abstract Most energy studies on the traditional ceramic manufacturing process focus on the Firing Stage because this is the process Stage that consumes the greatest amount of thermal energy. At present in Europe, using typical technologies, about 50% of the energy input in the Firing Stage is still lost through the kiln stacks. A key issue in energy studies is the accurate determination of the energy efficiency of the process, an issue that may become crucial in coming years to enable the energy management of different facilities and products to be compared. To reliably determine energy efficiency, accurate determination is required of the energy needed for the necessary physico-chemical transformations to develop in the material in the Firing Stage. This energy is also the only strictly unrecoverable energy, as the energy contained in other streams could, potentially at least, be partly recoverable. The present study was undertaken to develop an analytical methodology for estimating the heat of reaction of seven different traditional ceramic products, involving a broad spectrum of compositions, with peak Firing temperatures ranging from 850 °C to 1200 °C. The following industrial ceramic compositions were studied: four ceramic tile compositions (red-body stoneware tile, porcelain tile, red-body earthenware wall tile, and white-body earthenware wall tile); two structural ceramic compositions (white brick and roof tile), and a porcelain tableware composition. To estimate the energy involved in the physico-chemical reactions in the Firing Stage, an analytical methodology was developed, based on the mineralogy data of the unfired body composition and on the enthalpy of formation of the minerals in the fired tiles. The methodology was validated by comparing the results with experimental data.
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energy saving in ceramic tile kilns cooling gas heat recovery
Applied Thermal Engineering, 2014Co-Authors: A. Mezquita, J Boix, E Monfort, G MallolAbstract:Abstract A great quantity of thermal energy is consumed in ceramic tile manufacture, mainly in the Firing Stage. The most widely used facilities are roller kilns, fuelled by natural gas, in which more than 50% of the energy input is lost through the flue gas and cooling gas exhaust stacks. This paper presents a calculation methodology, based on certain kiln operating parameters, for quantifying the energy saving obtained in the kiln when part of the cooling gases are recovered in the Firing chamber and are not exhausted into the atmosphere. Energy savings up to 17% have been estimated in the studied case. Comparison of the theoretical results with the experimental data confirmed the validity of the proposed methodology. The study also evidenced the need to improve combustion process control, owing to the importance of the combustion process in kiln safety and energy efficiency.
S. Ferrer - One of the best experts on this subject based on the ideXlab platform.
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Beyond the energy balance: Exergy analysis of an industrial roller kiln Firing porcelain tiles
Applied Thermal Engineering, 2019Co-Authors: S. Ferrer, A. Mezquita, Vicente M. Aguilella, Eliseo MonfortAbstract:Abstract The ceramic tile manufacturing process consumes large amounts of energy, mainly in the Firing Stage. Firing usually takes place in natural gas-fuelled continuous roller kilns, the most widely used tile Firing facilities worldwide, which typically exhibit low energy efficiency (generally 5 to 20%). This paper investigates the application of energy and exergy balances to an industrial roller kiln Firing porcelain tiles in order to identify the most critical parameters affecting kiln energy efficiency and propose ways of improving kiln energy performance. The experimental kiln measurements and thermodynamic calculations confirmed the kiln’s low energy performance (15%). Exergy analysis showed that 83% of the total exergy input into the kiln was destroyed, only 10% of the exergy input being kept in the physico-chemical transformations of the ceramic tile composition. The main sources of irreversibilities: natural gas combustion, heat transfer in the fired tile cooling process, and heat transfer through the kiln surfaces, were identified and quantified. The study shows that waste heat (over 61%) recovery could be expected to significantly increase kiln energy performance. Finally, further measures are proposed for optimising kiln energy efficiency.
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Estimation of the heat of reaction in traditional ceramic compositions
Applied Clay Science, 2015Co-Authors: S. Ferrer, A. Mezquita, M.p. Gómez-tena, C. Machi, Eliseo MonfortAbstract:Abstract Most energy studies on the traditional ceramic manufacturing process focus on the Firing Stage because this is the process Stage that consumes the greatest amount of thermal energy. At present in Europe, using typical technologies, about 50% of the energy input in the Firing Stage is still lost through the kiln stacks. A key issue in energy studies is the accurate determination of the energy efficiency of the process, an issue that may become crucial in coming years to enable the energy management of different facilities and products to be compared. To reliably determine energy efficiency, accurate determination is required of the energy needed for the necessary physico-chemical transformations to develop in the material in the Firing Stage. This energy is also the only strictly unrecoverable energy, as the energy contained in other streams could, potentially at least, be partly recoverable. The present study was undertaken to develop an analytical methodology for estimating the heat of reaction of seven different traditional ceramic products, involving a broad spectrum of compositions, with peak Firing temperatures ranging from 850 °C to 1200 °C. The following industrial ceramic compositions were studied: four ceramic tile compositions (red-body stoneware tile, porcelain tile, red-body earthenware wall tile, and white-body earthenware wall tile); two structural ceramic compositions (white brick and roof tile), and a porcelain tableware composition. To estimate the energy involved in the physico-chemical reactions in the Firing Stage, an analytical methodology was developed, based on the mineralogy data of the unfired body composition and on the enthalpy of formation of the minerals in the fired tiles. The methodology was validated by comparing the results with experimental data.