Design and Simulation of Pottery Kiln

Kiran Govind  (  kirangpotti@gmail.com )

Birla Institute of Technology and Science
Keerthidas PU 
NSS College of Engineering
Karthik R 
National Institute of Design
Kishore R 
NSS College of Engineering

Research Article

Keywords: kiln, rewood, coconut husk, bon re, pottery, chimney, downdraught, simulation, fuel
consumption

DOI: https://doi.org/10.21203/rs.3.rs-593830/v1

License:   This work is licensed under a Creative Commons Attribution 4.0 International License.  
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 DESIGN AND SIMULATION OF POTTERY KILN
Kiran Govind1, Keerthidas P U2, Karthik R3, Kishore R4
1. Kiran Govind – Birla Institute of Technology and Science – kirangpotti@gmail.com

2. Keerthidas PU – NSS College of Engineering - keerthidas6464@gmail.com

3. Karthik R – National Institute of Design – karthik.sparx@gmail.com

4. Kishore R – NSS College of Engineering - sa.kishore.r@gmail.com

“*Correspondence to Kiran Govind”

Abstract
Pottery industry is one of the small-scale industries in India. Most rural potters depend upon
traditional pottery kilns for burning process by firewood or coconut husk. In order to produce
high quality pottery products better burning process is needed. The purpose of the project is
to thermal analysis of burning process in a traditional furnace in order to achieve uniform
temperature inside the kiln and decrease the fuel consumption through better distribution of input
heat. The traditional kilns are bonfire kilns, which involve open firing in
shallow pit. These kilns suffer higher fuel consumption, poor ware strength and
extensive breakage. Smokes produced during firing will serious health problems to
pottery workers and their family. There is lack of thermal studies on bonfire kilns. Accounting
the demerits of traditional one is led to development of downdraught kiln. The thermal studies in
performance of downdraught kiln by varying different parameters practically expensive and
almost impossible. For this reason, the downdraught kiln is modeled and simulated on the
computer by using the numerical method. By changing different parameter of the kiln like
change in firewall height, Chimney height and roof geometry in simulation, substantial
improvement in the performance of the kiln was detected. This modification is suggesting for the
new design of improved pottery kiln.

Keywords: kiln, firewood, coconut husk, bonfire, pottery, chimney, downdraught, simulation,
fuel consumption
1 Introduction
Upgradation of rural industrial sector is the key to the development of our rural masses and for
this, technological inputs are crucial for cutting down the costs, improving the productivity and
the quality of products. Pottery industry is one of the rural industrial sectors in our country and
pottery products are the source of income for many families in rural areas. For many generations,
this industry has been continued based on working experiences which make it weak and
insignificant. Traditional pottery workers are following conventional methods for manufacturing
products. Hence these products cannot compete with other products in the market.

Pottery industry is an energy intensive technology and most of the pottery kilns for firing the
pottery is used traditionally in rural areas have a very poor efficiency. The high efficiency
pottery kilns used in the organised sector are too expensive to be affordable by the small-scale
sector. In order to improve the quality of the products and decreasing the cost of the production it
is needed to optimize the burning process in traditional kilns.

After the visit of various rural pottery industrial sectors in Palakkad and the interaction with rural
potters’ various problems are identified. During the stages of firing smoke come out of the kiln
are directly exposed to atmosphere leads to air pollution and health problems to rural potters and
their families. Continuously fuels feeding about 6 hrs directly by potters are difficult and suffer
various health problems. Firing process time is higher. Fuel consumption is higher (fuel is
feeding separately through fire mouth and firewood also placed inside the kiln). Separate clay
and straw are required for covering the kiln. Uniform heating is not achieving most of time, so
some pots are needed to fire again. Fuel burning rate is controlled by feed rate of fuel, and
require skill and experienced persons. Poor ware strength and extensive breakage.

The main objective for this study is to support the design improved pottery kiln by simulating the
various models and analysing temperature distribution inside the kiln. Also study the flue gas
flow and radiation inside the kiln. The new improved pottery kiln has better uniformity of
temperature and lower fuel consumption than traditional kilns. It provides better working
environment for potters and fewer tendencies of hotspots on pots. Increase in the residence time
of gases inside the kiln makes better control of firing.

