Energy Equipment and Systems

Energy Equipment and Systems

Energy efficiency improvement solutions for Iran’s ceramic tile industry with fuzzy Delphi

Document Type : Research Paper

Author
Department of Industrial Engineering, Faculty of Engineering, Meybod University, Meybod, Iran
Abstract
Energy efficiency is a matter of immense importance for a wide variety of sectors, and especially industry as the driver of economic growth. Ceramic tile manufacturing is a basic industry that has turned into a nucleus of industrial development in some countries. However, this industry is extremely energy-intensive. Iran has a strong ceramic tile industry consisting of a significant number of manufactories with notably high production output and export. Given the energy-intensity of this industry, it can considerably benefit from energy efficiency improvement measures. In this study, first, a number of potential solutions for improving energy efficiency in Iran’s ceramic tile industry were identified by reviewing the subject literature and surveying a group of experts. The fuzzy Delphi method was then used to identify and ultimately prioritize 22 appropriate solutions from technical, managerial and production process standpoints for the said purpose. The results showed that the highest-priority solutions for energy efficiency improvement in the ceramic tile industry are Implementation of regular maintenance program of facilities and equipment, Adjusting the air in the kilns and burners, and Replacing electro motors according to the load of slurry mixers, and the lowest-priority solutions for this purpose are Insulation of transmission and distribution routes (steam and hot water pipes), Implementation of lighting management system in the factory, and Installation of heat exchangers to recover wasted heat (exhaust gases and the kiln’s cooling system).
Keywords

