Ibrick China Auto bricks plant clay brick tunnel kiln project
Productive Technology
Sintering bricks are produced by using clays as raw materials and adopting two-time setting and baking processes, that is Semi-stiff Plastic Extruding Process; Drying in the Tunnel Drying Chamber Process and Baking in the Tunnel Kiln Process.
Main equipment has box feeder, primary roller crusher, fine pulverizing grinder, double shaft mixer, reversible belt conveyor, multi-buckets excavator, mixing and extruder, double stage vacuum extruding machine, tunnel dryer, tunnel kiln.
Estimated Consumption for Materials & Power
| Serial No. s | Item | Unit | Consumption per 10000pcs brick | Annual consumption | Daily consumption |
| 1 | Finished products | 10000pcs | / | 3,000 | 10 |
| 2 | Clay | ton | 39.6 | 118,800 | 396 |
| 3 | Fuel coal | ton | 1.2 | 3,600 | 12 |
| 4 | water | ton | 7 | 21,000 | 70 |
| 5 | electricity | degree | 900 | 2,700,000 | 9,000 |
| 6 | Diesel oils | ton |
| 50 |
|
| 7 | Machine oils & lubricating oils | ton |
| 7 |
|
Notes:
1. The fuel coal is calculated on the basis of 5000x4.18 Kilo Joule / Kg.
2. The water consumption includes non-production (living) requirement.
Technological Description
For this production line, raw material is clay, finished products is India brick. Big quantity raw material is required to be treated.
In raw materials warehouse, loaders will supply raw materials to plate feeders. At the upper part of materials warehouse there are metallic fences so as to prevent masses of raw limestone and sandstone from damaging the equipment. Raw material will be sent to primary roller crusher and fine pulverizing grinder in turn. Coal powder will be added here and mixing with water.
In order to increase the warehouse capacity and improve the ageing effect, the inclined-shaft type ageing warehouse is adopted. Thus the raw material is being distributed on the top by movable belt conveyor, aged raw material will be unloaded from side edge by multi bucket excavator.
General process is adopting semi-stiff plastic extruding process for brick molding, tunnel dryer for drying and tunnel kiln for firing.
This is advanced and practical technology, which can meet the production requirement.
Clay Raw material preparation
Before raw material being sent into raw material stock, masses of impurity and some organic parts will be eliminated by man power. In raw material stock, clay will be sent to box feeder by loader, and being sent to roller crusher and fine pulverizing grinder. Crushed clay with grain smaller than 3mm, and will be sent to double shaft mixer, water added and mixed, here the material moisture content reach to 13-14%. Thus the raw material is being sent to aging room by warehouse reversible belt conveyor.
Clay Brick Raw material aging process
Material will be aged in the aging room, thus, water inside will be diffused and evenly divided, the grains will be further dissolved, tempered and plasticized so that the shaping performance will be greatly improved.
Aged material will be unloaded on belt conveyor by multi-bucket excavator, then being sent to box feeder in molding process. Box feeder with big stock capacity, which can guarantee the mixer extruder and extruding machine's feeding requirement, stabilize the green brick adobe moisture content and molding process. Meanwhile, this gives buffering time for multi-bucket excavator to change the working position. This also water down the synchronization requirement for former process. The aged material moisture content will reduce 1%.
Brick Molding process
Aged clay material first will be sent to mixing extruder for water replenishing and mixing, then the double stage vacuum extruder will squeeze material to clean-surface and solid-inside columns, which will be cut into the required adobes by cutter.
Extruding machine is the key equipment among the whole production line, its performance are required as follows:
1) They can meet the need of different specification and hole shapes of the brick
2) The vacuum degree is -0.092Mpa, the extruding pressure is 2.0~3.0Mpa.
3) The hourly output per set is more than 6000pcs bricks.
Brick Drying and firing
Drying and firing will adopt twice setting & firing process. Drying chamber adopts new type tunnel dryer with inner width of 2.4meter. Whole production line adopts 7 lines of double-rail tunnel dryers. The heating source is residual/waste heat from the tunnel kiln. The smoking air feeding temperature and air volume will be adjusted through the air-adjustment-system, so as to ensure the drying quality of green bricks. Well-dried green bricks will be unloaded from drying cart and re-stacking on the kiln cart manually.
Tunnel kiln adopt large section with inner width of 3.4 meter, it is designed as a flat ceiling structure with refractory bricks. Considering bricks can not have black center and patterns, the firing fuel source is major by inner-mixing-coal, outer-casting-coal as replenish, the heat should meet the firing technology requirement. This kiln is suitable for firing products with 1600-2600KJ/Kg.
Tunnel kiln has smoke-releasing system, recycling system, waste-heat recovery system, cooling system and pressure balancing system. This kiln has following features: large section, high yield, small section temperature difference, good heat preservation effect. Meanwhile, the kiln auto-control system is equipped to ensure the baking heat parameters are stable, so the firing quality is guaranteed.
Major Technological Parameters for Tunnel Kiln
| Kiln: | 111 meters |
| Cart numbers contained: | 38 pcs |
| Inner width: | 3.4 meters |
| Setting height: | 1.5m (11 layers, firing shrinkage about 3%, clearance between top about 60mm) |
| Kiln cart loading capacity: | 6336 bricks/cart |
| Firing temperature: | 1000ºC~1050ºC |
| Firing cycle: | 41 hours |
| Firing yield: | 95% |
| Thermal consumption index: | 1300-1500KJ/Kg products |
| Annual output: | 20million bricks |
| Tunnel kiln outer specification: | 111×4.82×3.4 meters |
IBRICK is the technology initiator whom firstly professional supply clay brick sintering two-step stacking-firing process in the world. We always implement rigorous, secure, and integrated industrial chain management and provide professional engineering management, technology solutions, equipment purchasing and etc. For the clay sintering hollow bricks, decorative brick, insulating block, paving bricks, western-style tiles; Split brick projects all around the world. Our service include below items.
The inspection of raw materials---raw material industrial test, providing specific and targeted technology solutions according to scientific data tested;
The complete technology design--- material processing, molding, drying, firing, packaging, unloading and etc.
The complete production line equipments------- supply and installation the most economical and high-quality equipments.
The construction of complete set production line-----contracting to build the EPC projects for building materials.
The accurate and timely local services-------- providing the production management service, the lifelong technology service support, make every projects to create more value for each users.
We are willing to make our progress with you hand in hand and become impeller for world-wide brick-making cultural by our constant innovation and non-stop efforts.