The Clay minerals are considered among the general group of Phyllosilicates that contains two
structural units, such as silica (SiO2) and alumina (Al2O3) studied by C.D. Barton et al [1]. The
uniqueness of clay is due to the variation in behavior in the presence of water to become plastic
in nature described by W. D. Kingery et al [2]. Kalali Atieh [3] studied the different potteries and
methods of producing molded pottery materials and analysed the heat flow during burning using
the CFD simulation of the furnace (Kiln). The Kiln which is classified into down draught and up
draught based on the flow of the flow gas inside the furnace chamber. The study based on the
down draught Kiln by Carl Persson [4] involved the study of numerical analysis of heat and mass
transfer phenomena. M.R. Ravi et al [5] contributed the energy utilization of the up-draught Kiln
during the heating and drying process of clay pottery. Furthermore, with the study of Sunil
Gokhale et al [6] about utility analysis and Kristina Nilenius [7] for flow analysis indicated the
efficiency of the Kiln that is utilized in the process. The Kiln thus can provide the necessary
temperature for the pottery substance to dry and for providing the material strength. This paper
involves the modification of the existing Kiln to obtain a better efficiency and environmental
impact by improvising the design.

2 Traditional Pottery Kilns

The traditional kilns are primarily based on wood as fuel and can be of different types: bonfire
kilns, updraught kilns and downdraught kilns. Bonfire kilns, dating back to 100000 years,
involve open firing in a shallow pit. An example on a bonfire kiln can be viewed in Figure 1.1
Loading of pottery items in bonfire kilns and covering of straw and clay on the surface of kilns
for firing are shown in Figure 1.2, Figure 1.3 respectively.

Figure 1.1 Bonfire Kilns in Kazhani Chungam, Thenur in Palakkad District

Figure 1.2 Loading of pottery items in Bonfire Kilns

Despite flexibility of fuel can be used, these kilns suffer from low temperature of firing, poor
ware strength and extensive breakage.

Figure 1.3 Pottery items in Bonfirekilns are covered with Staw and clay

An Updraught kilns is a cylindrical, square structure open at top. Fuel is fired below a perforated
platforn on which pottery is arranged, and the fire passes upward through the wares, escaping
from the top. Updraught kilns exhibit better uniformity of temperature and better retention of
heat as compared to bonfire kilns. Pottery temperature upto 900°C can be attained in this type of
kilns, when fired with wood. In these kilns, there is no control over air flow rate, while fuel
burning rate is controlled by skilful manipulation of fuel feed rate. An example of square
structured Updraught kiln shown in the Figure 1.4. Straw and clay covering is only in the top of
kiln and packing of clay wares are shown in this Figure.

In Downdraught kilns, A chimney is connected at the bottom thereby dragging the hot gases
produced at the entrance in such a way that initially the hot gases flow upwards and proceeding
to that flow downward due to the pull from the chimney. Along with a damper which is utilized
for controlling the rate of firing and excess air. The achievable temperature limits range from
1500-1600°C and provides a better uniformity and control over firing than the updraught kiln.
However, the cost of construction is much higher than that of an Updraught kiln, due to the
height of chimney and mass of masonry in the kiln.
 Figure 1.4 Packing of clay wares inside the squared Updraught kiln in Puthucode

2.1 The Firing Process for Pottery

For uniform contact between the flue gas and the pottery the gaps are filled with broken tiles and
pottery resulting into uniform porosity once clay wares are placed. Once the updraught kiln is
covered by straws wet clay is utilised for plastering the entirely such that the heat would not
escape. It will reduce the area available for escape of the flue gases, thereby retaining more heat.

Firing consists of various stages namely, smoking, slow firing, rapid firing and soaking.

In smoking, the process assists in removing the moisture to evaporate along with the prevention
of crack from generating since the violent evaporation of water vapor is retarded as the heating is
very slow, and pottery temperatures are below 150°C. The duration of smoking depends on the
quantity of the wares and atmospheric conditions to be fired, the bulkier the ware, longer the
smoking. Also depends on the climate conditions. Rainy seasons need longer time for smoking.
Typical heating rates in smoking range from 0.5 to 1°C per minute.
In slow firing, volatile matter other than moisture is removed at temperatures below 450-500°C,
at moderate rates of heating with typical temperature rise rates of 1.5 to 2°C per minute.

