High Capacity Oil Fuel Fried Clay Brick Kiln

High capacity Oil fuel fried clay brick kiln 
Saving fuel small cost clay brick firing tunnel kiln India 

3.6m clay brick tunnel kiln project Working System
Productive Technology
Sintering bricks are produced by using clay as raw materials, using coal as fuel and adopting two-time stacking-firing processes that is Semi-stiff plastic extruding process; drying in the tunnel drying chamber and baking in the tunnel kiln process.
Main equipment has plate feeder, primary roller crusher, fine pulverizing grinder, double shaft mixer, reversible belt conveyor, multi-buckets excavator, mixing and extruder, double stage vacuum extruding machine, automatic loading and unloading system, tunnel drying chamber, robot, tunnel kiln, de-hacking machine.

Technological Description
This production line adopts clay as raw materials to produce sintered bricks. owning to high moisture content of raw material, adopting fine pulverizing technology to ensure that the grain size distribution of the raw material and capacity to meet the design requirements. Aging house adopts upper moving belt conveyor distribute material, aging section storage material, multi-bucket lateral unloading. This production line adopts the semi-hard plasticity extruder to forming, gas tunnel kiln and its running system learn the advanced experience both at home and abroad. Process is more concise and practical, with domestic mature technology, easy to meet the design requirement.
This production line with advanced technology, reasonable equipment selection, and high degree of mechanization not only guarantee the product quality and production, but also produce a variety of products.

Raw Material Preparation
The raw material is fed into box feeder from shed by loader, be treated by ordinary rolling crusher, fine pulverizing double-roll grinder. The finely-divided material is mixed with water in double shaft mixer, then being put into aging house by revertible warehouse rubber conveyor successively.

Raw Material Aging Treatment
After aging, raw material moisture diffusion homogenize, fine granulation, humiditying and plasticizing, thus highly improve its processability, Aged material will be unloaded on belt conveyor by multi-bucket excavator, then being sent to box feeder in 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 10,000pcs bricks. (common standard bricks )

Clay brick cutting,stacking and transportation system
In order to assure product quality, the green brick with higher resistance to deformation. After being cut into required adobes by cutter, divided by brick distribution and transportation belt conveyor, then stacking on drying cart by manual and being pushed into drying chamber by hydraulic ferry pusher.
Dried brick cart being pulled to unload line by drying chamber outlet ferry cart and drag to unloading post by winch. Unloading on belt conveyor and stacking on kiln cart by manual.
 
Drying and firing
Drying and firing will adopt twice setting & firing process. Drying chamber adopts new type tunnel dryer with inner width of 2.52 meter. Whole production line adopts 6 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 3.6meter, it is designed as a flat ceiling structure with refractory bricks, burning source is natural gas. This kiln is suitable for firing products with 1600-2600KJ/Kg.
Tunnel kiln has smoke-releasing system, burning 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.

Thermal Engineering Equipment
Determination of thermal engineering equipment for drying and firing
According to raw material and technology process, the thermal engineering equipment for drying and firing process adopts 1 group of small section tunnel dryer & 1 piece of middle section coal tunnel kiln. The feature of this design is low investment, flexible production, make good use of the waste heat from tunnel kiln, make full use of the tunnel kiln advantage. At the same time, it can reduce the consumption of energy. In addition, the small tunnel dryer and kiln with high heat use efficiency, big capacity, advanced technology, thus enabling the investor to lower their production cost, to improve the product quality and to enhance their economic efficiency.

Drying and Firing Technical Parameters
Output index
The production scale which this project determines is to produce 25.25 million pieces per year of sintering common bricks. Given 7% of the aggregate wastes of the drying and baking, the annual actual production output of forming will reach 24 million pieces.

Setting form and dryer & kiln cart specification
Drying cart size: 1100×1050×250mm (L. x W x H)
Drying car quantity: 950 pcs (dryer inside contain: 732pcs.)
Considering the width of the bricks : 101.6mm , the wet green bricks are being put on the ductile cast iron drying cart manually. Stacking three layers the bottom of dyer cart at first, then put a simple steel bracket on the top of bricks , then stacking more three layers on of simple steel bracket, Total six layers ,considering drying shrinkage is about 5%.
 
