Brick Drying System Clay Brick Single Layer Chamber Dryer

Brick drying system clay brick single layer chamber dryer 


Technological Description
Technical key point
a.The material should be fully mixed when processing, thus to ensure the good molding of the green brick and drying uniformity.
b.The clay material should be proper treated, the biggest particles should be around 2mm or so.
c.Molding moisture content should be controlled under 18%. The section before critical point while drying must be strictly controlled and drying cycle is not less than 26 hours.
This production line has advanced technology, reasonable process equipment selection and high mechanization degree;It can not only meet the production requirement, but also ensure good products quality. It can product a variety of products at the same time.

Raw material crushing
In raw material stock, clay will be sent to box feeder by loader, and being sent to wet pan mill and fine pulverizing grinder to be crushed. Crushed clay will be sent to double shaft mixer, water added automatically and mixed. Thus the raw material is being sent to aging room by warehouse reversible belt conveyor.

Raw Material Aging Treatment 
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 for molding process.

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 10000pcs Chinese standard bricks.

Brick cutting,stacking and transportation system 
The whole system is used to automatically loaded green bricks on the pallet and bricks will be sent into the tunnel drying room for drying by drying cart or ferry cart, then dried bricks will be unloaded from the drying cart and pallet automatically, then sent into the automatic setting process. After unloading, empty pallet will be sent to the plate storage from storage and transportation line. A complete set of system is full automatic operation.

Brick Drying and firing
Drying and firing will adopt two times stacking & firing process with single layer drying technology. Drying chamber adopts tunnel dryer (83.65x22.625m). The heat of the dryer comes from high temperature heat of fired-products and residual heat from Tunnel Kiln, through change the system to adjust the feeding air temperature and volume, so that to ensure the drying quality of green bricks.

Tunnel kiln adopts large section with inner width of 6.6 meter, it is designed as a flat ceiling structure. This kiln is suitable for firing products with 1200KJ/Kg characteristics.
Tunnel kiln has smoke exhausting system, kiln cart heat releasing system, kiln cart cooling system, gas burning system, heat recovery system, rapid cooling system and back pressure system(pressure balancing system). This kiln has following features: large section, high capacity, small section temperature difference low, good heat maintain. Meanwhile, the kiln auto-control system can ensure the baking heat parameters are stable, so to guarantee the brick firing quality is good.

Drying chamber
System & Construction 
Drying chamber adopts tunnel dryer (83.65x22.625m). The high temperature fan and low temperature fan of Tunnel Kiln is able to recycle and collect the residual Tunnel Kiln heat and transferred to Dryer, it goes via the heating fan in the dryer beginning to rotating fan, then goes into dryer and bricks through mechanical properties.
Moisture will be removed by moisture exhaust fan, so as to ensure the drying quality of green bricks. Well-dried bricks will be unloaded from drying cart by unloading system and re-stacking on the marshalling transfer bench, then the well-dried bricks will be stacked on the kiln cart by stacking machine and sent to tunnel kiln by ferry car.
The heat source of drying chamber is the waste heat from tunnel kiln, which will be supplied to drying chamber through external pipe system. The drying chamber includes airing system, moisture exhausting system, operation system and monitoring system, besides the monitoring system, the airing and exhausting system are made of metal pipe and related fans. As all the air brakes and adjust switch are set outside of the drying chamber, which is not only conveniences for debugging but also make it more easier for maintain and fixing.

Tunnel Kiln 
Tunnel kiln system
The technology choose flat ceiling construction tunnel kiln. Tunnel kiln has smoke exhausting system, air exhausting fan under the kiln cart, cooling system under the kiln cart, gas burning system, heat recycle system, rapid cooling system and back pressure system (pressure balancing system).
We can simply adjust these system to make the Tunnel Kiln work more smoothly and efficiency. 
This Tunnel Kiln adopts advanced 4 doors technology, at both ends of the tunnel kiln. At the entrance side, there is a preparatory room, and a cut-off door between the preparatory room and the kiln joint zone. Thus it effectively avoid entering the cold air and ensure the baking system of the kiln.



Tunnel kiln structure
Red brick is laid for the pre-heating zone and cooling zone where the temperature is below 200ºC.
The rest part, baking zone and the innermost wall of insulating zone are adopt clay refractory brick. The clay insulting bricks will be used for laying the insulting area. Meanwhile, refractory fabric felt ( for the relative part of temperature curve above 600 Celsius) or rock wool felt will be used for stuffing and red bricks will be laid on the external wall.

Kiln ceiling structure:
in both low temperature side of the tunnel kiln, there is one kiln car space area adopt cast-in concrete top slab. For other area, using clay material slab and high alumina material hang down of the H type steel beam by cast product. Both sides wall be used as wall bearing to support the main beam's weight. High aluminum cotton , refractory fabric felt, rock wool felt, rock wool slab are put on the refractory hanging brick, which make up complex insulation layer.
The gap between the top plate will be filling with high aluminum fiber. The top of the insulating layer will be painted with high temperature binder material, in order to ensure the material's insensitivity and structure's durability.

Smaller clay brick drying room 
 
If you want to set up a new brick plant or purchase clay brick making machine and equipment, please contact with us at any time .
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