After all the volatile matter is gone, rapid firing is done at a high rate so as to raise the
temperature of the wares rapidly to 800-950°C. Typical temperature rise rates are 3-4°C per
minute.

In soaking, firing is done at a rate sufficient to maintain the temperature of the wares at the
required value over a period of time. The total duration of firing for pottery wares normally
range about 2-3 days.

Present study is focusing on the new improved pottery kiln and studies its characteristics on the
rapid firing stage. Firing process in Bonfire kiln and Updraught kiln are shown in Figure 1.5,
Figure 1.6 respectively.

Smoking

Firemouth of smoking and slow firing

Rapid firing soaking

Figure 1.5 Firing process in Bonfire kiln.

 Smoking Slow Firing Rapid Firing
Figure 1.6 Firing process in Updraught Kiln

2.2 The Structure of Clay

The Clay minerals are a part of a general group within the Phyllosilicates that contain large
percentage of water trapped between their silicate sheets with two structural units, such as silica
(SiO2) and alumina (Al2O3). The silica sheet is formed of tetrahedron consisting of Si4+ which is
surrounded by 4 oxygen atoms. The oxygen atoms are shared by adjacent tetrahedra. These
tetrahedra are repeated to arrange a hexagonal network where the sheet composition is Si2O52-.
The alumina sheets consist of octahedral where Al3+ is surrounded by six hydroxyl groups. The
clay minerals are formed by the aluminium hydroxide layers that condense with the silica sheets.
Water is bounded to the layer structure as hydroxyl groups. The fact that the atoms are not
closely packed together results in relatively low density which is an important property of clay
material. The strength of bonds results in a high melting temperature.

2.3 The Nature of Clay and Clay-Water Relationship

Clay usually contains one or more mineral clay minerals as well as accessory minerals, such as
iron oxides. Clay used in Puthucode, Thenur and Kazhani Chugam includes some iron
compounds and the “glowing” effect at the end of burning process is a result of releasing Fe2O3.
Clay is a unique group of materials. They differ from the others due to their behaviour when
associated to the water. During forming operation, water is added to the clay to get plasticity.
The water appears as thin water films which separates the clay particles and makes them free to
mover over one another. The plasticity is in a compromise with the porosity to form good quality
clay. The porosity controls the migration of water during the drying process.
2.4 Heat Transfer
This work is focusing on the design of improved pottery kiln. From these present studies
considering a Downdraught type kiln. Heat transfer occurs in three different types which are
conduction, convection and radiation. The heat flow inside the kiln is caused by Chimney effect.

2.4.1 Conduction

There are two governing mechanisms in heat conduction. The first mechanism is molecular
interaction where a temperature gradient is the driving force. The second mechanism is heat
transfer by free electrons. This mechanism is significantly in metals since the concentration of
free electrons is high in metals but does not exist in non-metallic solids. The equation describing
heat conduction is referred to as Fourier’s first law of heat conduction and is written as in
equation (2.4.1) where k is the thermal conductivity and is independent of direction making this
expression isotropic.
𝑞𝑥 𝑑𝑇
𝐴
= −𝑘 (2.4.1)
𝑑𝑥

2.4.2 Convection

Heat convection involves heat transfer between a surface and an adjacent fluid and there exist
two different types of convection; forced convection and free or natural convection. Forced
convection implies an agent forcing the fluid past the solid such as a fan or a pump. Free or
natural convection causes movement of the fluid by density difference resulting from the
temperature variation in the fluid. The rate equation is referred to as the Newton rate equation
and is written as in equation (2.4.2) where h is analogous to k in Fourier’s law of heat addition.
𝑞𝑥
= ℎ∆𝑇 (2.4.2)
𝐴

2.4.3 Radiation

Heat transfer by radiation differs some compared to conduction and convection since no medium
is required for its propagation. Stefan-Boltzmann law of thermal radiation describes the rate of
energy emission from a perfect radiator referred to a black body and it is written as in equation
(2.4.3) where σ is the Stefan-Boltzmann constant. Heat transfer by radiation is of great
importance at high temperatures.
𝑞𝑥
= 𝜎𝑇 4 (2.4.3)
𝐴
2.4.4 Chimney Effect

