With the continuous increase of energy price in today’s life, it is of high importance to invent a novel process for the tunnel kiln. In this work, counter-travelling tunnel kilns with ventilators have been introduced, which work with higher energy efficiencies compared to regular kilns. The necessary calculations and preliminary investigations have also been reported. The concept of a counter-travelling tunnel kiln was further developed and optimized. With this kiln type, kiln cars move in the two tracks in opposite directions through the central separated channel. Middle ventilators are used to keep the kiln gas recirculating between both kiln sides. Thus, the heat from the hot ware can be transferred to the cold ware on both sides of the kiln. To describe this complicated process of solid-solid-recuperation, a simplified mathematical model with analytical equations was built first; a standard clinker brick without holes were taken as an example. The principle effects and process mechanism were clearly shown with the model. The influence of all kinds of variables, such as temperature, brick piles' height, gap thickness of brick piles etc., were investigated. It was evident that the electrical ventilator power is strongly dependent on the gap thickness of the brick piles, and the ventilator power would be minimal at a gap thickness of around 10-20 mm. Meanwhile, an energy balance of the whole kiln process was done, including the sum of fossil and primary electrical energy, illustrating the optimum temperature difference between the hot and cold side. As this study demonstrated, because of the solid-solid-recuperation, the energy consumption of this counter-travelling kiln is only approximately 40% of that of conventional brick tunnel kiln. The most obvious energy-saving term is that from the flue gas. This is the effect that by the solid-solid-recuperation process the ballast gas by the solid-gas-recuperation process is avoided. Therefore, the aim of this research project is fully achieved.