Tony Cotton, Johnson Tiles - Cost Effective Use of Heat Recovery


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Tony Cotton, Johnson Tiles - Cost Effective Use of Heat Recovery

  1. 1. Cost Effective Use of Heat Recovery Tony Cotton
  2. 2. Johnson Tiles <ul><li>Formed in 1901 </li></ul><ul><li>One of the UK’s largest tile manufacturers </li></ul><ul><li>Up to late 1990’s – 3 sites in the Tunstall area </li></ul><ul><li>Operations consolidated onto one site in 2001 with £35m investment </li></ul><ul><li>Highly automated process consuming ~1,500 tonnes of raw materials per week </li></ul><ul><li>4,500,000 m 2 of tiles per annum </li></ul>
  3. 3. Why Save Energy? <ul><li>Reduce the environmental impact of energy usage </li></ul><ul><li>Protect the world’s resources: </li></ul><ul><ul><li>the UK consumes 8% of oil resources & 4% gas resources every year </li></ul></ul><ul><li>To reduce our carbon footprint </li></ul><ul><li>To meet legal obligations of climate change legislation </li></ul><ul><li>Good business sense - to save money & improve profitability </li></ul>
  4. 4. Energy Use <ul><li>126 GWh of gas per annum </li></ul><ul><li>21.5 GWh of electricity per annum </li></ul><ul><li>All firing by continuous gas roller-hearth kilns </li></ul><ul><li>All production is fast once-fired using gas </li></ul><ul><li>Slowest firing cycle is 1 hour & fastest ½ hour </li></ul>
  5. 5. The problem of waste heat <ul><li>“ Surplus industrial heat should be better exploited. Industrial plants often generate large amounts of high quality heat as a by-product. </li></ul><ul><li>A comprehensive heat strategy must include ways to ensure this heat is reused wherever possible. In some cases industrial firms can reuse heat in their own processes.” </li></ul><ul><li>“ The Heat is On”: CBI </li></ul>
  6. 6. Nothing new! <ul><li>Waste heat has been used for decades! </li></ul><ul><li>Heat exchangers on tunnel kilns provided space heating </li></ul><ul><li>Exhaust gases preheated spray driers to save gas </li></ul>
  7. 7. Kiln Heat Recovery System <ul><li>Retrofit on existing roller kiln in 2008 </li></ul><ul><li>Applicable to any continuous kiln </li></ul><ul><li>Heat exchanger in rapid cooling zone </li></ul><ul><li>Combined with heat extracted from slow & final cooling zones </li></ul><ul><li>Recovered heat ~200°C into gas burners as combustion air </li></ul>
  8. 8. Energy Savings <ul><li>Since installation </li></ul><ul><ul><li>Saved: </li></ul></ul><ul><ul><li>>£83K of gas </li></ul></ul><ul><ul><li>>4,000,000 kWh of gas (9% of the kiln’s gas) </li></ul></ul><ul><ul><li>>750 tonnes of CO 2 emissions </li></ul></ul><ul><ul><li>Payback estimated ~3 years </li></ul></ul>
  9. 9. Current Site <ul><li>Innovative use of waste heat: </li></ul><ul><ul><li>Excess heat from kiln fan platform used for space heating </li></ul></ul><ul><ul><li>Warm cooling air used for two process driers </li></ul></ul><ul><ul><li>Ducted hot air to replace electric heating in canteen </li></ul></ul>
  10. 10. Important Considerations <ul><li>Use for heating is seasonal </li></ul><ul><li>New buildings require little space heating </li></ul><ul><li>Old buildings have high heat loss & need to consider insulation </li></ul><ul><li>Target heat recovery for use in 24/7 process </li></ul><ul><li>Minimise creation of airborne dust </li></ul>
  11. 11. Training & Communication <ul><li>Involve the workforce </li></ul><ul><li>Continuous Improvement Teams </li></ul><ul><li>Energy CIT </li></ul><ul><li>Departmental Energy Champions </li></ul><ul><li>Encourage suggestions </li></ul><ul><li>Regular bulletins & posters </li></ul><ul><li>Newsletter to inform of improvements </li></ul><ul><li>Home energy-saving tips </li></ul>
  12. 12. Energy Performance
  13. 13. Carbon Footprint 2009 Down 7.8% on 2008 66% from gas consumption 33% from electricity consumption 1% from company road vehicles Note: Excludes deliveries & distribution Specific Energy Consumption 2000 4,519 kWh/tonne 2010 3,143 kWh/tonne 2,936 tonnes of CO 2 reduction in 2009 30% Reduction of SEC in CCA
  14. 14. Future Opportunities <ul><li>Evaluate CHP systems </li></ul><ul><li>Heat recovery as standard on kilns </li></ul><ul><li>Heat exchangers on kilns for space heating </li></ul><ul><li>Main kiln exhaust scrubbing to use heat in spray drier </li></ul><ul><li>New concept of kiln exhaust control </li></ul>
  15. 15. Questions EMS 40817 FM 26818 2008 2009 2010