It is the natural phenomenon that occurs when the density difference between hot and cold air
column creates a natural flow through a chimney. When heat is added to a fluid there will be a
fluid motion caused by the heat transfer. This is due to that the fluid density will vary with the
temperature. In Downdraught kilns air flow is heated and density becomes gradually lighter and
the air rises. This will cause a pressure difference between the furnace top and bottom. The
height of the chimney and the temperature gradient affects the pressure difference. This pressure
difference will cause the natural circulation of air through the kilns. This effect is named as
chimney effect. This is also affected by the height and temperature of the walls. Induced pressure
due to chimney effect will be change with chimney height. In this project variation in the
pressure due to change in the chimney height was calculated by equation (2.4.4) where ρ is
density of air in kg/m3 , g is acceleration due to gravity in m/s2 and h is the height of the chimney.

𝑃 = 𝜌𝑔ℎ (2.4.4)

2.5 CFD Theory

Computational fluid dynamics (CFD) is a tool for solving the Navier Stokes equation (N.S)
numerically by computer software. N.S. Equations are differential equations that describe the
motion of a fluid. CFD utilizes N.S. Equations for solving momentum, heat and mass transfer for
a certain geometry. The geometry is divided into computation cells, and then N.S. Equations are
solved numerically for each cell in a iterative manner. The quality of geometry resolution, input
data and software knowledge affects the result significantly. Usually computer capacity is a
limiting factor. The results can give a picture of temperature distribution and flow field, must be
analyzed with critical eye. An advantage with CFD is that it is possible to get detailed knowledge
of a system rather fast. This makes CFD very useful for both existing systems and preliminary
studies for the functionality of new systems. In this project study the performance of a new
design of Downdraught kiln are practically expensive and almost impossible. For this reason,
thermal analysis of new downdraught kiln using CFD computer simulations is sometimes the
most practical way.

2.5.1 Governing transport equations

Some assumptions must be made in solving fluid flows. The flow is assumed incompressible
which is defined as no variation in density along the streamline and this assumption reduces the
equation of continuity to equation (2.5.1). The flow is also assumed to be considered as a
Newtonian fluid. For a Newtonian fluid, the viscous stress is a linear function of the rate of strain
and this is true for most common fluids such as gas or water where the viscous stress can be
written as equation (2.5.2). Based on these assumptions the equation of motion is written as
equation (2.5.3). Note that i and j denote the tree dimensions. In this equation first term describes
accumulation, the second term describes convection, the third term describes the rate of change
of pressure due to motion, the fourth term describes diffusion and last term is the source term.
Uj (2.5.1)
=0
xj

Uj Uj (2.5.2)

ij = ji = − ( + )
xj xj

Ui Ui 1 P  Uj Uj

+ Uj =− + ( + ) + Gi (2.5.3)
t xj  xi xj xj xi

These equations are solved numerically by CFD software by dividing the computational domain
into cells and thus reformulate them from partial differential equations to algebraic equations.
This reformation also leads to numerical errors and the magnitude of these errors depends of the
cell size. A smaller cell size will decrease the error but increase the computational time, which is
costly. When working with CFD a compromise between accuracy and expense must always
made.

2.5.2 Turbulence modelling

Turbulence enhances mass transfer and chemical reaction and is often encountered in industrial
applications. It is therefore interesting from an engineering point of view to be able to simulate
turbulence. Turbulence is a state of the fluid flow, which can be considered as chaotic and
random. The most characteristics features of turbulence flows are its irregularity (different shape,
size), diffusivity, instability, three dimensional structures and its dissipation of the kinetic
energy. All these characteristics together, make turbulent flows very random and difficult to
model. Many models, based on different assumptions, are available and they all have different
applicability and limitations. The model used in this project is RNG k-ε model.

2.5.3 RNG k-ε model

Two-equation model allow the determination of both, a turbulent length and time scale by
solving two separate equations. The RNG-based k-ε turbulence model is derived from the
instantaneous Navier-Stokes equations, using a mathematical technique called ‘renormalization
group’ (RNG) methods. The effect of swirl on turbulence is included in the RNG model,
enhancing the accuracy for swirling flows. While the standard k-ε model is a high-Reynolds
number model, the RNG theory provides an analytically derived differential formula for
effective viscosity that accounts for low-Reynolds number effects.
2.5.4 Transport Equations for the RNG k-ε Model

