I. Design principle 1.,,10,30,300/. Adopt auto drying technology, thus the production is weather-immune, working this is based on 10 month, 30day/month,it means based on 300day/year. 2.:250X125X883 Daily capacity: 30,000 pieces for 250X125X88mm hollow bricks 3.,,5-12%(). The raw material in this proposal mainly is soft clay, adopt coal for inner firing fuel, the dosing proportion is 5~12%(decided by thermal value) of raw material. 4.,,,,. For reduce labor intensity and labor cost, this proposal use the most advanced one time setting and firing technology in the world, the extruded green bricks are set to kiln car by auto setting machine directly, then go to tunnel dryer for drying and then go to tunnel kiln for firing. 5. ,,,,,,,. The proposal designs based on economical investment, lowest fuel consumption, high automatic degree, reduce labor intensity and labor cost as low as possible, at the same time the machinery is durable and steady and the production technology is mature and reliable.
6. : Production line technology process: →→→→→→→→→→→→→→→→→→ forklift→feeder→jaw crusher→multi-way adjusted high speedcrusher→roller screen→two=shaft mixer→feeder→vacuum extruder→line cutter→adobe cutter→auto loading machine→pulling machine→ferrying car→pusher→drying kiln→ferrying car→tunnel firing kiln→ferrying car→car back orbit
equipment details: 1. 1000X5 Feeder The feeder can continue giving material homogeneously and realize the quantify definite proportion giving material equipment. The equipment has firm structure, easy inst-allation, usesafety, low in labour intensity and so on. Capacity:20-40M3/h Motor power: 5.5KW width of the belt: 800-1000mm reducer size:JZQ500#-40.17 belt width:800-1000mm Overall size(L×W×H):7000×2100×2300mm Weight:3100Kg
2. 400X600 Jaw crusher Size of Feeder Opening (mm): 600×400 Max. Feeding Size (mm):350 Capacity (t/h): 16-64 Motor Power (KW): 45kw Weight:7500Kg Overall Dimensions (mm): 1700×1732×1653 Output size(centimeter): 20-30
3. 1100×1000 High Speed adjusted crusher The crusher is mainly used for raw material processing in brick and tile factory for further crushing raw materials being coarse crushed in process to make raw material grain size<2mm for increased plasticity and homogeneity of raw material. It is of primary importance to product quality improvement and production of hollow products and solid brick. apacity: 50-70M3/h qty crushing: 21sets turning speed: 865rpm requirement of material water ratio:<12% Inlet granularity(max): ≤100mm Power:132KW-6group Overall size(L×W×H):3650×1650×1500mm Weight:10000Kg
4. BP800 Belt conveyer Tape speed of sealing-tape machine: 1m/s Orbit distance: 900mm Drive of travel mechanism:1.5KW Power sealing-tape machine:5.5KW
6. SJ 4000 huge two-Shaft mixer The mixer adds water to brick-making raw materials after crushing process and then mix, blend and homogenize, which can further enhance the comprehensive plastic index of raw materials, and greatly improve appearance quality and yield rate of brick and tiles, thus it is the indispensable raw material processing equipment for brick and tiles enterprises. It is mainly used for watering and mixing treatment for clay, shale, coal gangue, coal ash and other raw materials. Double-shaft mixing, large turning radius, good mixing effect; adopt protective bearing to protect double axies with no wear and easy maintenance. Capacity:32-37M3/h Power:75KW effective mixing length: 3600mm Rev of main shaft:43rpm Overall size(L×W×H):4100×1200×800mm Weight:4900Kg 7. JKY550-4.0 Vacuum extruder The machine is new brick-making equipment the based on the current wall reform situation, in line with the conditions of actual medium and small brick factory. It has stable performance, high quality body, and inexpensive, gets the favor of small and medium brick factories. Capacity:9000-12000pcs/h(for hollow brick) power:90kw-6/185kw-6 forming moisture: 14-20% overall size: about 6850×3670×2650mm up reducer:JZQ850-12.64- down reducer:JZQ1200-17.14- material size:≤2.5mm vacuum degree:≤-0.092/mpa extrusion pressure:4.0mpa vacuum pump power:15kw-4 up mixing knife speed: 37rpm down mixing knife speed: 28rpm weight:23700kg
8. Hydraulic ferry car lifter Type:YJ25 Power:7.5+3kw Overall size:3300×2200×1540mm 9. Automatic cutter transport speed:1-1.3m/s cutting length: 1.7m-1.8m(can be adjusted) Power: Y6-1.5kw Overall size: 2500×650×1140mm weight: 700kg
