Brief Introduction of 120 Million/ Year Fired Brick (Block) Production Line
Source KEDA Industrial brick
Different raw materials are scientifically matched, crushed, mixed by water, and sent to aging house for homogenizing (temporary store), Then extruded by two-stage vacuum extruder into slugs, The slug will be cut into green body as demand. Automatically flipping, grouping and to the pallets, pallets with green body then be sent into dryer by finger forklift for single layer drying.
After drying, bricks are removed from shelves, separated from pallets, flipping and grouping. Robot stacking machine then stacking bricks onto kilns cars, Kiln cars then automatically moves to firing tunnel kiln. After firing, bricks are ready to be sold after packing.
Currently, this automatic cutting & stacking & conveying equipment, which suitable for setting kiln car after drying technology is most advanced in China. It equipped with large dryer and energy saving large cross section tunnel kiln, thus can reach a capacity of 150 million brick /year /line (ordinary brick). The equipment widely adopts raw materials and different products and can provide decorative facing brick, floor tile, square brick and fired heat insulation block and high hollow rate products. Consequently, save labors and improve operation condition.
1、Section assembly type energy saving tunnel kiln
- Net width of section: 9.2m，7.1m，6.9m，4.8m，4.6m;
- Length range: 131.3 ~ 166.1 m (depending on the specific raw materials and product category)
- Height of layers: 12 ~ 16 layers (120 mm direction, depending on the specific raw materials and product category)
- Firing temperature: 950 ~ 1100 ℃
- Exhaust temperature: ≦ 150 ℃
- Dimension of kiln car length: 4.35 m, 3.78 m;
- Fan quantity: sets of centrifugal fan, 1 ~ 3 axial flow fan
- Fan model: depending on inner width, height of packages and firing characteristics
- Annual capacity of a kiln with inner width 9.2m: over 150 million bricks (depending on the product category and firing characteristics)
- Firing cycle: 24 ~ 36 h (depending on the product category and firing characteristics)
- Heat consumption: 280 ~ 320 kcal/kg of product;
Structure of large cross section and energy-saving tunnel kiln is modular prefabricated in professional factory and assembled on site, compare to traditional tunnel kiln is time saving. It be prefabricated by factory can guarantee sealing and quality, which is helpful in energy saving.
Application of advection discharge flue gas, top discharge flue gas and side discharge flue gas is highly reducing temperature difference and the ventilation quantity of edge gap, rapidly improving surface temperature of kiln car, releasing pressures effect on firing, consequently improves capacity and quality of products. The tunnel kiln uses specific structures, thus surface temperature of outer wall and kiln top reaches Chinese standard. Rapid cooling device on kiln top can send fresh air for firing, lowering excess air coefficient, which saves energy and lowers discharge flue gas. Above 90% fresh air is pumping to drying chamber as medium from sides and top of kiln (small parts are feeding the fire), maximizes the using of waste heat of tunnel kiln. Adding of car bottom pressure balance wind into the dryer can satisfying heat source needed, prevent high temperature flue gas to drying room, avoid contamination to product and corrosion to pipes, fan and pallet. Flue gas is exhausted by line pipes on the top.
Working system of tunnel kiln consists of discharge flue gas system, flue gas cleaning system, rapid cooling system, slow cooling system, waste heat exhaust system, car bottom pressure balance system, etc., To classified by functions, they are pre-heating (low temperature area, high temperature area), firing, soaking, cooling (rapid cooling and slow cooling area).
2、High automatic cutting, stacking, conveying and lifting system equipment
Currently, this automatic cutting & stacking & conveying equipment, which suitable for setting kiln car after drying technology, designed by KEDA (Anhui) Industrial Co., Ltd. and GuiZhou Building Materials Science Research and design Institute is most advanced in China. It equipped with large dryer and energy saving, large cross section tunnel kiln, thus can reach a capacity of 150 million brick /year /line (ordinary brick). The equipment widely adopts raw materials and different products and can provide decorative facing brick, floor tile, square brick and fired heat insulation block and high hollow rate products. Consequently, save labors and improve operation condition.
The system includes slitter, clay-strip speed-up conveyor, green body cutting machine, grouping& conveying machine, turning machine, on pallet system, on shelve system, finger forklifts, transfer car, off shelve system, dried bricks systemized, dried bricks turning machine, dried bricks grouping machine, robotic stacking device, empty pallets returning system, online storage and so forth.
3、Equipment of automatic unloading kiln car and product packing system
While automatic and mechanical stacking equipment joining to heavy clay production line, unload kiln car would be the most labor intensity process. Besides, follow the fast development of heavy clay industrial in China and increasing of middle-top level products, for example, decorative facing brick and high hollow rate brick are package needed, for easy transporting, less consumption and convenient usage purpose. In this view, equipment of automatic unloading kiln car and product packing system that researched and manufactured by KEDA (Anhui) Industrial Co., Ltd efficiently solve blocking problems of ordinary and hollows bricks; highly improve productivity and lower labour intensity. The system includes: blocking elimination device, gripping device, grouping& conveying device, stacking device, strapping& packing device, heavy chain conveyor, etc. Robotic unloading kiln car, automatic unloading machine with triple grippers, finishing machine, packing conveyor
Source KEDA Industrial brick