Partners – A Historical Breakthrough in Ceramic Industry!

Revolutionising Ceramics with Kingtau Low Maintenance Ceramic Printing Machine

As cutting-edge technology enters into the ceramics industry, tile manufacturing processes are undergoing significant transformation. Only a few years ago, the idea of machinery capable of producing effects such as sugar textures, embossing, matte finishes, and mirror-like polish seemed unimaginable.

A Historical Breakthrough in Ceramic Industry!

China’s ceramic industry has achieved a historic milestone in the goal of carbon neutrality. After nearly one year’s hard research work, the world’s first piece of ceramic tile fired with zero-carbon fuel was successfully produced in Oceano Test Center, giving a great technological support to the building ceramic industry in realising the target of Carbon Peak and Carbon Neutral. It was announced at a press conference in Foshan Xianhu Lab on December 23, 2022, the world’s first piece of ceramic tile f ired with zero-carbon pure ammonia fuel has successfully exited the Ammonia-fueled Roller Kiln at Oceano Test Center. The Associated R&D Center on Advanced Zero-carbon Combustion Technology was jointly established by Foshan Xianhu Lab, Oceano Ceramics and DLT Technology on December 27, 2021. HLT & DLT are the world’s leading suppliers of complete plant equipment for the ceramic sector. To provide turnkey project solutions to the global ceramic industry, Foshan HLT DLT Technology has been the first tunnel kiln that integrated green, low-carbon, and intelligent automation for the Chinese ceramic machinery industry to enter. Headed by Academician Mr. Cheng Yibing, a strategic scientist working at Foshan Xianhu Lab, as Chief Director of the center, the lab was aiming at the key technology of zero-carbon combustion in ceramic kilns to explore new solutions for Chinese ceramic industry. By giving full play to the advantages of the three parties in terms of production, developing and research, the center has developed the “ammonia-hydrogen fusion zero-carbon combustion technology” as well as key systems and solutions for the industrialisation. The center has developed a new series of pure ammonia type and natural gas – ammonia mixture type industrial burners with related auxiliary technologies, having realised stable ignitions in DLT industrial experiment kiln fueled with mixed ammonia and pure ammonia, showing good control of nitrogen oxides emission in compliance with the national standards. This achievement has confirmed for the first time the practical feasibility for the ceramic industry to achieve carbon peak and carbon neutral technology’s industrialisation in the future, marking an important milestone for the industry. The f iring of ceramics with zero-carbon fuel is a disruptive technical innovation, having filled up blanks of both domestic and international, showing a new energy technological path for the ceramic industry as well as for the whole of building material industry to achieve carbon peak and carbon neutral goal with great practical significance. While developing the zero-carbon combustion technology, the team also established a set of safety system and emergency management measures suitable for ammonia-fueled ceramic kilns, including operating procedures, ammonia storage, transportation and other important aspects. Based on this, the team successfully completed the update of Oceano’s ceramic roller kiln by converting the kiln from natural gas fueled mode into pure ammonia and natural gas – ammonia mixture fueled mode. Moreover, it has also developed a precision control system for liquid ammonia evaporation and supply, which is monitoring system for residual ammonia in the fume, and has jointly developed a complete set of high-efficiency liquid ammonia SCR de-nitrification system as well as other technologies and equipment. suitable for the pure ammonia combustion, an online On December 18, 2022, the kiln fueled with 100% ammonia (NH3) successfully produced glazed and unglazed tiles with continuous tile feeding and production. Tested by Oceano Research & Development Center, the quality of finished tiles is above the national standard. According to the on-site test by a third-party environmental assessment agency, the exhausted fume emission of the kiln complies to the national standard. As the first thermal equipment manufacturer to participate in the research and development of Ammonia-Hydrogen Zero-Carbon Combustion Advanced Technology, DLT has been focusing on the energy saving and emission reduction of kilns and dryers for the ceramic industry, and has been contributing greatly to the industry’s carbon consumption reduction in order to undertake its social responsibility. In future, the Associated R&D Center on Advanced Zero-carbon Combustion Technology will be further utilised in the application of mass production in the industry on the basis of the results from this pilot production, and will keep breaking through and optimising the new technology adapting with mass production, as a contribution to the ceramic industry as well as the building material industry to achieve the goal of carbon peak and carbon neutral, in order to create a disruptive technological path leading from “0” into “1” as being the first time in the world. Project Initiation: Ammonia-Hydrogen Zero-Carbon Combustion Tech When the zero carbon combustion chemical equation appeared on the screen of the launch ceremony, it marked a significant breakthrough in carbon neutrality technology. On December 28, the “Advanced Ammonia-Hydrogen Zero-Carbon Combustion Technology Demonstration Project for Ceramic Slab and Tile Mass Production Line” (“Ammonia Hydrogen Zero Carbon Combustion Project”) was officially launched at the headquarters of Monalisa Group. This is a new path explored by Monalisa in collaboration with Foshan Xianhu Laboratory, DLT, Oceano, Guangdong Anqing Technology and other companies to build ceramic zero carbon manufacturing and green development, which marks a major step forward for the industrial application of carbon-neutral technology in China’s ceramics industry, and is of great significance for accelerating the green and low-carbon transformation and development of the industry. Ammonia-hydrogen Zero-Carbon combustion technology to explore the optimal solution for the path of carbon neutrality and emission peak. With the current carbon neutrality and emission peak strategy, hydrogen energy and ammonia energy, as renewable green energy sources with high energy density, good storage and transportation convenience, clean and efficient energy, have gradually become an important part of the future energy system and are energy terminals. At present, the ammonia-hydrogen zero-carbon combustion technology has successfully completed technical tests and demonstration production in the Oceano’s experimental kiln. In order to promote the industrial application of ammonia hydrogen zero carbon combustion technology, Monalisa has joined the industrialisation research project of this technology and launched the demonstration project. Based on the developed advanced ammonia hydrogen zero carbon combustion pilot test and pollutant emission detection and control pilot test, the advanced ammonia hydrogen zero carbon

