Optimization of the energy efficiency of a dome-type furnace through computer simulation
Red clay ceramics; Production efficiency; Sustainability.
The red ceramic industry has significant socioeconomic importance, standing out for its job creation and intensive use of natural raw materials, such as clay. However, the production cycle of this sector is characterized by high energy consumption and significant environmental impacts, especially in the firing stage, which is responsible for a large part of the thermal losses and emissions associated with the process. Industrial dome-type kilns, widely used in the sector, have limitations related to thermal non-uniformity, compromising both energy efficiency and the quality of ceramic products. The overall objective of this research is to evaluate and develop, through computational simulation, a proposal for thermal optimization of dome-type kilns used in the red ceramic industry. The research is organized into three chapters, structured in the format of scientific articles derived from the studies. A methodology divided into three phases was chosen: (i) literature review on the red ceramic production process, combined with practical observation through technical visits; (ii) a systematic literature review on the use of Computational Fluid Dynamics (CFD) as a reliable tool for innovation and optimization of industrial thermal systems, focusing on the ceramic sector; (iii) application of CFD simulation in an industrial dome-type furnace for analysis of thermal behavior and energy efficiency. From the results obtained through validated CFD simulations, it was possible to analyze the thermal behavior of the furnace and identify that thermal uniformity can be improved through modifications to the internal arrangement and the adoption of dynamic control strategies for the flow rate of combustion gases. These measures favor the circulation of hot gases, reduce thermal losses, and contribute to the optimization of energy efficiency and the quality of the final product. From an environmental and industrial point of view, the study provides consistent technical support for decision-making in dome-type furnaces, aligning energy efficiency, reduction of atmospheric emissions, and sustainability of the production process.