[1] Manrique, R., et al., Analysis of barriers to the implementation of energy efficiency actions in the production of ceramics in Colombia. Energy, 2018. 143: p. 575-584.
[2] D'Ambrosio, F.R., et al., Indoor Environment and Energy efficiency in Schools. Part 1 Principles. Rehva Guidebook n. 13.(FR d'Ambrosio editor). 2010.
[3] Khosravi, A., Investigating the Convergence of Provincial Energy Efficiency in Iran: A Spatial Econometric Approach. The Economic Research, 2017. 17(2): p. 177-197.
[4] Zalaghi, A.H., et al., Applying data envelopment analysis (DEA) to improve energy efficiency of apple fruit, focusing on cumulative energy demand. Energy Equipment and Systems, 2021. 9(1): p. 37-52.
[5] Menegaki, A.N., On energy consumption and GDP studies; A meta-analysis of the last two decades. Renewable and sustainable energy reviews, 2014. 29: p. 31-36.
[6] Agrafiotis, C. and T. Tsoutsos, Energy saving technologies in the European ceramic sector: a systematic review. Applied thermal engineering, 2001. 21(12): p. 1231-1249.
[7] Bellaiche, L., Energy savings in drying and firing operations. Interceram, 1985. 34(5): p. 72-74.
[8] Ancona, M.A., et al., Energy and environmental assessment of cogeneration in ceramic tiles industry. Energies, 2022. 16(1): p. 182.
[9] Gabaldón-Estevan, D., et al., Unwanted effects of European Union environmental policy to promote a post-carbon industry. The case of energy in the European ceramic tile sector. Journal of cleaner production, 2016. 117: p. 41-49.
[10] Ruivo, L., et al., Energy management in the Portuguese ceramic industry: Analysis of real-world factories. Energy, 2021. 237: p. 121628.
[11] Mezquita, A., et al., Energy saving in ceramic tile kilns: Cooling gas heat recovery. Applied Thermal Engineering, 2014. 65(1-2): p. 102-110.
[12] Monfort, E., et al., Analysis of energy consumption and carbon dioxide emissions in ceramic tile manufacture. Boletin De La Sociedad Espanola De Ceramica Y Vidrio, 2010. 49(4): p. 303-310.
[13] Patterson, M.G., What is energy efficiency?: Concepts, indicators and methodological issues. Energy policy, 1996. 24(5): p. 377-390.
[14] Liu, F., M. Ross, and S. Wang, Energy efficiency of China's cement industry. Energy, 1995. 20(7): p. 669-681.
[15] Zabihi, M., Nasrabadi, Optimizing the consumption of electrical energy in the dry cement unit of the North, in. The first international conference on energy management and planning. 2006.
[16] RastGoftar, S., Improving energy consumption (electricity and heat) in the tile and ceramic industry of the country., in The 9th Iranian Electrical Engineering Student Conference. 2006.
[17] Chu, W. and S. Man-hong, What is the driving force of the energy productivity? Evidence from China. Frontiers of Economics in China, 2009. 4(2): p. 265-273.
[18] Vissari, D., , Rumizadeh, Akbari, A roadmap for optimizing energy consumption in the country's tile and ceramic industry, in 9th International Energy Conference. 2015.
[19] Hadipour Zimsar, S., S. Firouzi, and M.S. Allahyari, Enhancers of the energy efficiency in tea processing industry. Energy Equipment and Systems, 2018. 6(2): p. 201-209.
[20] Oyebanji, M.O. and D. Kirikkaleli, Energy productivity and environmental deregulation: The case of Greece. Environmental Science and Pollution Research, 2022. 29(55): p. 82772-82784.
[21] Li, T., Energy productivity and financial inclusion: Evidence from non-parametric novel panel methods. Energy Efficiency, 2022. 15(7): p. 51.
[22] Shah, W.U.H., et al., Energy efficiency evaluation, changing trends and determinants of energy productivity growth across South Asian countries: SBM-DEA and Malmquist approach. Environmental Science and Pollution Research, 2023. 30(8): p. 19890-19906.
[23] Cassant, F., Recovering energy - From kilns, dryers, spray dryers and mills. 2010. 87: p. E35-E39.
[24] Bendig, M., F. Maréchal, and D. Favrat, Defining “Waste Heat” for industrial processes. Applied Thermal Engineering, 2013. 61(1): p. 134-142.
[25] Ciacco, E.F., J.R. Rocha, and A.R. Coutinho, The energy consumption in the ceramic tile industry in Brazil. Applied Thermal Engineering, 2017. 113: p. 1283-1289.
[26] Castro Oliveira, M., et al., Review on energy efficiency progresses, technologies and strategies in the ceramic sector focusing on waste heat recovery. Energies, 2020. 13(22): p. 6096.
[27] Türkmen, B.A., Ş.K. Özbilen, and T.B. Duhbacı, Improving the sustainability of ceramic tile production in Turkey. Sustainable Production and Consumption, 2021. 27: p. 2193-2207.
[28] Ibiyemi, A.O., Y.M. Adnan, and M.N. Daud, The validity of the classical Delphi applications for assessing the industrial sustainability-correction factor: an example study. foresight, 2016. 18(6): p. 603-624.
[29] Ahmadi, F., Nsiriyani, Khadijeh  Delphi technique is instrumental in research. Medical education, Delphi technique is instrumental in research. Medical education, 2005.
[30] Caglayan, H. and H. Caliskan, Energy, exergy and sustainability assessments of a cogeneration system for ceramic industry. Applied Thermal Engineering, 2018. 136: p. 504-515.
[31] Delpech, B., et al., Energy efficiency enhancement and waste heat recovery in industrial processes by means of the heat pipe technology: Case of the ceramic industry. Energy, 2018. 158: p. 656-665.
[32] Shwedhi, M. and M. Sultan. Power factor correction capacitors; essentials and cautions. in 2000 Power Engineering Society Summer Meeting (Cat. No. 00CH37134). 2000. IEEE.
[33] Madlool, N., et al., An overview of energy savings measures for cement industries. Renewable and Sustainable Energy Reviews, 2013. 19: p. 18-29.
[34] Ferrer, S., et al., Beyond the energy balance: Exergy analysis of an industrial roller kiln firing porcelain tiles. Applied Thermal Engineering, 2019. 150: p. 1002-1015.
[35] Firdaus, N., H. Ab-Samat, and B.T. Prasetyo, Maintenance strategies and energy efficiency: a review. Journal of Quality in Maintenance Engineering, 2023. 29(3): p. 640-665.
[36] Shen, C., X. Shao, and X. Li, Potential of an air curtain system orientated to create non-uniform indoor thermal environment and save energy. Indoor and Built Environment, 2017. 26(2): p. 152-165.
[37] Gordić, D., et al., Development of energy management system–Case study of Serbian car manufacturer. Energy Conversion and Management, 2010. 51(12): p. 2783-2790.
[38] Wang, L., et al., Lighting system design based on a sensor network for energy savings in large industrial buildings. Energy and buildings, 2015. 105: p. 226-235.
[39] Oliveira, M.C., M. Iten, and H.A. Matos, Assessment of energy efficiency improvement in ceramic industry through waste heat recovery modelling, in Computer Aided Chemical Engineering. 2021, Elsevier. p. 1653-1658.
[40] Trianni, A., E. Cagno, and D. Accordini, A review of energy efficiency measures within electric motors systems. Energy procedia, 2019. 158: p. 3346-3351.
[41] Bortnowski, P., et al., Energy efficiency analysis of copper ore ball mill drive systems. Energies, 2021. 14(6): p. 1786.
[42] Anantharaman, N., Energy audit in cement industry (1500 tpd). International Journal of Science Technology & Engineering, 2017. 3(10): p. 12-18.