SACMI’S Challenge ZERO-EMISSION CERAMIC KILNS

In the world of ceramics, the name of SACMI is known as the world leader in the supply of advanced technologies for Ceramics and Advanced Materials through continuous development in innovation. The company’s strong positioning on the world market, and its relentless thrive for ensuring high quality standards and customer service is praiseworthy. The Ceramic Industry is focusing on bringing innovative solutions and effective alternatives of traditional machineries through research. The company is focused on working for development of alternative fuels, digitisation and heat recovery aimed at zeroing or reducing consumption in other stages of the process. These are the three pillars of the modern approach to ceramic kiln design, which SACMI recently presented to the market with the first prototype of a 100 per cent hydrogen-fired kiln. The presentation was made during the ‘open week’ organised by SACMI, which took place at the same time as the CERSAIE trade fair. Over 400 international customers of 90 delegations from 35 countries visited the fair. “Making ceramic manufacturing more sustainable is the primary challenge that SACMI has been pursuing for years, implementing optimisations and innovations in all areas of the plant, from forming to firing,” explained SACMI President Paolo Mongardi. Firstly, the kiln accounts for a good 37 per cent of total factory emissions, 46 per cent if one considers all thermal processes (kiln and drier). “With the FMH Maestro, we developed the world’s first industrial kiln fired using up to 50 per cent hydrogen. Today we are taking a further step towards what will be a potentially zero-emission kiln.” The prototype is ready and will be tested to make actual products in the coming months. Meanwhile, the market is moving towards new machines with the full digital management of all parameters in order to optimise quality and consumption. The project The prototype kiln implemented by SACMI is capable of working with variable mixtures of methane and hydrogen – in any percentage – and up to 100 per cent pure hydrogen. The kiln will be ‘switched on’ over the next few weeks, to test its effect on actual products and to take on significant technological challenges, such as the fact that hydrogen has a different calorific value compared to methane and the corrections necessary for managing the firing curves and material feed. From this point of view, the digital control of parameters (e.g. oxygen content at every point in the process) is the prerequisite of this development and has already been implemented in the ‘Maestro’ range of kilns, starting from the FMD model, introduced by SACMI in 2022. The fuel The pure hydrogen production and storage station has already been inaugurated at the SACMI Forni and Filters site in Salvaterra di Casalgrande. The facility, one of the first of its kind in Italy, consists of an electrolyser where hydrogen is produced at a rate of 20 Nm‑ per hour. It is then compressed to increase the outlet pressure from 8/12 bar to approximately 200 bar. This is essential in order to make storage easier, since one of the ‘defects’ of hydrogen is that it is very voluminous (much more so than methane/LPG and up to seven times more voluminous for the same calorific value). The third and last station involves its storage in cylinders, which for the prototype that will be tested in the Lab, “is equivalent to an operating autonomy of 2.5 days” – underlines Daniele Baldini, product manager at Kilns and Driers BU Tiles, SACMI – “sufficient for carrying out full testing on the products”. The advantages Currently, SACMI’s best-selling kiln globally is the modulated air-gas FMA model, which allows air and fuel mixtures to be optimised at every stage, optimising consumption and with great advantages in terms of product quality (especially for complex products, such as slabs), repeatability and consistency of the process. More and more customers are moving towards the latest FMD models (with digital firing parameter and recipe management) and FMH models (already designed for use with methane-hydrogen mixtures of up to 50 per cent). What are the real advantages of ‘full hydrogen’? You just have to consider that by adding 50 per cent clean hydrogen to the mixture, the total saving on CO2 emissions is as much as 23 per cent. This would increase to 55 per cent (more than double) if the mixture were 80 per cent H2 + 20 per cent methane. “What remains constant is the amount of energy required for the process,” notes Baldini, adding, “while to obtain the same amount of energy, a larger volume of hydrogen is required as its calorific value is lower than that of methane (2560 kcal/m3 compared to 8600 kcal); Hence more than proportional savings in emissions to the increase in the amount of hydrogen in the mixture”. This is why it makes sense to increase the hydrogen in the mixture and to get ready for the evolution of the infrastructure, which in all probability will lead to hydrogen-methane ‘blends’ being supplied in increasing but variable amounts.   “From this point of view, the way forward already appears to have been decided,” says Claudio Ricci, Tiles R&D Coordinator, BU Tiles, SACMI. “So technology suppliers around the world are getting ready for this development, without forgetting the two conditions which make this scenario viable and truly beneficial to the environment.” First, hydrogen has to be obtained from renewable sources (or rather the electricity needed for the electrolysis process has to be). Secondly, in order for it to be actually applied on an industrial level, the problem of storage has to be overcome (the laboratory prototype is one thing; in a ‘real’ kiln the system would have to be powered directly from the supply network). The 100 per cent H2 kiln is the main but not the only development at SACMI. “By 2024 we will also present a new prototype for an all-electric kiln, exploring all the opportunities in this area as well, with the aim of being ready for the evolution of the infrastructure and