The RNG k-ε model has a similar form to the standard k-ε model. The turbulence kinetic energy
k, and its rate of dissipation ε, is obtained from the following transport equations are written as
Equations (2.5.4) & (2.5.5).
    t  k 
( k ) + ( kuj ) =   +   + Gk + Gb −  − YM + Sk (2.5.4)
t xj xj    xj 

    t     
(  ) + ( uj ) =   +   + C1 (Gk + C 3Gb) − C 2 + S (2.5.5)
t xj xj    xj  k k

In these equations, Gk represents the generation of turbulence kinetic energy due to the mean
velocity gradients. Gb is the generation of turbulent kinetic energy due to buoyancy. YM
represents the contribution of the fluctuating dilatation in compressible turbulence to the overall
dissipation rate. The quantities αk and αε are the inverse effective Prandtl numbers for k and ε,
respectively. Sk and Sε are user-defined source terms.

2.5.5 Radiation Model

The model for the radiation absorption in the porous clay wares and firewall is discrete ordinates.
Discrete ordinate method estimates the directional variation of the radiative intensity using a
discrete representation of the directions. Radiative transfer equation (RTE) is solved to calculate
Q, which is determined by the radiative heat fluxes. The RTE for the gray medium at any
position r along a path s through an absorbing, emitting, and non scattering medium is shown in
equation (2.5.6) where ka is absorption coefficient and Ib(r) is black body intensity.
dl (r,s )
= −kaI (r , s ) + kbIb(r ) (2.5.6)
ds

3. CFD Modelling
It is very complicated to model the real pottery kiln is packed with lot of clay bodies. The
simulation model in this project has a simple geometry with three clay bodies in it. Clay bodies
are approximated as rectangular slabs having thickness 150mm. Rapid firing stage in firing
process of clay is mainly focused to simulate the project. The overall way of working while
developing the model was done in an iterative and step-by-step way. Simulation was done and
re-done as knowledge about the behaviour increased and the simulations got more detailed and
advanced. The presented model has good quality mesh especially close to the walls.
3.1 Development of Geometry
Figure 3.1 shows the final geometry of the improved pottery kiln. The geometry was created
using the Solid Edge ST9 and imported to ANSYS Workbench platform. To reduce the
computational time, a simple model is adopted. Inlet chamber of firewall and chimney are
eliminated in the model and pottery wares are approximated as rectangular slabs of
1500x1300x150 mm3. Only three wares are placed in the FLUENT model, to reduce the
computational cost and increase the accuracy level. Wares are placed vertically from firewall
side.

Figure 3.1 Final improved pottery kiln Ansys model

3.3 Mesh
The mesh was created in the meshing tool from the ANSYS Workbench platform. Curvature
was chosen as advanced size function having growth rate of 1.1280. Tetrahedrons assembly
meshing method was selected for meshing. Number of nodes are 30309 and number of elements
in the mesh are 168413. Orthogonal quality of mesh is 0.2070504-0.9936169 having average of
0.8456520. Cell skewness is 0.2562770.

3.4 Setting in FLUENT and Assumption

Since there is chimney draught, pressure variation is small. The ideal gas law is used to estimate
the relation between density and temperature. The flue gas is approximated to be air. Flow is
incompressible, so Pressure-based solver is used. The solution methods, where the used pressure-
velocity coupling scheme is SIMPLEC, the gradient solved with least square cell based, the
pressure with standard. The momentum, turbulent kinetic energy was solved with second order
upwind and the turbulent dissipation rate were solved with first order upwind. For complicated
flows involving turbulence, SIMPLEC will improve convergence in pressure-velocity coupling.
In the solution control the under relaxation factors were all default values.

