For its new
Koscian facility, which will produce 30 mill. large-size clay roofing tiles (10
tiles/m2) and related accessories, the Belgian Etex Group has decided to
entrust Ceric Technologies with the design of its kiln. Measuring 220 m in
length and 10.28 m in width, the kiln is exceptionally large, but key features
of this new project of the ceramics manufacturing equipment specialist are its
performance and innovative elements.
The Casing
tunnel kiln with a sand seal is equipped with all Ceric Technologies’ latest
innovations. Once complete, it is set to be the largest kiln in the world for
the firing of tiles on H-setters. Around 750 panels were cast in the workshops
of Ceric Technologies and shipped to Poland. Given the large dimensions of the
kiln, the mechanical strength of the panels was the subject of extensive
modelling calculations to ensure their stability, especially in the assembly
phase.
On average,
38 cars per day will be pushed through the kiln, in which tiles and accessories
will be simultaneously fired to ensure colour consistency and optimum energy
utilization. The average firing cycle lasts 21 hours at just over 1 000° C.
Cars with an individual loading area of 60 m2 are equipped with lightweight
refractories for better thermal efficiency. Perlite is used to insulate the
kiln walls while expanded clay is used for the car floor.
“With a
kiln width of more than 10 m, it was necessary to improve temperature
uniformity and air circulation efficiency”, says Lionel Dumont, Manager of the
Process Engineering Department at Ceric Technologies. For this reason, the
equipment supplier chose to distribute 338 low-power unitary burners in the
high firing area to ensure homogeneous firing. High-speed burners are installed
for preheating in the kiln roof, but not on the kiln walls as is often the
case. In the pre-heating and cooling zones, patented Thermobooster circulation
systems are integrated into the roof. The Koscian kiln is the first roofing
tile kiln in Europe to be equipped with this system. It lowers the number of
burners and improves the kiln’s energy performance. The air circulation in the
pre-heating area enables a reduction in the consumption of energy while
ensuring regular and improved heat exchange in the cooling zone. To minimize
energy consumption, the fans are powered with variable speed drives.
Ceric
Technologies’ new computerized Diapason control system will ensure permanent
monitoring of the kiln as well as mapping of the kiln cars and provide a clear
real-time image of energy transfers between the kiln and the dryer. Ceric
Technologies has developed the best solution to best capitalize on the
exceptional size of this kiln.
Source
Ziegelindustrie Internatonal
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