Material Roller Screen for Clay Brick Making

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.
Capacity: 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

5 GS material roller screen
capacity: 30-40m3/hour
moisture: ≤10%
turning speed: 16rpm
power:7.5KW
weight: 4400kg

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. JKY600-4.0  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:10000-15000pcs/h(for hollow brick)
power:90kw-4/200kw-6
forming moisture: 14-20%
overall size: about 6850×3670×2650mm
up reducer:ZQSH850-15.75-
down reducer:JZQ1300-20.49-
material size:≤2.5mm
vacuum degree:≤-0.092/mpa
extrusion pressure:4.0mpa
vacuum pump power:15kw-4
up mixing knife speed: 32rpm
down mixing knife speed: 25rpm
weight:27500kg


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


10. Automatic adobe cutter
travel distance :400/mm
max cutter height: 240/330mm
cutting times: 30-40piece/time
Power: 1.5kw-4/2.2kw-4/7.5kw-6
Overall size: 2800×3250×1550mm


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:          3760mm×3600mm
power:          27KWX4
loading stockyard:   16stockyard
loading layers: 15layers
weight:        28000kg


II. Dryer and Firing kiln technology proposal   

1.1 .1     Production scale: yearly capacity 30,000,000 standard size bricks.
1.2 :     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. 
2.2.2 Firing
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
Drying kiln design description:  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.    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.    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.    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.   

1. Drying kiln calculation:

   ,    Drying adopt firing kiln car, single car can load4703bricks, according production experience, the drying period is 21 hours, the car inside kiln is:  
36,3.6,:36*3.6=129.6.
Thus the kiln car is around 36sets, kiln car length is 3.6m, tunnel kiln total length is: 36*3.6=129.6.
3,:    Tunnel dryer technical parameter as below:
-                         Length               130m
-                          Width                4200mm
-                     Kiln car size        4200*4200mm
-                     Air resource     Waste air from Smoke extraction Fan
-                           Kiln wall             refarctory brick and Red bricks
-                          Kiln roof             Precast slab
-                      Air enter way       Side
-                Air regulating model  flue damper and regulating hole
-                       Mixing model          axial fan
-                      De-humidification model  disperse upper de-humidification
-                 Kiln car QTY          160 sets
-                 Enter kiln moisture   less than 18%
-                 Exit kiln moisture    less than 5%
-               Drying period         21 hours
-                     Drying capacity       30,000,000pcs/year
-                       Qualify rate          93±3%
-                     Dryer channels        1
-                     Year working time     300 days
-              
 Daily working time    24 hours


3.3    Firing part

1. 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:
       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:
- :                    Length                    130M
- :                Effective width           4200mm
- :            Effective loading width    1800mm
- :                       Fuel                      Coal
- :                Firing model:             Inner firing+ outer firing
- :                    Enter kiln moisture       <5%
- :                    Firing temperature        900-1000 degree
- :                    Firing period             42 hours
- :                 Product qualify ration    96%
- :               Single car capacity      5460
- :                   Car enter model           Auto
- :                      Yearly capacity            30,000,000
-                     Yearly working time     300 days
-                    Daily working times      24 hours
-  :                 Car exit speed          70-90min/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
: Kiln car size: 4200x4200mm
: Kiln car QTY: 160set (include drying car and spare)
: Kiln car material: steel frame
: Transfer trail cars: 3
: Orbit Qty: 6
: Wheel diameter:320mm

Pushing system: hydraulic pusher