11,Automatic loading machine 1.technical description -this system including the following parts: 1,adobe cutter:();According to the design requirements, cut the slime into the required number of blocks (bricks). 2,automatic separate adobe system:,,;The divided adobe will be automatically separated, put in place according to the design requirements, so that the automatic code adobe cantilever snatch; 3,Hydraulic cantilever snatch system:;Automatically code the brick on the kiln car. 4,kiln car rotary system:,.Automatic rotary kiln car, convenient code adobe. -technical parameter: size: ZMP360 adobe size: 250/125/88mm capacity: 16000piece/hour Number of billet clamps: 16billets each time loading adobe: 288pieces/time running cycle: 1.0-2.5min max loading height: 1.75m loading pressure: 0.5Mpa adobe stockyard distanceL: 110-130mm suitable kiln car: 2100mm×2100mm power: 27KWX4 loading stockyard: 16stockyard loading layers: 15layers weight: 22000kg
II. Dryer and Firing kiln technology proposal
1. 1.1 :900. Production scale: yearly capacity 9,000,000 hollow bricks. 1.2 :250×125×88mm Production specification: 250×125×88mm 1.3 :. Productions: hollow bricks and other firing products. 2.: Firing technology proposal 2.2 : Firing technology description 2.2.1 Green bricks drying .,.,.. Adopt tunnel dryer for green bricks drying. Extruded bricks set to kiln car directly and enter drying room per ferrying car. Drying thermal resource from residual thermal of tunnel kiln, moisture exhaust model is mechanical native pressure combine with positive pressure moisture exhaust. Green brick enter dryer controlled by hydraulic pusher. 2.2.2Firing ,(). After drying, the green bricks enter to tunnel kiln by ferrying car for firing (see details on kiln car technology part). 2.2.3 Finished brick stocking, inspection and ex-factory ,,,,,,,,. The fired bricks are sent to kiln car back track for unloading, then are sent to stocking area by manual cars or other transportation equipments, and then inspect and classified fired bricks.
3.2, Drying and firing part
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Drying kiln design description:
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The drying kiln adopt most advanced continuous tunnel type drying design in the world, per computer controlling can realize fast drying, lowest energy computation, reliable and high drying performance.
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According bricks drying character, it is drying sensitive period when brick just enter drying kiln, at this time it need lots of wet air surround bricks quickly, and the air temperature can not be too higher, it should remove the water from green bricks patiently, gradually and step by step, on this stage, the bricks is easy to crack if not handle well, the air condition on this stage should be uniformly, lower temperature and wet.
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After this stage, temperature warming speed can speed up gradually, through hot air from kiln, the water is removed from green bricks gradually, at the same time, the temperature of green brick is increase while water decrease, this condition will be more apparently when enter back stage of drying.
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According to drying curve character, this proposal adopt high ration air blower, also installed dehumidify fan on the dryer head to make the air flow direction is counter kiln car moving direction, hence can realized fully thermal exchange, meet drying requirement.
3.3 Drying and Firing part
Kiln car introduction ,,,.,,,,,,,.,,,,.,,,,,;,,.,,,,,,. This high quality and energy-saving tunnel kiln is designed by our professional engineer based on the combination of foreign and domestic technology for different firing product. It featured by high capacity, high steady performance, high product quality, energy saving, easy to operation, high automatic degree, it is the top choice and ideal firing equipments for building material factory to produce high quality product. This kiln all adopts top grade material, it have reasonable height-width ration, kiln roof is flat structure, and all weight is bear by wall bricks. The roof of pre-heating section, firing section and cooling section equipped smoke extraction system, residual thermal treatment system, cooling system, kiln car pressure balance cooling system. Temperature and pressure inspection system can guarantee the wider controlling range. The cross section temperature difference is small, product quality is good, energy consumption is lower, control and operation is flexible and accurate, maintenance is easy and performance life is long.
2,: Kiln technical parameters: 2.1: Kiln technical parameter calculation: 4703,42(,),96%: Single kiln car can load bricks is 4703pcs, firing period is 42 hours(the actual firing hours is according to raw material condition, coal dosing ration and other, factory should confirm its raw material and formula is suit for this firing cycle ), firing qualify ration is 96%.
