High-Tech Extrusion Machine of Brictec Builds Sintered Brick Project in Shaoxing

Product Description

Product Description

Brictec's Advanced Extrusion Brick Machine Powers Shaoxing 35% Solid Waste Utilization Sintered Brick Project
In May 2022, Brictec, with its leading engineering and technical strength in the industry, successfully undertook the construction of the new lightweight composite integrated assembly panel project for Shaoxing Green Exhibition Environmental Protection Co., Ltd. Positioned in the field of high-end sintered wall materials for green environmental protection and solid waste utilization in China, this project aims to create a modern clay sintered brick demonstration base through the construction of a fully automated intelligent production line, integrating high-value utilization of raw materials, low-carbon roasting processes, and high-end product output.

During the planning and implementation of the project's infrastructure engineering, Brictec demonstrated profound professional expertise. Based on the analysis of raw material characteristics and process requirements, Brictec employed Computational Fluid Dynamics (CFD) simulation technology to optimize the factory layout, ensuring an efficient material flow for processes such as raw material transportation, aging, forming, and roasting. The key-constructed double-helical raw material aging silos strictly adhere to the GB 50528 Design Code for Sintered Brick and Tile Factories. By controlling aging time and humidity parameters, these silos facilitate physical and chemical reactions among raw material particles, providing a stable and homogeneous raw material base for green body forming.

As the core of the project, thermotechnical engineering construction showcased Brictec's technical prowess. In the construction of the tunnel kiln system, modular construction techniques were applied, with precise control over the flatness of kiln lining, maintaining an error ≤1.5mm to ensure uniform gas flow distribution inside the kiln. The self-developed Italian-technology regenerative pulse burners, integrated with an intelligent temperature control system and staged combustion technology, achieve a roasting temperature fluctuation range of ±5ºC. Compared with traditional burners, these burners enhance energy efficiency by 28% and meet the stringent requirements of GB 29620 Emission Standard of Air Pollutants for Brick and Tile Industry. In the raw material processing section, multi-stage crushing and screening systems and vacuum extrusion molding equipment are configured. Through precise control of the particle size distribution (0.1 - 2mm proportion ≥90%) and vacuum degree (≥92%), the density and strength indicators of the green bodies are guaranteed. The drying chamber adopts a countercurrent drying process, combined with temperature and humidity gradient control, effectively preventing drying cracks in the green bodies and shortening the drying cycle by 15%.

Relying on its core technical process system, Brictec innovatively integrated thermotechnical equipment engineering with intelligent control systems. Through the optimized design of the kiln pressure field and dynamic regulation algorithms for roasting systems, Brictec achieved precise control over the sintering process. Throughout the project implementation, Brictec strictly adhered to the ISO 9001 quality management system. From the accuracy inspection of equipment installation to the calibration of commissioning parameters, 3D laser scanning, infrared thermal imaging, and other detection methods were employed to ensure that each process node met the design standards.

The successful completion of the Shaoxing Green Exhibition project marks another breakthrough for Brictec in the construction of high-end clay sintered brick factories. The project not only achieves an industrial solid waste blending ratio of over 35% and an annual production capacity of 120 million standard bricks but also, with its outstanding product quality (compressive strength ≥MU20, qualified frost resistance), becomes a benchmark case for green wall material production in China. This fully demonstrates Brictec's leading position in the industry in terms of thermotechnical equipment integration, process technology innovation, and full-cycle project management.

