REFRESH, UPGRADE, PERFORM. Revamping Kits and Digital Solutions for quality improvement and energy savings

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Beryl Sullivan
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1 Revamping Kits and Digital Solutions for quality improvement and energy savings

2 Burners Sacmi for energy savings Complete range of burners for all fuel types. Heads specially designed for different capacities ensure optimal combustion in all working ranges. Optimized consumption management YOUR ADVANTAGES Broad working range More stable flame detection Better flame speed Compatibility with all burner block types Burner body suitable for use with hot air Simple head cleaning

3 BURNERS Technical features SACMI provides a wide range of burners, suitable for all fuel types, specially developed for ceramic products. The burner families most commonly used with gaseous fuels are: PLC 50 kw series PL kw series. This series also includes a version with calibrated diaphragms (for precision control of air and gas flows) mounted directly on the burner body Sacmi Forni also provides a kit for converting existing PL7 APG, PRO or DUAL burners into PL7 L030 burners. The kit was designed in order to maintain the existing burner body and therefore contain the cost of conversion. PLS 30 and 75 kw series PL8 65, 90, 130 kw series. This series also includes a version with calibrated diaphragms (for precision control of air and gas flows) mounted directly on the burner body PL9 300 kw series Lean gas: PLP 50 kw series For liquid or dual (liquid + gaseous) fuels we provide the following series: BBH 40kW series RPR and RFI 80 and 90 kw series (used on heavy clay kiln roofs)

4 RECOVERY SYSTEM Sacmi for energy savings Final cooling air retrieved for use as combustion air. Air is filtered and sent to the combustion air fan before being heated further via an exchanger in the fast cooling zone, reaching a temperature of between 150 C and 250 C. Optimized consumption management YOUR ADVANTAGES Immediate savings of up to 10% Simple installation Combustion air temperature up to 250 C

RECOVERY SYSTEM Technical features Cooling air may have a temperature that ranges from 120 C in the case of cooling with a single chimney to 250 C in the case of dual cooling circuits.

5 RECOVERY SYSTEM Technical features Cooling air may have a temperature that ranges from 120 C in the case of cooling with a single chimney to 250 C in the case of dual cooling circuits. Air is drawn downstream from the fan and sent to a filter before being made available to the combustion air fan. If the air temperature exceeds 150 C it is necessary to check that fan and burners are suitable for high temperature use. If the kiln has only a single fan a new one can be inserted, thus separating the first high temperature extraction hoods from the main circuit and from the final low temperature ones.

6 CONSUMPTION MONITORING KIT Sacmi for energy savings Device for real-time reading of gas consumption. Optimized consumption management The data is shown on the operator control panel. YOUR ADVANTAGES Can be installed on dryers and kilns Real-time gas consumption monitoring Instantaneous pressure and temperature readings Easy calibration

7 CONSUMPTION MONITORING KIT Technical features The kit consists of gas pressure and temperature control devices. The connection kit lets users monitor real-time consumption on the kiln control panel.

8 CONTROLLED-AIR KILN Sacmi for energy savings The combustion system is divided into 3 macro-zones, each of which supplies a specific kiln zone: pre-heating, pre-firing and firing. The operator panel can be used to adjust air flow to burners in specific zones according to recipe, product and kiln conditions. Optimized consumption management Maximum efficiency is obtained by combining this modification with the oxygen analyser to optimise combustion air under all conditions and, consequently, optimise product quality and consumption. YOUR ADVANTAGES Flexibility: volumes can be set according to the product Consumption optimisation Reduced consumption if there is a gap in production 3 independent macro-zones

9 SERVE FOTO CONTROLLED-AIR KILN Technical features The combustion air circuit is modified to create 3 fuel feed macro-zones. Each macro-zone is, in turn, sub-divided into an upper branch and a lower one and each branch has a motorized valve connected to a pressure transducer. The system is completed by installation of an inverter on the fan and a pressure transducer on the main duct to keep circuit pressure stable under all operating conditions. The system is managed via a control panel, ensuring repeatability of settings and letting the user differentiate opening in the different zones according to production requirements. In the event of a gap in production valve aperture can be adjusted to a pre-defined setting.

