Investigating the effects of modifications to semi Eberhart type kilns on production enegy, fuel economy and air pollution

The aim of this study is making improvements to a widely used type of kiln in Turkey so that the hazardous environmental effects are minimized, emissions are kept in permissible range, fuel consumption is minimized while energy output of the burned fuels are maximized. To this objective, a company using semi Eberhart type kiln is chosen for this experimental study. Some structural modifications were introduced in the kiln prior to the experimental work.These modifications include air flow control, creation of a special combustion chamber where hot air is blowed through special and kiln gas regeneration using automatic control system. Air flow rates were adjusted through fans by periodical monitoring of the flue gases. Emission measurements taken during the experiments are evaluated based on the Industrial Air Pollution Regulation. Flue gas speed, carbon monoxide (CO), sulphur dioxide (SO2), nitrogen oxides (NOX), smoke and aerosol concentration measurements are found to be in the range permitted by the regulation. As a result, regulation limits on the plant emissions have been satisfied after all the work performed to improve the emissions.Application of the modifications resulted 33% increase in the production rate. The reason for this increase is attributed to the use of air flow fans that blows air in a steady and controlled form so that fuels are burned more rapidly. Rapid burning of fuels when compared to natural air flow burning provides more production rate in unit time.