Drying chamber
System & Construction
This design adopts small section drying chamber with flattop. It is with brick & concrete structure, with precast-concrete top plate, partition wall with thickness of 240mm, side wall with thickness of 490mm, top layer and insulating layer with thickness of 500mm.

The heat source of drying chamber is the waste heat from tunnel kiln, which will be supplied to each drying chambers through air channel by heat-supply blower from the chamber bottom. The drying chamber set up air-feeding system, moist-releasing system and testing system. Bottom layer bricks are end-up setting method, so that to improve the drying efficiency and quality.

Tunnel Kiln
4.5. 4.1. Kiln cart setting form
Dry green brick are being put on the kiln cart manually, 4 x 11 bricks per layer.
2 stacks in vertical direction, 3 stacks in transverse direction. 16 layers in 101.2mm side, 3456 bricks per kiln cart.
Kiln cart size: 3660×2900×840mm (Lx W x H), this dimension include the lining brick height.
Kiln cart quantity: 65pcs (46 pcs of the carts contained inside the kiln)
 
4.5.4.2 Tunnel Kiln System and Structure
System
The tunnel kiln has complete system of smoke discharging, cooling, waste heat releasing, pressure balancing under the kiln car, running and detecting system. Baking curve inside of the kiln will be more reasonable, production system more coordination through the adjustment of those system.
At the entrance side, there is a preparatory room, and a cut-off door between the preparatory room and the kiln pre-heating zone. There are entrance and exit doors at both ends of the tunnel kiln. Thus it effectively avoid entering the cold air and ensure the baking system inside not be influenced by outside.

Structure
Foundation:
Tunnel kiln is with strip foundation. From bottom to up by order is plain concrete, reinforced concrete girder (railway girder)/ board (under kiln wall).

Wall:
Red brick is laid for the pre-heating zone and cooling zone where the temperature is below 200ºC. The rest is adopting combined wall. The fireclay bricks will be laid on the baking zone and inner wall of insulting zone. The clay insulting bricks will be used for laying the insulting area. Meanwhile, refractory fabric felt (for the relative part of temperature curve above 600ºC) or rock wool felt will be used for stuffing and red bricks will be laid on the external wall.

Kiln roof structure:
One kiln car space remained in low temperature zone on both sides, which adopt cast-in concrete top slab. For other position, from the bottom to up in order are: refractory plate brick, refractory hanger brick, cast steel hanger, steel minor beam, and H type steel major beam. Both sides firebrick walls support the main beam's weight. Refractory fibrofelt, rock wool felt, rock wool boards are put on the refractory hander plate, which compose complex insulation layer. High temperature binder is being filled up to the gap between the boards, and is being painted on the upside of the insulating layer, thus to ensure the material's insulativity and structure's durability.

Coal casting hole:
It is with function such as following, replenish heat, debugging, observation, replenish oxygen or cooling under negative pressure, releasing heat under positive pressure etc. This is widely used for tunnel kiln process with inner fuel technology, which cannot be cut down or cancelled.

Sand seal:
Sand seal slot is being put in the kiln cart skirt board, which insulate the hightemperature from outside, thus to avoid cold air sucked into kiln under negative pressure which will lower the kiln temperature, and to avoid high temperature gas go to kiln cart underside under positive pressure which will destroy the kiln cart steel structure or deform the railway.

Afterheat System
Products direct heat and afterheat system are being put on top of the tunnel kiln, temperature curve in 450-200 ºC range. Extractive afterheat occupies 80% of the total required heat for drying, heat source clean and no pollution. Through heat exchanger, except whole factory workshop heating, the rest high temperature gas is being sent into drying chamber. Direct heat is being extracted quickly and effectively, this will shorten the kiln length so that to lower the kiln construction investment.

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