3.5 Boundary Conditions

The turbulence model was used the RNG k-ε model enhanced near-wall treatment. Because it
does not require fine mesh near the walls but still can handle the low Reynolds number zone. The
energy equation was selected to simulate the energy. Radiation for the walls and wares was
modelled with Discrete Ordinates method (DO) with 10 iterations per radiation iteration, the
absorption coefficient was set that high so the outer surface would absorb most of the radiation
and not get deeper into the wares or walls. Materials and its properties for modelling kiln are
shown in Table 3-1. Wares are set as porous material of porosity 0.1 and with a fixed value of
zero for the velocity in all three directions. Inlet was set as mass-flow inlet and outlet set as a
pressure-outlet. Mass flow inlet input is 0.16 kg/sec was calculated from Matlab code that can be
found in appendix A. Inlet temperature is 1100k taken from Nilenius 2011 Thesis about CFD
simulation of flue gas in traditional Indonesian Pottery Furnace. The walls of kiln thermal setting
was modelled as mix or convective and radiation, outside temperature of 300k and a heat
coefficient of 25 W/m2K. Thermal conditions of wares are set heat flux as zero. The radiation
was activated by setting internal emissivity to one. In this simulation process first flow is
stabilized in steady state. That gave a solution with a velocity profile that was used to initialize
the next part of the simulation. Next in transient state consider the equations of flow, Turbulence,
Energy and Discrete Ordinates and was calculated for 300 seconds with 0.1 second time steps.
The solution convergence is obtained by monitoring the continuity, momentum, energy and
turbulence separately. A convergence criterion 10-3 is used for mass conservation, velocities
turbulence values 10-6 is used for energy equations. Each time step is considered to be converged
in the simulation.

Table 3-1 Materials and its Properties

Materials Density(Kg/m3 ) Specific heat(Cp)(j/kg-k) Thermal Conductivity(w/m-k)

Brick 2050 1840 0.52

Clay 1997 880 1.25

Source: Energy Audit and Improvement of an Updraught Pottery Kiln

M.R.Ravi, P.L. Dhar and Sangeeta Kohli
3.6 Mesh Convergence study
Mesh convergence determines how many elements are required in a model to ensure that the
results of an analysis are not affected by changing the size of the mesh. System response will
converge to a repeatable solution with increasing the element size. Mesh convergence study
conducted using the tetrahedral mesh.

Graph is plotted from the output of mesh convergence study as shown in Figure 3.3. From this
results solution is almost constant at the end last two models. So mesh convergence is obtained.
All the meshed models used for analysis is in the range of 181297 – 221991 number of elements.

Figure 3.3 Mesh convergence graph

4 RESULTS AND DISCUSSIONS
The Downdraught pottery kiln was tested with changing firewall height, Chimney height and
changing shape of the roof on the CFD simulation at rapid firing stage. The results are obtained
in each modelling are compared in terms of temperature distribution inside the kiln and on wares,
heat flux distribution and velocity of flow. Every model temperature distributions are analyzed
after 14400 sec (4 Hours).

4.1 The Effect of Changing Firewall height on the Temperature Distribution

Modeling of kiln is start with modifying the firewall height. In this work models of firewall
height 2, 1.75, 1.5, 1.25, 1.0 and 0.75 metre are created and simulated in the ANSYS Fluent.
Results of each model can be found in appendix B Table B-1. From these results analysis of
temperature distribution inside the kiln, almost even temperature distribution is obtained at
firewall height 0.75 m. Temperature contours inside the kiln and temperature distribution on
surface of wares at firewall height 0.75 m is shown in Figure 4.1 & 4.2 respectively.

Figure 4.1 Temperature contour inside the kiln at firewall height 0.75 m
Left Side View Right Side view

Figure 4.2 Temperature contours on surface of wares

For the analysis rectangular slabs are approximated as wares and temperature on wares almost
uniform near the firewall and also the other end of firewall from both side views.

Mean temperature distribution on three ware are obtained from simulation results. From these
graphs are shown in Figure 4.3.a, 4.3.b and 4.3.c. Form these graphs at firewall height 0.75 m
shows uniform mean temperature on all these three wares. Mean temperature of wares are about
900k at firewall height 0.75 m. At firewall height of 1 m mean temperature of two wares further
from firewall is 900k, but clay ware placed near to the firewall has about 600-700k temperature
is obtained.

