Sacmi: EKO, single-layer roller kiln equipped with self-recuperating burners

As part of the H.E.R.O. project focusing on Energy Management, Sacmi is presenting its new EKO single-layer roller kiln equipped with self-recuperating burners. Rather than a mere development of the existing single-layer kiln, EKO is a real breakthrough, a pioneering machine that sets the standard for a new generation of kilns. EKO has lower energy consumption, a lower installed electrical power, more consistent colours and calibres and 30% lower atmospheric emissions of fumes and CO₂. The total recovery percentage with respect to FMS with the XTR recovery system can be as high as 10% (from the burners and from cooling). Above 900°C, where heat exchange occurs prevalently by irradiation, the EKO kiln consists of a series of thermal modules called "thermal cells", in which the fumes exchange thermal energy with the material more efficiently than on conventional kilns (transversal flows and longer time spent by the fumes in the firing chamber). The combustion gases are evacuated in the cell itself, giving up part of their residual heat energy to the ceramic heat exchanger located inside the burner, which in turn intensely pre-heats the combustion air (up to 700°C). The average temperature of the evacuated fumes is below 200°C. Below 900°C, where heat exchange occurs by convection, conventional type open flame burners are installed. The fumes are extracted by a flue at the head of the kiln. Perhaps the most interesting aspect of this machine is that of fume management. Compared to a conventional kiln, EKO releases smaller volumes of fumes to the atmosphere, thereby reducing CO₂ emissions per kg of fired product. Approximately 30% reductions in fume volumes compared to conventional kilns have been observed right from the very first installations.

To sum up, with the EKO solution:

- there are smaller quantities of polluting fumes that need to be purified

- the fumes can be discriminated and treated differently in the various kiln zones

- the filtering systems are small in size and are specifically designed for the pollutants present.

EKO is managed by a highly advanced control system with a double touch-screen interface. Traditional temperature regulators are no longer present. Process control occurs by way of an innovative system of temperature and pressure curves.