A new low-energy tunnel kiln concept has been developed to help ceramic manufacturers minimize energy and investment costs while improving production flexibility and product quality.* The basic principle of the kiln is that the firing chamber has four fixed sides: two walls, one roof and one bottom (hearth). The products, their supports and the moving media are all completely immersed in the firing chamber and are therefore always at the same temperature.
In addition, the product supports and the moving media weights are reduced, representing 8-10% of the product weight, compared to traditional kilns with kiln cars that comprise 50-100% of the product weight. The kiln cars in a traditional tunnel kiln are often responsible for 25-30% of the energy consumption because of their heating and cooling needs. Additional ventilation needed under and mostly above the cars (air going through the products) significantly inflates the kiln exhaust volume and the resulting heat loss.