The next generation
of kiln technology

HYBRID KILNS

Test firing in a hybrid kiln
is possible at the CTB Firing Center!

Hybrid kilns

The smart alternative
for today’s ceramic firing process

The industrial production of technical ceramics is associated with very high energy consumption. In the face of advancing climate change and increasing resource problems, it is therefore also important to switch to alternative energies or to further develop potential savings in a more targeted way.


The aim is to develop cost-effective strategies that increase energy efficiency and reduce carbon and greenhouse gas emissions, thereby significantly improving the environmental footprint and economic efficiency of ceramic production in general. Approaches such as using hydrogen as a fuel or electrically operated kilns are already in use but have proved inferior to established firing systems from an economic and quality point of view. A promising approach to optimizing ceramic production from both an environmental and economic perspective is using a gas-fired kiln supported by electric heating elements. In this way, the advantages of both technologies can be maximized, and the disadvantages minimized. A major disadvantage of gas-fired kilns is that during the sintering phase (900-1700 °C), the hot exhaust gases are hardly used and are released into the environment via the chimney. If the heating process during the sintering phase utilized electric heating elements, the waste gas losses would be virtually zero. Heat transfer during the sintering phase is mainly by thermal radiation, while convection, such as that produced by a gas burner, has a decreasing effect since thermal radiation only occurs at high temperatures above about 1000 °C, as illustrated by the definition of heat exchange between two bodies.

Since the heat flow by radiation is proportional to (T14 − T24), but the heat flow by convection is proportional to (T1 − T2), the proportion of heat transfer by radiation increases with the temperature at which the heat transfer occurs. It, therefore, makes sense to use natural gas burners at low temperatures, i.e., during the heating phase, to ensure the necessary convection and oxygen concentration in the kiln atmosphere.


Hybrid operation (natural gas–electric) allows an improved process to be run for both environmental and economic reasons. Compared to conventional firing with natural gas burners, carbon dioxide and nitrogen oxide (NOX) emissions are significantly reduced. In addition, significant energy savings are achieved, and nitrogen oxide (NOX) emissions are reduced more than when hydrogen burners are used. The following section shows the energy consumption and CO2 emissions converted into CO2 equivalents for a typical firing cycle for technical ceramic products.

STATISTICS

Energy consumption, CO2 emissions, and costs
for one cycle (without other electrical consumers)

ENERGY
CONSUMPTION

2,9 MWh
Hybrid

11,2 MWh
Natural gas

CO2 EMISSIONS

0,741 t-CO2
Hybrid

2,247 t-CO2
Natural gas

NOx EMISSIONS

7,375 gNOXx
HYBRID

€13,730 €
Natural gas

ENERGIEKOSTEN

421 €
Hybrid

1019 €
Erdgas

Data: kiln internal volume: 10 m3; installed burner capacity: 1600 kWK; gas CO2 equivalent: 0.201 tCO2/MWh; electricity CO2 equivalent: 0.366 tCO2/MWh; gas price: € 0.12/kWh; electricity price: € 0.30/kWh; sintering temperature: 1450°C; carbon permit price: € 30/tCO2

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