10 RECOVERY FROM KILN TO dryer (RVE) Sacmi for energy savings Cooling air retrieved and then fed towards the dryers (RVE). Optimized consumption management The retrieved air is used as drying air, providing immediate savings. YOUR ADVANTAGES Immediate savings Control system maximises the economic advantages Fast return on investment Complete integration with existing plants Suitable for all kilns and dryers, horizontal and vertical Minimal maintenance

Recovery from Kiln to dryer (RVE) Technical features The air is drawn from the final cooling chimney by a fan and sent via an insulated duct to the dryers.

11 Recovery from Kiln to dryer (RVE) Technical features The air is drawn from the final cooling chimney by a fan and sent via an insulated duct to the dryers. The booster fan is equipped with an inverter and, thanks to the pressure transducer mounted on the duct downstream from the fan itself, the user can control transfer flows. The control panel is independent; this means the RVE system can be installed on any machine. System parameters are monitored constantly by software to maximise savings without having to alter production cycles.

12 ENERGY MANAGEMENT SYSTEM (SEM) Sacmi for energy savings On horizontal dryers, inverters are installed on the recirculation and chimney fan motors to optimise energy consumption according to the production recipe. Optimized consumption management Completing the system is a chimney humidity probe; this supplies a key adjustment parameter. YOUR ADVANTAGES Inverter for every recirculation and fume fan Working frequency setting for every recipe Cycles controlled according to product size and thickness Energy consumption optimisation 20-30% less electricity consumption

ENERGY MANAGEMENT SYSTEM (SEM) Technical features The SEM system consists of a set of additional adjustment components and functions that let you optimise dryer electricity consumption under

13 ENERGY MANAGEMENT SYSTEM (SEM) Technical features The SEM system consists of a set of additional adjustment components and functions that let you optimise dryer electricity consumption under different operating conditions. To make dryer operation more stable, the humidity probe is not placed in automatic adjustment mode; however, it is extremely useful in determining the correct operating point and thus optimising thermal consumption of the dryer. Fan speed control is automatic and linked to the recipe, making the system highly flexible and allowing management of extremely different cycles according to size and thickness while optimising energy consumption at all times. EXAMPLE TABLE OPERATING POINT WITHOUT INVERTER RPM ABSORBED POWER (kw) WORKING TEMPERATURE ( C) SHUTTERING WITH INVERTER-CONTROLLED ADJUSTMENT (40Hz)

14 FAST COOLING MANAGEMENT Sacmi for enhanced process control and quality Modification of Fast Cooling by separating the upper and lower zones and making them independent, with the possibility of further separation into two distinct zones. Qu Process consistency Self-tuning All Fast Cooling is controlled automatically via the operator control panel. YOUR ADVANTAGES complete control of piece planarity all parameters are set via recipe volume control if there is a gap in production flow control via fan inverter adjustment flexibility above and below the roller bed

FAST COOLING MANAGEMENT Technical features Intervention involves modification of the fast cooling duct by separating the upper and lower circuit; both circuits mount a motorized valve which is

15 FAST COOLING MANAGEMENT Technical features Intervention involves modification of the fast cooling duct by separating the upper and lower circuit; both circuits mount a motorized valve which is controlled via the operator panel. Further modification to the duct can allow the creation of two separate fast cooling zones. Each zone has a general motorized valve which is controlled by a thermocouple; it also has two motorized valves with position control, one for the upper channel and one for the lower channel. To complete the system an inverter is fitted on the fan and a pressure transducer fitted on the main duct. All regulators and valves are controlled via the operator panel.

16 BURNER IN FAST AND INDIRECT COOLING ZONES Sacmi for enhanced process control and quality Qu Process consistency Self-tuning Burners in fast cooling and indirect cooling to control temperature during transitory stages and in the event of a gap in production. YOUR ADVANTAGES temperature control under all conditions automatic burner on/off control complete control of piece size and planarity temperature uniformity over cross-section, even at low temperatures automatic control in the event of a gap in production

BURNER IN FAST AND INDIRECT COOLING ZONES Technical features Modification involves installation of burners below the roller bed in the Fast Cooling and Indirect Cooling zones.

17 BURNER IN FAST AND INDIRECT COOLING ZONES Technical features Modification involves installation of burners below the roller bed in the Fast Cooling and Indirect Cooling zones. Burners are controlled and switched on/off automatically. All parameters can be set via the operator panel. The combustion system is modified by lengthening the burner service ducts.