Figure 4.3.a Firewall height versus temperature on ware placed near to firewall
Figure 4.3.b Firewall height versus temperature on second ware

Figure 4.3.c. Firewall height versus Temperature on ware placed far from firewall

Consider the total heat transfer rate to the kiln body from simulation results. For the optimum
performance of the kiln, minimum heat transfer rate to the kiln body. In downdraught kilns
radiation heat transfer is dominant. Radiation heat transfer between clay wares and to the kiln
walls are significant. Radiation heat transfer to kiln body is less for enhancing the efficiency of
kiln. Here total heat transfer rate to kiln body and radiation heat transfer rate to kiln body are
accounted and graphs are plotted about effect of heat transfer rate to kiln body and radiation heat
transfer rate to kiln body of different firewall heights. Graphs are plotted shown in Figure 4.4.a
and Figure 4.4.b

Figure 4.4.a Firewall height versus Total Heat transfer rate to kiln body

Figure 4.4.b. Firewall height versus Radiation heat transfer to kiln body

From Figure 4.4.a least heat transfer rate to kiln body at Firewall height of 1.5m and high heat
transfer rate at height of 1.25 m. Heat loss to kiln body least at a range of 1.25 -2 m firewall
height. Radiation heat transfer rate almost same for all firewall heights, but least radiation heat
transfer rate to kiln body at height of 1.25 m.
4.2 The Effect of Changing Chimney height on Heat Flux Distribution
From the simulation results of changing firewall height, we found that almost uniform
temperature distribution is obtained at a firewall height of 0.75 m. Therefore, we fixed the
firewall height as 0.75 m for the further analysis of the kiln. For reducing the complication in
simulation the chimney height in ANSYS Model was eliminated. Simulation was done by
changing the pressure in the pressure-outlet. Induced pressure is calculated for different chimney
heights are set as pressure-outlet. Chimney heights of 2, 3, 4, 5 and 6 m are simulated and results
are obtained. Analysing the temperature distribution inside the kiln is almost same. Considering
total heat transfer to the kiln body and radiation heat transfer to the kiln body and heat transfer
rate to wares are evaluated. Variation of total heat transfer rate and radiation heat transfer to the
kiln body with change in chimney height is plotted as shown in Figures 4.5.a & 4.5.b.

Figure 4.5.a. Change in Total heat transfer rate with chimney height

Figure 4.5.b. Change in radiation heat transfer rate with chimney height

Heat transfer to the kiln body is more at chimney height 5 m and almost same heat transfer rate
to change in the chimney height. Heat loss to the kiln body is slightly higher at 5 m. From this
graph radiation heat transfer rate to kiln body is independent of change in chimney height.
Heat transfer rate to wares are studied and graphs are plotted about radiation and total heat
transfer to wares with chimney heights are shown in Figure 4.6.a and 4.6.b.

Figure 4.6.a Total heat transfer to ware with chimney height

Figure 4.6.b. Radiation heat transfer rate with Chimney height

From the graph of total heat transfer rate to wares at chimney height of 3 m is minimum. There is
almost linear increase in heat transfer to clay wares, when increase in chimney height to 5 m.
Further increase in chimney height heat transfer rate is constant. In radiation heat transfer to clay
wares is more at 5 m and further increase in height shows decrease in the radiation heat transfer
to wares.
4.3 The Effect of Changing Roof Geometry on Temperature Distribution
Consider the influence of kiln’s roof geometry on temperature distribution inside the kiln and
temperature on surface of wares. Different types of roofs are modelled, simulated and analysed
results. In this work aerofoil type roof is simulated and temperature contours inside the kiln,
temperature on the surface of wares are shown in Figure 4.7 and 4.8 respectively.

Figure 4.7 Temperature profile of aerofoil type roof

Left Side View Right Side view

Figure 4.8 Temperature on surface of wares of aerofoil type roof kiln

Previously analysed dome type roof’s similar temperature contours inside the kiln and surface of
wares are obtained in the analysis of aerofoil type roof. For the further study on roof geometry
focused only on dome type roofs. Another alteration in roof geometry is decreasing dome’s
height by increasing radius of curvature of dome. Temperature profiles of dome has larger radius
of curvature is shown in Figure 4.9 and 4.10. Comparing the previous results of temperature
contours even temperature distribution is obtained on wares and inside kiln of dome has larger
radius of curvature.

Figure 4.9 Temperature contours inside the kiln has dome of larger radius of curvature

Left Side view Right Side view

Figure 4.10 Temperature on the surface of wares of dome has larger radius of curvature
5.1 Conclusion
The thermal performance of the Downdraught kiln according to change in parameters like
firewall height, chimney height and roof geometry are analysed using simulation models in
ANSYS Fluent. The results from the simulations indicate that it is possible to obtain quite an
even temperature distribution inside the kiln with firewall height of 0.75 m, Chimney height of 5
m and dome has larger radius of curvature. The radiate heat transfer inside the kiln was
calculated using DOM method. The kiln is evaluated in terms of temperature distribute on the
surface of wares and inside the kiln at rapid firing stage of firing process of pottery. The
predictions of CFD modelling have been found to yield results close to the actual operating
conditions according to the applied boundary conditions. Here the better performance are
obtained using one inlet, so it will reduce fuel consumption and better control of firing.

