Full Automatic Big Capacity Gas Firing Brick Tunnel Kiln

Ibrick China Big Capacity Gas Firing System Brick Tunnel Kiln

The Core Technology of Ibrick
1. The sintering brick one-step or two-step stacking-firing process with the raw materials of clay or shale with various production capacity (Industry leading tech)
2. The sintering brick two-step stacking-firing process with the raw materials of fly ash (fly ash accounted for 40%-70% by weight) with 60 million, 80 million or 120 million annual production capacity. (Industry leading tech)
3.The sintering brick one-step stacking-firing process with the raw materials of coal gangue with 50 million, 60 million, 80 million or 120 million annual production capacity. (Industry leading tech)
4. The sintering Decorative tile production process with 2 million, 4 million, or 6 million annual production capacity.
5. The sintering Decorative brick two-step stacking-firing process with 10 million, 20 million, or 40 million annual production capacity.     
6.Autoclaved aerated concrete blocks process with 100~200 thousand cubic meters annual production capacity.
7. Autoclaved brick process with 100~200 thousand cubic meters annual production capacity.
8. The sintering vanadium decarbonization tech with 1.2 thousand tons daily production capacity. (Industry leading tech) .
9. Operation equipments, electrical equipments, ventilation equipments, environmental protection equipments for big capacity wall and roof material production line.

Brick 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.

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.

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.

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%.

Clay 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.

We supply following brick making machine and brick making equipment
1. Belt type box feeder, plate type box feeder 
2.  Primary roller crusher, fine high speed rolling crusher, jaw crusher , hammer crusher
3. Double shaft mixer , double shaft mixer and extruder 
4. Energy saving vacuum extruder, double shaft vacuum extruder 
5. Automatic brick cutter system 
6. Green bricks separation machine 
7. belt conveyor 
8. Brick dryer 
9. Brick tunnel kiln 
10. kiln automatic control and monitoring system 
11. Brick kiln equipment 
12. Automatic brick loading and unloading machine 
13. Automatic brick packaging machine
14. Automatic robot brick setting machine 
15. Automatic brick stacking machine 
16. Brick dryer and tunnel kiln design and construction 
17. Technical provide and technical supervision  
18. Undertake turn-key project 

 
If you want to set up a new brick plant or plan to purchase automatic brick making machinery and brick equipment, please contact with us at any time .
Welcome to contact with us online : 
Phone Number: 0086-15991710216
Company Wetchat : ibrick / ibricktechnology