The lmportance of Process Design in the Early Stage of Clay Brick Project Planning
1.Process Design Perspective
2.Raw Material Processing
Raw material processing directly affects brick quality and equipment longevity:
Crushing size control: Double toothed roll crusher output s3mm (oversize reduces plasticity, fines increase energy use)
Aging & homogenization: 272 hours aging ensures moisture uniformity and forming stability
Impurityremoval: Magnetic separators + screening for iron and stones
3.Aging & Forming
Aging process: Enclosed aging shed with >80% humidity promotes clay ion exchange
Extrusion forming: Vacuum extruder (vacuum 2-0.092MPa) improves green body density
Die design: L/D ratio 24:1 minimizes spiral marks, chrome-plated lips reduce friction
4.Drying Technology
Drying is the most critical pre-sintering stage:
Multi-stage drying:
Preheating (40-60°C,70% RH) to prevent cracking
Fast drying (80-120°C) for bound water removal
Airlow design: Vertical airflow to keep temperature difference <5'C in stacks
Waste heat recovery:Reuse tunnel kiln cooling zone heat for drying
5.Tunnel Kiln Firing Curve
The firing curve determines brick strength and fuel efficiency:
Preheating zone (200-600°C): Heating rate ≤50°C/hour to prevent explosions
Firing zone (900-1050°C): Hold for 2-4 hours under oxidizing atmosphere
Cooling zone: Slow cooling to <80°C (rapid cooling causes glass-phase cracking)
Failure Cases vs. Good Design

Issue	Poor Design	Good Design
Brick Cracking	Single-stage drying	Multi-stage gradient drying
High Fuel Consumption	No Kiln waste heat recovery	Integrated drying-firing heat recovery system
Low Production Capacity	Mismatched crusher and extruder capacity	Holistic equipment capacity coordination
Spiral Mark Defects	Insufficient extruder compression ratio	Optimized die L/D (≥4:1)
Material Waste	No homogenization causing material incosistency	Enclosed sging shed+automated batching system

Additional Notes
Consequences of Poor Design:
Increased rework costs
Reduced equipment lifespanLower product qualification rate
Benefits of Good Design:
20-30% energy savings
215% production increase
40% lower maintenance costs

The Critical Role of Kiln Cars
Load-Bearing Core:
Kilin cars must continuously carry tons of green bricks under combined mechanical and thermal stress, Poor-qualitycars cause:
Frame deformation triggering "kiln jams"(>$10,000/day downtime)
Refractory spalling contaminating bricks (15% defect rate)
Sealing Vitality:
Ineffective sand sealing between cars and kiln walls leads to:
Heat loss (8-12% higher energy consumption)
Flue gas crossflow disrupting firing curves
Mobility Foundation:
Wheel systems must feature:
High-temp bearings (>400ºC)
Self-adjusting rail alignment (derailment prevention)

Brictec's Commitment
"We refuse to compromise kiln car quality for cost savings, Every refractory brick laid is a pledge to our client'sproductivity for the next decade."
-----Brictec Process Director
Data Backing: Projects using Brictec kiln cars report <0.5% annual failure rate vs. industry average 3%.
Brictec's Philosophy in Tunnel Kiln Manufacturing
At Brictec, we consider tunnel kiins the "heart" of clay brick production. Every kiln we build embodies our clients'demands for product quality and energy efficiency. We insist on:
Stringent Refractory Standards: Kiln walls use high-load-bearing bricks (>60% Al,0,, refractoriness> 1750'C),while roofs adopt lightweight insulation composites for maximum thermal efficiency.
Milimeter Precision: Kiln straightness tolerance <3mm/10m, eliminating temperature deviation or product colorvaration caused by deformation.
Dynamic Validation: CFD simulation + physical kiln testing to optimize firing curve stability.
The Critical Role of Tunnel Kilns
Quality Determinant:
Kiln temperature control directly affects bricks:+5ºC variation causes>10MPa strength differencePreheating-firing-cooling balance sets water absorption (optimal 6-10%)
Energy Center:
Consumes>70% oftotal energy. Brictec solutions achieve:>65% waste heat recovery (industry avg.40%)<90m* gas/10k standard bricks
Production Hub:
Kiln width and car speed coordination ensures:Uninterrupted production (>95% capacity utilization)<15min/car cycle time deviation
"Every refractory brick in our kiins carries a traceable '"D', documenting material batches and firing parametersmaking your high-temperature investment transparent and controllable,-----"Brictec Kiln Division
Industry Comparison: Brictec kiln bricks last 8-10 years (industry avg. 5-7) with 40% lower annualmaintenance costs