ENERGY EFFICIENCY IN CERAMIC INDUSTRY

Abstract

In this thesis an analysis of energy use and energy conservation in the Ceramic industries is presented. It has been found that ceramic industries consume a substantial amount of energy. Excessive use of energy is usually associated with many industrial plants worldwide, and Ceramic industries are no exception. This study is based on the realization that enormous potential exists for cost-effective improvements in the existing energy-using equipment. Through the method of a walkthrough energy audit, power rating, operation time of energy-consuming equipment/machineries and power factor were collected. The data were then analyzed to investigate the breakdown of end-use equipment/machineries energy use. The results of the energy audit in the R.K. ceramics and other ceramic industries showed that the kilns account for a major fraction of total energy consumption followed by motors, making systems and lighting. Since the kiln takes up a substantial amount of the total energy used in ceramic industries, energysavings strategies such as the use of high efficient kiln, and variable speed drive (VSD) for motors have been used to reduce energy consumption of kiln and motors by 20-30% that of current use in ceramic industries. Energy-savings strategies for grinding, mixing, and making have also saves up to 10-20% of energy. It has been found that significant use of good machines and technology save the overall energy of plant by 30-40%.