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12/14/2001
Energy-saving system

Saving with Sacmi kilns: reducing consumption while containing pollution.

Over the last six months increases in fuel costs have weighed heavily on the economic performance of heat treatment machinery. Reducing consumption, however, does not just mean reducing costs: it should also be part of an ongoing environmentally-conscious strategy designed to safeguard resources and abate pollution. In theory this can be achieved by sending less combustion air to the burners and reducing consequent fume weight per unit of product. Yet it a solution that carries risks: 1) “black core” caused by lower oxygen content; 2) altered colour tones where burners are running on reduced air feed and there are firing or product weight flow changes; 3) increased waste if an extensive power output range is no longer available where product feed is discontinuous; Sacmi Forni has been effecting research into these problems for some time now, operating on two different fronts: firstly by modifying combustion systems on existing machines through updating of equipment and, secondly, by installing combustion air recovery and preheat systems on both new and existing machines. Recent modifications made to an existing machine at the Fincuoghi di Bedonia ceramic plant (PR) have resulted in savings in excess of 20% with respect to initial consumption levels – just by updating the combustion system, installing the latest generation of burners in place of existing ones. As far as recovery systems are concerned, Sacmi Forni has developed the new SPR system. The SPR (Super-heated air) system splits the hot air expulsion flues: one expels the last fraction of final cooling air (60-70 °C) which, free from chemical pollutants, can be used to heat the factory (after single-stage filtration where necessary). The other flue expels the last fraction of slow cooling air (140-160°C) which, withdrawn by the combustion air fan and filtered, is sent on to the heat exchanger on the rapid cooling section; modifying the geometry of the exchanger maintains cooling efficiency even though the withdrawn air is already hot; the combustion air arrives at the burners at a temperature of 220-240°C. This system yields further savings of 15% in addition to the savings already provided by the latest generation of burners. The new SPR system will be installed in several ceramic plants in the Sassuolo area such as Panaria, CMV Magica, Novabell, and, outside the area, at Tagina, SCA, ICF and Monoceram.
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