5.2 Suggestion for the new design of pottery kiln

From this study, can discover that the better performance and even temperature distribution is
obtained in the model has firewall height of 0.75 m and chimney height of 5m and dome has
larger radius of curvature. The new improved pottery kiln design model is shown in Figure 5.1.

Figure 5.1 New design model of improved pottery kiln

5.3 Recommendation
This simulation models, clay wars are approximated as rectangular slabs and this approximation
could be further modified to closer to real pottery wares to get more accurate results. Packing of
pottery wares inside the kiln and pattern of placing them can be studied for better performance.
Different roof geometries can be analysed for change in performance of kiln and there is lot of
scope for development of new type of roofs.

The water evaporation should be good to implement in the model and it might give information
of how the evaporation affects the process. The simulation results will get closer to reality.

6 REFERANCES
[1] Energy Audit and Improvement of an Updraught Pottery Kiln. M.R. Ravi, P.L.Dhar and
Sangeetha Kohli Department of Mechanical Engineering, Indian Institute of Technology
Delhi
[2] Nilenius Kristina. CFD Simulation of Flue Gas Flow in Traditional Indonesian Pottery
Furnace. Göteborg, Sweden: Department of Chemical and biological engineering, Division
of Chemical Reaction Engineering, CHALMERS UNIVERSITY OF TECHNOLOGY, 2011.
[3] Schotte Cecilia. CFD Simulation of Flue Gas Flow in Traditional Kasongan Pottery
Furnace. Göteborg: Department of Chemical and biological engineering, Division of
Chemical Reaction Engineering, CHALMERS UNIVERSITY OF TECHNOLOGY, 2010.
[4] Kalali Atieh. CDF simulation of Flue Gas Flow in Traditional Pottery Furnace. Göteborg:
Department of Chemical and biological engineering, Division of Chemical Reaction
Engineering, CHALMERS UNIVERSITY OF TECHNOLOGY, 2010.
[5] Callister William D. Materials science and engineering, an introduction. New York: John
Wiley Sons, Inc, 2003.
[6] Kothandaraman, C.P. and Subramanyan, S., 2007, Heat and Mass Transfer Data Book, Sixth
edition, New Age International Publishers, New Delhi.
[7] ANSYS Fluent Theory Guide 15.0.
Figures

Figure 1

Bon re Kilns in Kazhani Chungam, Thenur in Palakkad District

Figure 2

Loading of pottery items in Bon re Kilns

Figure 3

Pottery items in Bon rekilns are covered with Staw and clay
Figure 4

Packing of clay wares inside the squared Updraught kiln in Puthucode

Figure 5

Firing process in Bon re kiln.

Figure 6

Firing process in Updraught Kiln

Figure 7

Final improved pottery kiln Ansys model

Figure 8

Mesh convergence graph

Figure 9

Temperature contour inside the kiln at rewall height 0.75 m

Figure 10

Temperature contours on surface of wares

Figure 11

a. Firewall height versus temperature on ware placed near to rewall. b. Firewall height versus
temperature on second ware. c. Firewall height versus Temperature on ware placed far from rewall.
Figure 12

a. Firewall height versus Total Heat transfer rate to kiln body. b. Firewall height versus Radiation heat
transfer to kiln body.
Figure 13

a. Change in Total heat transfer rate with chimney height. b. Change in radiation heat transfer rate with
chimney height.
Figure 14

a. Total heat transfer to ware with chimney height. b. Radiation heat transfer rate with Chimney height.
Figure 15

Temperature pro le of aerofoil type roof.

Figure 16

Temperature on surface of wares of aerofoil type roof kiln.

Figure 17

Temperature contours inside the kiln has dome of larger radius of curvature
Figure 18

Temperature on the surface of wares of dome has larger radius of curvature

Figure 19

New design model of improved pottery kiln

Supplementary Files
This is a list of supplementary les associated with this preprint. Click to download.

AppendixKiln.docx