Ceramics factories are high energy consumption enterprises. The sum of high power consumption and high fuel consumption accounts for nearly half or more than half of the of production cost. 

The followings are 7 energy-saving measures to reduce the cost of ceramic kilns. 

Data show that, heat loss of the surface of the furnace and regenerative loss of the furnace account for more than 20% of the fuel consumption. Increasing the temperature of the refractory bricks in the high temperature zone and insulation layer can reduce the heat loss and regenerative loss. The thickness of the crown of the high temperature zone and the insulation bricks of the walls is increased. The thickness of the crown has been increased from 230 mm to 260 mm, while the wall insulation layer is increased from 140 mm to 200 mm. 
 

Currently, the insulation of the bottom has not been improved correspondingly. 20mm cotton blanket and five layers of insulation bricks are laid on the bottom for the insulation. This situation has not been improved now. In fact, since the bottom has a huge heat dissipation area, the heat dissipation in the bottom is very impressive. It is necessary to increase the thickness of the bottom insulation layer and improve the insulation of the bottom with insulation layer with a lower bulk density and larger thickness. 
 

If the high temperature zone adopts the arced structure, it will be convenient to increase the thickness and tightness of the insulation layer to reduce heat loss. If it adopts the suspended structure, it is better to use ceramic pieces rather than heat resistant steel plate, supplemented by heat-resistant steel hooks, so all the pieces can be buried and the thickness and tightness of the insulation layer can be increased. If heat-resistant steel is used as the hanging board, bury the board into the insulation layer. The board may be oxidized and fall into the furnace when the furnace leaks fire, resulting in shutdown. When using ceramic pieces as the hang pieces, the roof can be insulated with castables which is flexible. This will greatly improve the insulation and tightness of the furnace and reduce the heat loss. 

Materials with better quality and insulation performance are developed and make the design and construction more convenient. High quality insulation materials can reduce the thickness of the insulation layer and achieves better insulation results and minimize energy consumption. Lightweight insulation bricks and ceramic fiber board can reduce the heat dissipation with a more rational structure and improved design. 
 

Enhance the tightness of the furnace by filling the accident Handling port, expansion joints, fire blocking plate opening, the surrounding of the burner tiles, the inner side of the roller and the roller hole bricks with ceramic fiber cotton which is more heat-resistant, more difficult to be pulverized and more resilient. This can reduce the heat dissipation, ensure the temperature and stability of the atmosphere, improve the thermal efficiency and reduce the energy loss. 

Burying the waste heat air ducts into insulation bricks can greatly maximize the insulation of waste heat air ducts and reduce the heat dissipation.  

The waste heat refers to the heat taken away by cooling media when cooling. The most heat used in the drying kiln comes from the waste heat. The utilization of waste heat can be subdivided. The high-temperature portion can spray into dry tower; intermediate temperature portion may be used as combustion air; the rest can be used in the drying kiln to dry bricks. 
 

The hot air pipes should be insulated well to minimize heat loss and improve efficiency. In addition, there are many factories arranging the hot water tank in the cooling section to use waste heat for the offices and dormitories heating and hot water for bath. Waste heat can also be used to generate electricity. 

High temperature zone with an arch structure helps to reduce the cross section temperature difference and improve energy conservation.
 

Since the high temperature heat transfer is mainly by radiation, the furnace has large center space and can hold more high temperature flue gas. The radiant heat reflection in the normal direction of the arc roof makes the temperature in the center higher than the surroundings. The temperature of the combustion air should be reduced to ensure the consistency of the cross section temperature. 
 

This will bring several consequences. First, the positive pressure is too large and the heat dissipation increases; second, it is not conducive to the control of atmosphere; third, the combustion air and the load of exhaust fan have increased, resulting in the increasing of the power consumption; Fourth, too much air enters the kiln, which will consume extra calories and will inevitably lead to the increase of gas consumption and costs.
 

The right way is to switch to combustion burner with high combustion speed and high ejection velocity with longer burner bricks or reducing the outlet size of the burner. This must be adapted to the mixing speed and the combustion speed of gas and air. It works well for high-speed burner but not low-speed burners. Another way is to insert a recrystallized silicon carbide roller into the burner bricks to enhance the heating in the central part of the furnace. 
 

Combining long and short recrystallized silicon carbide guns is also an effective way. The best solution is to not increase energy consumption or reduce energy consumption.

Improve the burners and optimize the air-fuel ratio. Improve the combustion efficiency to achieve energy saving by adjusting the air-fuel ratio, because there is no excessive input of combustion air. 
 

Isothermal burners with high ejection velocity have been developed to increase the heat supply central part the furnace and reduce the cross-section temperature difference. 
 

Repeated mixing of combustion air and fuel can increase the combustion rate and efficiency. 

Now there are two way to heat the combustion-supporting air with the waste heat. One is to heat combustion-supporting air when passing through Stainless steel heat exchanger in the quenching zone furnace. The temperature can reach up to 250-350℃. Another way is to use the heated air in the cold air pipes of the cooling zone as combustion-supporting air. The temperature can reach up to 100-250℃.