18 RCC VALVE AUTOMATION Sacmi for enhanced process control and quality Qu Automation of the valve in the extraction hood located at the end of indirect cooling. The valve is controlled via a pressure transducer positioned in indirect cooling. Process consistency Self-tuning YOUR ADVANTAGES Process stabilization Automatic valve opening control Setting via recipe In-kiln stability at all times, even if there is a gap in production

RCC VALVE AUTOMATION Technical features The valve positioned on the hoods at the end of indirect cooling is motorized to allow control of valve opening via a pressure

19 RCC VALVE AUTOMATION Technical features The valve positioned on the hoods at the end of indirect cooling is motorized to allow control of valve opening via a pressure transducer installed in Indirect Cooling. The pressure setting is established in the recipe and opening is controlled by the PLC. The system ensures in-kiln stability at all times.

20 AUTOMATIC COOLING CONTROL Sacmi for enhanced process control and quality Automatic blowing control system in Fast Cooling. Qu Process consistency Self-tuning Insertion of ceramic blowers in the roof and wall-mounted blowers beneath the roller bed allows correction of planarity differences between the middle of the kiln and the walls. YOUR ADVANTAGES Automatic blowing control Centre-to-wall temperature uniformity Planarity control over cross-section Parameters set via recipe

AUTOMATIC COOLING CONTROL Technical features The system involves installation - in the fast cooling zone - of ceramic ducts on the roof and blower pipes beneath the roller bed.

21 AUTOMATIC COOLING CONTROL Technical features The system involves installation - in the fast cooling zone - of ceramic ducts on the roof and blower pipes beneath the roller bed. Roof blowing focuses on the central section of the channel to cool the surface of centrally positioned tiles. Side blowers are installed under the roller bed and have the purpose of cooling the undersides of tiles near the walls. The result is the evening out of temperature differences over the cross-section and correction of piece planarity differences from centre to sides. The project mainly concerns wide-mouth single-layer tile kilns. Both roof ducts and wall blowers are fed with air from the fast cooling circuit: both feature a modulating valve through which air flow can be regulated. Both valves are positioned according to the recipe, thus ensuring the system starts automatically only when really needed.

22 OXYGEN ANALYSER Sacmi for enhanced process control and quality Qu The oxieye System allows constant monitoring and recording of the percentage of oxygen in the roller kiln combustion chamber. The data is displayed on the existing Supervisor. Process consistency Self-tuning YOUR ADVANTAGES Optimised combustion (thus avoiding operation with excessively high reduction parameters) Energy savings Improved manufacturing quality (especially with light coloured products or those sensitive to or influenced by changes in oxygen content) The oxieye system is designed to be installed on all existing Sacmi Forni machines with EwS 600, EwS 114, EPCEBP Praktico Supervisors and Hercules.

23 OXYGEN ANALYSER Technical features Using O 2 analysers, the oxieye system is installed along the pre-heat and firing zones. The analysers, in addition to a connection with the displays, are network-connected to the kiln control computer (integrated system) with selfregulating instruments. The O 2 value is monitored, displayed and recorded in the field and on the existing Supervisor like any other thermal adjustment/display zone. It can also be called up in the running, trend and recorder sections. For O 2 monitoring zones it s possible to establish a set point and minimum/maximum alarm thresholds (% content) on the recipe. This allows comparison between detected value and set point to provide a visual cue for the operator. The oxieye System consists of the following equipment items: Probes with Zirconium Oxide cell for oxygen content analysis directly in the combustion chamber Field transmitters that convert signals from the probe and show them on the high-brightness LED display Shielded connection lead Materials for modifications to the existing electrical panel: Set of materials to modify the electrical panel Thermoregulators / PLC analogue cards - Software upgrade Flash-USB for installation of modification on PC Instrument power leads and shielded signal leads Raceways

24 FINAL COOLING BOOST Sacmi for enhanced process control and quality Qu Final cooling blowing circuit boosted to reduce the temperature of tiles exiting the kiln. Process consistency Self-tuning YOUR ADVANTAGES Outgoing tile temperature reduced by up to 25 C

installing new lower and upper manifolds; flow rates of intake and blowing

25 FINAL COOLING BOOST Technical features The final cooling blow circuit is boosted by replacing existing blower pipes with dual-feed pipes and installing new lower and upper manifolds; flow rates of intake and blowing fans are checked to see if flow is sufficient or whether the fans need replacing.

