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A numerical approach for the combined analysis of the dynamic thermal behaviour of an entire ceramic roller kiln and the stress formation in the tiles

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  • Milani, M.
  • Montorsi, L.
  • Venturelli, M.
  • Tiscar, J.M.
  • García-Ten, J.

Abstract

The numerical analysis of thermal and fluid dynamics behaviour of an industrial roller kiln used for manufacturing ceramic tiles is carried out and combined with the analysis of the mechanical stresses formed in the final ceramics product. The developed numerical approach is able to address the energy efficiency, the fuel consumption as well as the pollutant emissions and the quality of the final product. The model of the ceramic kiln is based on a lumped and distributed parameter model and accounts for the heat and mass transfer phenomena that take place in the real components under actual operating conditions of the systems. Models for the simulation of the different components that are used for the kiln functioning are included in the modelling, such as the burners, the fan, the valves and the control system. The numerical approach demonstrates to predict accurately the temperature distribution of both the tiles and the hot gases along the kiln length. Numerical results are validated against experimental measurements carried out on a real kiln during regular production operations. Additionally, the calculated temperature profile of the tiles is employed to predict the mechanical stresses that form in the ceramic product within the kiln. A thermomechanical model is adopted to determine the curvature and residual stresses in the tiles and particular care is devoted to the final stresses that remain at the end of the kiln since they affect the quality of product.

Suggested Citation

  • Milani, M. & Montorsi, L. & Venturelli, M. & Tiscar, J.M. & García-Ten, J., 2019. "A numerical approach for the combined analysis of the dynamic thermal behaviour of an entire ceramic roller kiln and the stress formation in the tiles," Energy, Elsevier, vol. 177(C), pages 543-553.
    • Handle: RePEc:eee:energy:v:177:y:2019:i:c:p:543-553
    DOI: 10.1016/j.energy.2019.04.037
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    References listed on IDEAS

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    1. Jouhara, Hussam & Bertrand, Delpech & Axcell, Brian & Montorsi, Luca & Venturelli, Matteo & Almahmoud, Sulaiman & Milani, Massimo & Ahmad, Lujean & Chauhan, Amisha, 2021. "Investigation on a full-scale heat pipe heat exchanger in the ceramics industry for waste heat recovery," Energy, Elsevier, vol. 223(C).

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