Brictec's GPH Bangladesh Lab-to-Production One-Stop Service

GPH Project in Bangladesh - Turnkey Clay Brick Plant Solution from Design to Production
ECO CERAMICS is part of the Bangladesh GPH Group, which is the largest building material manufacturer in Bangladesh. It has the top three cement factories and the largest steel plant in Bangladesh, and the brick factory project currently under construction will also become Bangladeshi domestic The brick factory with the largest volume and the highest degree of industrialization.
The project adopts advanced secondary burning technology, the drying process adopts automatic upper and lower racks and tunnel-type single-layer drying system, and the burning process adopts two tunnel kilns with a section of 4.8 meters and an automatic pulverized coal combustion system. The entire brick-making production process has a high degree of automation and strong controllability, which can simultaneously meet the needs of producing ordinary bricks and high-end bricks. On March 31, 2019, Xi'an brictec Mining Machinery Project Department officially settled on the site, and the groundbreaking ceremony was held with Party A to formally take over the construction and management of the entire project.

The Importance of Process Design in the Early Stage of Clay Brick Project Planning
1. Process Design Perspective
Process design serves as the project's "blueprint," determining the overall layout and equipment selection. Key considerations include:
Raw material properties (plasticity index, mineral composition)
Product specifications (solid bricks, perforated bricks, etc.)
Capacity coordination (avoiding over/under-capacity issues)
Energy efficiency (integrated thermal system design)
2. Raw Material Processing
Raw material processing directly affects brick quality and equipment longevity:
Crushing size control: Double toothed roll crusher output ≤3mm (oversize reduces plasticity, fines increase energy use)
Aging & homogenization: ≥72 hours aging ensures moisture uniformity and forming stability
Impurity removal: Magnetic separators + screening for iron and stones
3. Aging & Forming
Aging process: Enclosed aging shed with >80% humidity promotes clay ion exchange
Extrusion forming: Vacuum extruder (vacuum ≥-0.092MPa) improves green body density
Die design: L/D ratio ≥4:1 minimizes spiral marks, chrome-plated lips reduce friction
4. Drying Technology
Drying is the most critical pre-sintering stage:
Multi-stage drying:
Preheating (40-60°C, 70% RH) to prevent cracking
Fast drying (80-120°C) for bound water removal
Airflow design: Vertical airflow to keep temperature difference <5°C in stacks
Waste heat recovery: Reuse tunnel kiln cooling zone heat for drying
5. Tunnel Kiln Firing Curve
The firing curve determines brick strength and fuel efficiency:
Preheating zone (200-600°C): Heating rate ≤50°C/hour to prevent explosions
Firing zone (900-1050°C): Hold for 2-4 hours under oxidizing atmosphere
Cooling zone: Slow cooling to <80°C (rapid cooling causes glass-phase cracking)

Failure Cases vs. Good Design:

Additional Notes:
Consequences of Poor Design:
Increased rework costs
Reduced equipment lifespan
Lower product qualification rate
Benefits of Good Design:
20-30% energy savings
≥15% production increase
40% lower maintenance costs

The Critical Role of Kiln Cars:
Load-Bearing Core:
Kiln cars must continuously carry tons of green bricks under combined mechanical and thermal stress. Poor-quality cars cause:
Frame deformation triggering "kiln jams" (>$10,000/day downtime)
Refractory spalling contaminating bricks (↑15% defect rate)
Sealing Vitality:
Ineffective sand sealing between cars and kiln walls leads to:
Heat loss (8-12% higher energy consumption)
Flue gas crossflow disrupting firing curves
Mobility Foundation:
Wheel systems must feature:
High-temp bearings (>400ºC)
Self-adjusting rail alignment (derailment prevention)
Brictec's Commitment
"We refuse to compromise kiln car quality for cost savings. Every refractory brick laid is a pledge to our client's productivity for the next decade."
- Brictec Process Director
Data Backing: Projects using Brictec kiln cars report <0.5% annual failure rate vs. industry average 3%.

Brictec's Philosophy in Tunnel Kiln Manufacturing
At Brictec, we consider tunnel kilns the "heart" of clay brick production. Every kiln we build embodies our clients' demands for product quality and energy efficiency. We insist on:
Stringent Refractory Standards: Kiln walls use high-load-bearing bricks (>60% Al2O3, refractoriness>1750ºC), while roofs adopt lightweight insulation composites for maximum thermal efficiency.
Millimeter Precision: Kiln straightness tolerance <3mm/10m, eliminating temperature deviation or product color variation caused by deformation.
Dynamic Validation: CFD simulation + physical kiln testing to optimize firing curve stability.

The Critical Role of Tunnel Kilns:
Quality Determinant:
Kiln temperature control directly affects bricks:
±5ºC variation causes>10MPa strength difference
Preheating-firing-cooling balance sets water absorption (optimal 6-10%)
Energy Center:
Consumes>70% of total energy. Brictec solutions achieve:
>65% waste heat recovery (industry avg. 40%)
<90m³ gas/10k standard bricks
Production Hub:
Kiln width and car speed coordination ensures:
Uninterrupted production (>95% capacity utilization)
<15min/car cycle time deviation

"Every refractory brick in our kilns carries a traceable 'ID', documenting material batches and firing parameters, making your high-temperature investment transparent and controllable."
- Brictec Kiln Division
Industry Comparison: Brictec kiln bricks last 8-10 years (industry avg. 5-7) with 40% lower annual maintenance costs.