2.2.: Kiln technical parameters: - : 130(1) Length 130M - : 3600 Effective width 3600mm - : 1800 Effective loading width 1800mm - : Fuel Coal - : + Firing model: Inner firing+ outer firing - : <5% Enter kiln moisture <5% - : 900-1000 Firing temperature 900-1000 degree - : 42 Firing period 42 hours - : 96% Product qualify ration 96% - : 4703 Single car capacity 4703 - : Car enter model Auto - : 900 Yearly capacity 9,000,000 - 300 Yearly working time 300 days - 24 Daily working times 24 hours - : 120-150min/ Car exit speed 120-150min/car ,,,. The actual capacity is according to actual firing period, we promised this capacity only when the green bricks pass the test thus meets our designed firing period and thermal treatment calculation.
2.3,: Kiln car system :3600x3600mm Kiln car size: 3600x3600mm :100() Kiln car QTY: 100set (include drying car and spare) : Kiln car material: steel frame : Transfer trail cars: 2 :6 Orbit Qty: 6 :320mm Wheel diameter:320mm : Pushing system: hydraulic pusher
3,: Kiln design description 3.1: Kiln body brief introduction ○,,,,,. According project requirement and layout on site, we will use top grade steel, refractory material, thermal inuslation material and other, installation and commissioning on site. ○,. This kiln can adjust the product on a very wider firing range and realize fast firing. ○,,,.,.,,. The kiln adopts top grade refractory material, thermal insulation is good, and kiln body has good thermal resistance and anti-shock performance. It can solve a lot of problem such as product size difference, color difference, distortion etc.At the same time it can pass most of thermal into brick and short firing period. ○,,.,,.,. Kiln consists of plane of kiln car, bricks move forward with kiln car on this plane, and bricks go through different area with different thermal property. Kiln body consists of a group of standard module; they concocted and formed to physical and chemical reaction channels. On the top of kiln spread different coal-adding opening which can form to different temperature area. ○: This kiln consist of below sections: ;;;;; Smoke extraction section; pre-heating section; firing section; slowly cooling section; final cooling section. ,.,,,.,,.,.,,.,,. During the smoke extraction section, the residual moisture of tunnel kiln is removed and brick bodies are heating gradually. During pre-heating and firing section, green bricks will take place physical and chemical reaction, and give some property to bricks. Heating the bricks through some coal adding openings, make the bricks inner firing and save fuel computation. In directly cooling section, directly import some environmental air, in indirect cooling section; remove the air for other applications by ventilation hood. In final cooling section, it through fans on the front of kiln further decrease brick temperature. 3.2. Standard unit ,,,..,,,,,. All standard unit and module is made from read bricks, top grade steel and thermal insulation material. Outer wall is constructed by red bricks. It is easy disassemble for inspection and normal maintenance, beside, there are some ventilation opening for avoid over heating on high temperature area and frozen on cooling area. 3.3: Platform frame and pipe system ,: Below platform and pipe system are included ○; Operation platform and fan platform include staircase and handrail. ○,,,, All pipe system are paint treatment, hot air pipe outer pack thermal insulation cotton and aluminum plate, and they include flange, anti shock connector, expansion joint. ○. Flow rate and pressure controlling valve 3.4. Thermal insulation liner ○,,,; Thermal insulation liners of kiln side, roof and kiln car are made by high strength refractory bricks, liner length is different per Maximum using temperature. ○,.,. ,,,. Kiln roof use flat ceiling and made by light insulation bricks. Different expansion joint is filled with anti-high temperature refractory fiber felts, it can absorb the stress happened during kiln lighting and extinguished. There designed inspection opening and inspection door for watching burning room, flame and firing product. 3.5. Kiln car pushing system ○,,,.,,30. Kiln car pushing device adopt continuous oil pressure pusher, hydraulic controlling platform is installed on gauge room, there have fast pump, slow pump and manual pump on platform for handle different status, maximum pushing pressure is 30 ton. 3.6,Air blower
- ,,,. All air blower equipped independent motor, base, anti shock connector and safe protection devices. - :1Smoke extract fan qty: 1set - 1Moisture removal fan 1set 3.7, Electrical control cabinet ,,,,,. It made by spray metal components, include switch, fan motor and main motor safe protection device, alarm device, electrical connect device and Analogue board. - ,;Smoke extraction and fast cooling adopt frequency converter control.
- C.I.E; According C.I.E connect cables for electrical cabinet 3.8,Kiln car - ,,,,,,,,,. Kiln car adopt repeated bend sealing low heat storage kiln car, it means adopt low thermal conductivity, small density and well strength refractory material for work sealing frame, can reduce kiln car heat storage and heat disputation effectively, and reduce up and down temperature difference on pre-heating area, improve product quality, save energy, improve operation environment and extended kiln car performance life.
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