Solar Power Generation Solutions for Ceramic Production

Introduction

On a global level, India is one of the fastest-growing ceramic tile marketplaces. The ceramic industry ranks at 3rd position in the world in terms of production. Though there are a number of large companies in the ceramics sector, it is mainly dominated by unorganized players with a market share of approximately 60% small and medium enterprises (SMEs). The Rs 26,500-crore ceramic tiles industry in India is expected to witness compounded annual growth rate of around 9 per cent in the coming years.

The rising real estate sector, together with government initiatives fuelling robust growth in the housing sector, are some of the primary reasons boosting ceramic tile demand in India. Furthermore, increased disposable income in India as well as a desire to beautify living and working environment, are fuelling the demand for ceramic tiles in the country. In the Indian ceramic sector, solar power panels are quickly becoming the norm rather than an alternative. Given the current trend of increasing fossil-fuel prices and decreasing renewable energy prices solar energy is expected to become economically feasible for the ceramics industry.

This article attempts to study the ceramic sector energy consumption trends and the key challenges that the ceramic industry faces, along with the feasibility of Solar PV Energy in the ceramic sector in India.

Let’s get started.

Product Categorization

Key Energy Challenges before the Ceramic Industry

When it comes to environmental challenges, ceramic manufacturing has a negative reputation. This is because, like steel, cement, and glass, the ceramic industry is an energy-intensive business. To produce ceramics at a national level, they use and transform massive amounts of raw materials (particularly clay) and energy. Greenhouse gases, sulphur oxides, and nitrogen oxides are among the gaseous air pollutants produced by the combustion of fossil fuels.

As a result, cost-effective techniques that boost energy efficiency and minimise carbon emissions will greatly benefit the environment as well as ceramic manufacturing prices. The amount of energy consumption within a ceramic plant is highly significant. It accounts to about 30% of the overall production costs, and points out to the evidence that the ceramic industry is an energy intensive sector. In terms of subsector distribution, the manufacture of tiles accounts for 80% of the overall energy consumption in the ceramic industry. Considering this, it is possible to verify that the tile manufacturing industry is the most representative subsector in terms of sales turnover and energy consumption.

Ceramic clusters across India confront major challenges with regard to energy availability. High fuel prices, especially of natural gas, are a major challenge faced by the ceramic industry, and has been one of the key reasons affecting the profitability of the ceramic industry. Analysis shows that the share of power, fuel and water expenses in total sales had gone up from 10.8% in 2010-11 to about 13% in 2011-12.

Given the scenario of heavy usage and higher than average electricity consumption, renewable energy is becoming the first choice for the ceramic industry. Renewable energy refers to energy sources — such as wind and solar energy — that are constantly replenished from either the Sun or the Earth and will never run out. Fossil-fuel, such as petroleum, natural gas, coal, and nuclear are not considered renewable resources as they will eventually run out.

In this current situation, in-house solar power plants in the form of captive models and/or off-site solar farms are fast becoming a norm rather than an option in India. These solar energy producing units are useful especially during times of peak overloading of grids, which result in power outages.  Additionally, they eliminate the high tariff rates that are applicable during peak hours.

Thermal Processes in the Ceramic Industry

Some of the most common production methods that have been used to make ceramics for thousands of years include : material storage, mixture and preparation, shaping (extrusion or pressing), drying, glazing, firing, quality check, and packaging. The processes that entail the highest energy consumption in a ceramic production facility are mainly related to processes of firing, drying and spray drying. Due to the long annual operating hours of the kilns and the resulting high operating temperatures, the firing process consumes the most energy. In most ceramic subsectors, the specific fuel consumption is superior to the electric energy consumption, which is due to the operation of these energy intensive thermal processes.

Feasibility of Solar PV Energy and major areas

The Indian ceramic industry offers significant scope for the implementation of some energy efficiency improvement measures. The application of solar technologies and strategies in the sector can help to obtain several associated benefits, such as: reduction in energy consumption and associated CO₂ emissions; reduction in manufacturing costs; increase in company competitiveness; reduction in resource consumption and the associated environmental impacts, contributing to a low carbon economy. 

Possible energy efficiency measures for key processes/ systems

The major energy efficiency measures in various processes as well as utilities in ceramic industries are provided below.

1. Kiln : 

• • Transitioning from intermittent type to continuous type kilns
  • Using best operating techniques, such as reducing surplus air levels

2. Spray dryer : 

• • Replacing LPG firing with diesel firing
  • Arresting infiltration of air in the spray drier system

3. Vertical dryer : 

• • Switching off chiller circuit when hydraulic press is not in operation
  • Installing interlock to avoid idle operation of hydraulic press pump

Apart from these, ceramic firms can implement a variety of energy conservation alternatives in utilities, ranging from modest housekeeping efforts to converting to energy efficient equipment.