Direxa Engineering, LLC, an engineering company based in Colorado, USA, and specializing in heat treatment for various industries, and its R&D projects partners Ceritherm and Seipia, both French companies, have combined their skills to develop an innovative concept for a low-consumption tunnel kiln, otherwise named the Skate-Kiln. The current thermal treatment equipment are becoming outdated. Following the two oil crises and the energy cost increase, the 1980s saw numerous development projects, however, none of these solutions was successful. Up to now, two major families of kilns are supplied, which are: tunnel kilns with cars for heavy product mass and firing cycles over 8 h roller kilns for lower product mass and shorter firing cycles The pros and cons of each of these solutions are well known. Direxa, Ceritherm, and Seipia have studied the limitations of each kiln. For the roller kiln, the ledges and the roller’s drives, and thus the supports, are outside of the kiln walls. This presents the following disadvantages: lack of airtightness, heat losses by thermal conduction, limitations in terms of product mass and kiln width, as well as the unreliable product tracking. In the case of tunnel kilns, the main weakness are the kiln cars themselves! A large part of the kiln mass is exposed to the firing cycle and must be considered as part of the total mass to be fired. Depending on the car design, the extra energy consumption can amount to 30 to 50 % of the...
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