26 MOTORIZED HOOD IN THE PRE-KILN Sacmi for enhanced process control and quality A motor-powered extractor hood is installed on the pre-kiln roof and/or floor in the last low module to introduce ambient air into the kiln chamber. Valve opening is thermocouple-controlled. Qu Process consistency Self-tuning YOUR ADVANTAGES Temperature control in the pre-kiln Elimination of breakages at kiln infeed

27 MOTORIZED HOOD IN THE PRE-KILN Technical features A motor-powered extractor hood is installed in the last low module of the pre-kiln. Its opening is controlled by a thermocouple positioned in the initial kiln modules. Introducing cool air into the channel lowers pre-kiln temperatures, thus preventing any bursting or lateral cracking that might be caused by residual moisture content in the tile. It also results in lower temperatures at the chimney.

28 dryer: STABILISATION MODULE Sacmi for enhanced process control and quality The insertion of a new stabilisation zone in final drying modules ensures consistent outgoing material temperatures. The temperature is set via the software and controlled automatically; this ensures that pieces exiting the dryer are at a suitable temperature for subsequent stages. In the event of a line stoppage the temperature is kept constant. Qu Process consistency Self-tuning YOUR ADVANTAGES Automatic temperature control Consistent outgoing piece temperature Controlled temperature also in the of event line stoppages Piece temperature suitable for digital decoration Versatile module: can also be used as a drying module

Transforming a dryer module into a stabilisation module involves modifying the fume expulsion circuit with the introduction of an

29 dryer: STABILISATION MODULE Technical features Digital decoration requires temperature control of pieces leaving the dryer. Depending on the size of the plant, the stabilisation module can be obtained by modifying the existing dryer or inserting a new module. Transforming a dryer module into a stabilisation module involves modifying the fume expulsion circuit with the introduction of an independent chimney and modification and motorization of the exhaust air valve (controlled by a thermocouple positioned on the recirculation duct).

30 MOISTURE CONTENT SENSOR Sacmi for enhanced process control and quality A radio frequency-based instrument ensures continuous reading of tile moisture content. Qu Process consistency Self-tuning This sensor can be installed at any point on the line and comes complete with a PC that displays moisture content readings. Warning thresholds can be set. The system can be supplied with a thermogravimetric analyser for calibration purposes. YOUR ADVANTAGES Real-time sensor data Two warning threshold settings (pre-alarm and alarm) Activation of warning light and beeper if thresholds exceeded Line stoppage in the event a warning Compressed air self-cleaning system Process stabilization

31 MOISTURE CONTENT SENSOR Technical features Measuring probe placed upstream from kiln load feed system. A small touch-screen PC is positioned alongside the probe for moisture content reading and control purposes. Moisture content probe electronics are located directly on board the machine near the touch-screen PC. The detection system consists of: Moisture content control sensor A support to attach the sensor to the line Display with stand or support Industrial PC Cooling fans A base module with warning beeper/light Measurement synchronism photocells (on passage of the material) Clamps, leads and wiring accessories

32 4.0 SYSTEMS Sacmi for easiness and real-time info Industry 4.0 provides the perfect opportunity to make full use of our data control and management systems. Our 4.0 systems are modern, compatible with the most widely used data platforms and ensure machines can be used flexibly; they also ensure excellent usability of collected data. Easiness Real time info YOUR ADVANTAGES Major plant modernisation thanks to integrated data collection and control systems Production and consumption data can be shared with company management systems Coordinated automation to plan production Remote/tele-assistance systems Productivity and plant problem analysis

33 4.0 SYSTEMS Technical features Our 4.0 systems provide: Network-connected PLC systems for automation and worker/machine safety A simple, user-friendly man-machine interface that can be used by workers in any situation (even when personal protection items need to be worn) Continuous monitoring of working conditions and process parameters via suitable data sensors Adaptive-behaviour system control in the event of any process drift Remote tele-assistance service (automatic or worker-supervised) allows modification of process parameters and updating of control software PC/SCADA (Supervisory Control And Data Acquisition) system allows control, monitoring and supervision of the machine via a connection network Complete, exhaustive production and consumption databases made available to corporate network and to management software via Modnet or Database SQL protocols

ENERGY UTILIZATION IN CERAMIC TILES INDUSTRIES

ENERGY UTILIZATION IN CERAMIC TILES INDUSTRIES Solanki Kaushik M 1, Prof S.R.Shah 2 1 Student, Chemical engineering, L.D.College of engineering Ahmedabad, Gujrat, India 2 Assistant professor, Chemical