| Customization: | Available |
|---|---|
| Condition: | New |
| Automation: | Automatic |
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ECO CERAMICS is a subsidiary of the GPH Group in Bangladesh, which is the country's largest building materials manufacturer. The group owns one of the top three cement plants and the largest steel plant in Bangladesh. The brick factory currently under construction is set to become the largest and most industrialized brick production facility in the country.
The project adopts advanced twice-firing technology. The drying process features automatic loading/unloading systems and a single-layer tunnel drying system, while the firing process utilizes two tunnel kilns with a 4.8-meter cross-section, equipped with fully automatic pulverized coal combustion systems. The entire brick production process is highly automated and well-controlled, capable of producing both standard and premium bricks.
On March 31, 2019, Xi'an Brictec's project team officially arrived on site. A groundbreaking ceremony was held together with the client, marking the formal commencement of construction and project management responsibilities by Brictec.
The Importance of Process Design in the Early Stage of a Clay Sintered Brick Project
The success of a clay sintered brick project heavily relies on a well-conceived and scientific process design. In the early stage of construction, a rational process layout ensures product quality, reduces energy consumption, improves production efficiency, and minimizes the cost of future modifications. The following outlines the importance of process design by analyzing key process stages:
1. From the Perspective of Process Design:
Process design serves as the "blueprint" of the project, determining the overall layout of the production line and equipment selection. It must comprehensively consider the following aspects:
Raw Material Characteristics (e.g., plasticity index, mineral composition):
A deep understanding of raw materials ensures stable shaping, drying, and firing processes.
Product Specifications (e.g., solid bricks, perforated bricks):
Different product types require distinct shaping and kiln configurations, which must be integrated from the outset.
Capacity Matching (e.g., avoiding "overkill" or production bottlenecks):
Each production stage must be capacity-aligned to prevent inefficiencies or idle equipment.
Energy Efficiency Optimization (e.g., integrated design of thermal systems):
A coordinated design of drying and firing systems helps reduce fuel consumption and improves overall energy performance.
2. From the Perspective of Raw Material Processing
The raw material processing stage has a direct impact on the quality of green bricks and the longevity of equipment:
Crushing Size Control:
The discharge from the double-toothed roller crusher must be ≤3mm. Oversized particles reduce plasticity, while overly fine particles increase energy consumption.
Homogenization and Aging:
Aging the clay for ≥72 hours ensures uniform moisture distribution, which improves forming stability and reduces cracking during drying.
Impurity Removal:
Magnetic separation and screening are essential for removing iron impurities and stones, which can otherwise damage equipment and affect product quality.
3. From the Perspective of Aging and Forming
Aging Process:
A closed aging chamber with humidity maintained above 80% promotes ion exchange within the clay, enhancing its plasticity and workability.
Extrusion Forming:
Using a vacuum extruder with a vacuum degree of ≥-0.092 MPa increases the density of the green body, leading to stronger, more consistent bricks.
Mold Design:
A length-to-diameter ratio of the die nozzle of ≥4:1 helps reduce spiral marks on the surface of the green bricks. Chrome-plated die lips reduce friction and wear, improving product finish and equipment lifespan.
4. Drying Process
Drying is the most failure-prone stage before sintering, requiring careful control to ensure brick integrity:
Staged Drying:
Preheating Zone (40-60°C, ~70% humidity): Prevents surface cracking by slowly evaporating surface moisture.
Rapid Drying Zone (80-120°C): Removes bound water effectively and prepares bricks for firing.
Airflow Control:
Vertical air delivery minimizes temperature differences between the top and bottom of the brick stacks. A vertical temperature gradient >5°C can cause warping or cracking.
Preheating Zone (200-600°C): The temperature should rise at a rate of no more than 50°C per hour to avoid explosive spalling due to rapid water vaporization.
Firing Zone (900-1050°C): Maintain an oxidizing atmosphere and hold the peak temperature for 2-4 hours to ensure complete vitrification and optimal mechanical strength.
Cooling Zone: Controlled slow cooling to below 80°C is essential. Rapid cooling may cause the glassy phase in the bricks to fracture, leading to internal defects.
Brictec's Core Philosophy on Tunnel Kilns
At Brictec, we regard the tunnel kiln as the "heart" of clay sintered brick production. Each tunnel kiln we design and construct embodies our clients' core demands for product quality and energy efficiency. Our commitment includes:
Stringent Refractory Standards:
Kiln walls are built with high-load soft firebricks containing ≥60% alumina, with a refractoriness above 1750°C. The kiln roof uses a lightweight composite insulation structure to ensure maximum thermal efficiency.
Millimeter-Level Construction Precision:
Kiln body straightness deviation is kept under 3mm per 10 meters, eliminating temperature inconsistencies and color variations caused by kiln deformation.
Dynamic Thermal Verification:
We combine CFD (Computational Fluid Dynamics) simulation with full-scale thermal testing to optimize the stability of the firing curve and ensure consistent, high-quality results.
The Importance of Tunnel Kilns
1. Quality Determinant
The precision of temperature control in the tunnel kiln has a direct impact on brick performance:
A temperature variation of just ±5°C can result in a compressive strength difference of over 10 MPa.
The balance among the preheating, firing, and cooling zones determines the final water absorption rate of the product, ideally maintained between 6-10%.
2. Energy Consumption Core
The tunnel kiln accounts for more than 70% of the total energy consumption in the production line. Brictec's kiln design delivers exceptional efficiency:
Waste heat recovery rate >65% (compared to the industry average of 40%)
Natural gas consumption <90 m³ per 10,000 standard bricks
3. Capacity Hub
The kiln's effective width and the coordinated speed of kiln car movement are crucial to ensuring:
Bottleneck-free continuous production, with an achieved capacity rate of over 95%
Kiln car turnaround time deviation <15 minutes per cycle, ensuring smooth and predictable output flow
In essence, the tunnel kiln is not just a thermal system-it's the performance engine of the entire brick plant.
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