Since the roller kiln has been put into use in China's ceramic industry, due to the advantages of small cross-section, uniform temperature in the kiln, rapid firing, large output, low energy consumption and high degree of mechanization and automation, the product quality and output of various ceramic enterprises have been greatly improved and the energy consumption has been significantly reduced. Especially in recent years, the use and development of wide-section roller kilns have further greatly improved the quality and output of ceramic products. The energy saving of the roller kiln is to reduce the heat of fuel combustion under the premise of ensuring the output and quality. Let's talk about the energy-saving technology and approach of ceramic roller kiln from the heat balance sheet. 
Fuel combustionImprove the combustion efficiency of fuel.
The use of clean fuels is not only conducive to improving combustion efficiency, but also conducive to reducing harmful gas emissions. According to different fuel types, advanced and efficient combustion devices are adopted. Rational design of the structure of the kiln gun bricks.
Improve the heat transfer efficiency of combustion heat.
Optimize the design of the structure of the kiln, especially the roof structure of the kiln. The multi-functional coating material is applied to the refractory material on the kiln wall to improve the emissivity of the material, increase the heat transfer efficiency in the kiln, and improve the anti-chalking ability of ceramic fibers.
The material entering the kiln brings sensible heatThe materials entering the kiln include fuel, combustion air, green billet, quenching air, slow cooling air, and cooling air. They carry a very small percentage of sensible heat. To increase this part of the heat income, there are the following ways:
Increase the temperature of the combustion air. The sensible heat brought out by the flue gas and the sensible heat brought out by the hot air are used as the heat source.
Increase the temperature of the fuel. The sensible heat brought out by the flue gas and the sensible heat brought out by the hot air are used as the heat source.
Increase the kiln temperature of the green billet. The green billet should be dried before entering the kiln, and the heat loss on the way from the drying kiln to the firing kiln should be reduced as much as possible.
Quenching air, slow cold air, and cooling air are all aimed at cooling, and there is no need to increase their temperature to increase the sensible heat they bring in.
The product brings out sensible heatAfter the product comes out of the cooling belt, the temperature is higher than the ambient temperature, and this part of the sensible heat will be dissipated into the environment, so the temperature of the product out of the kiln should be reduced as much as possible to reduce the sensible heat brought out by the product.
Ceramic roller kiln.
The evaporation of water in the green body and the heat consumption of the water vapor are consumedThis heat expenditure is determined by the moisture content of the green billet entering the kiln and the temperature at which the kiln is entered. Reduces the moisture content of the green body. Increase the kiln temperature of the green billet.
The process of firing the green body decomposes the clay and consumes heatThis heat expenditure is determined by the raw materials, formula and process conditions of the green body, and this heat expenditure is unchanged when the process formula is determined. It is fired with ultra-low temperature formula to achieve low temperature and fast firing. According to the literature, if the firing temperature is reduced by 100, the heat consumption per unit product can be reduced by more than 10%, the firing time can be shortened by 10%, the output can be increased by 10%, and the production cost can be saved. The use of ceramic tile thinning technology can greatly reduce the heat consumption per unit area of the product, and save a lot of mineral raw materials at the same time.
Pumping air brings out sensible heatPumping air is mainly the wind that is removed after the quenching air and cooling air absorb heat, which is relatively clean and is a good waste heat utilization resource. Also considered from two aspects:
Reduce the amount of heat that comes out of the exhaust air.
Under the condition that the firing system remains unchanged, after the product comes out of the firing zone, the sensible heat brought out by the product is unchanged, and this part of the sensible heat will be converted into the sensible heat brought out by the extraction air, the heat dissipation of the kiln body surface of the cooling belt and the sensible heat brought out by the product, if the insulation performance of the kiln body of the cooling belt remains unchanged, the sum of the sensible heat brought out by the extraction air and the sensible heat brought out by the product is unchanged. Therefore, in this case, it is impossible to reduce the sensible heat brought out by the exhaust air and the sensible heat brought out by the product at the same time. Therefore, the best way is to reduce the sensible heat brought out by the product as much as possible, appropriately increase the sensible heat brought out by the extraction air, and then use the extraction air to bring out the sensible heat.
Pumping air brings out sensible heat
It is directly used as combustion air in the kiln or used to dry the green body. Because the oxygen content of the hot air is very high, it is relatively clean. In the case that the combustion air of the kiln and the drying body of the green body are not used up in this part of the sensible heat, the remaining hot air and humidifying air can be mixed and sent to the hot blast furnace of the spray drying tower for the preparation of green powder.
Waste heat power generation technology is usedDue to the strict firing system of ceramics, when the sensible heat and sensible heat of the pumping air are brought out by the dehumidifying air, the firing system of the kiln cannot be affected, thereby affecting the quality and output of the product. Therefore, it is necessary to use an intelligent control system to make use of this part of sensible heat.
Optimize the kiln structureReasonable selection of low heat storage, small bulk density, high strength, good thermal insulation performance of refractory materials as the masonry materials of the kiln body. A new type of thermal radiation coating is sprayed on the inner wall of the kiln. When the surface temperature of the kiln body is high, the low-temperature waste heat power generation technology can be used to dissipate this part.