Brictec's Turnkey Clay Brick Plant Solution with Secondary Burning Technology and Automated Drying System

ECO CERAMICS is part of the Bangladesh GPH Group, the largest building material manufacturer in Bangladesh. The group operates the top three cement factories and the largest steel plant in Bangladesh. The current brick factory project under construction will become the largest and most industrialized brick factory in Bangladesh.

The project features advanced secondary burning technology, with an automated upper and lower rack system for drying and tunnel-type single-layer drying. The burning process utilizes two 4.8-meter section tunnel kilns with an automatic pulverized coal combustion system. This highly automated production process offers strong controllability for manufacturing both standard and high-end bricks.

On March 31, 2019, Xi'an Brictec Mining Machinery Project Department officially began on-site operations, holding a groundbreaking ceremony with Party A to commence full project construction and management.

Process design serves as the project blueprint, determining layout and equipment selection. Key considerations include:

• Raw material properties (plasticity index, mineral composition)
• Product specifications (solid bricks, perforated bricks)
• Capacity coordination (avoiding over/under-capacity issues)
• Energy efficiency (integrated thermal system design)

Raw material processing directly affects brick quality and equipment longevity:

• Crushing size control: Double toothed roll crusher output ≤3mm
• Aging & homogenization: ≥72 hours aging ensures moisture uniformity
• Impurity removal: Magnetic separators + screening for iron and stones

• Aging process: Enclosed aging shed with >80% humidity
• Extrusion forming: Vacuum extruder (vacuum ≥-0.092MPa)
• Die design: L/D ratio ≥4:1 minimizes spiral marks

The most critical pre-sintering stage:

• Multi-stage drying with preheating (40-60°C) and fast drying (80-120°C)
• Vertical airflow to maintain temperature difference <5°C
• Waste heat recovery from tunnel kiln cooling zone

• Preheating zone (200-600°C): Heating rate ≤50°C/hour
• Firing zone (900-1050°C): 2-4 hour hold under oxidizing atmosphere
• Cooling zone: Slow cooling to <80°C to prevent cracking

• Increased rework costs
• Reduced equipment lifespan
• Lower product qualification rate

• 20-30% energy savings
• ≥15% production increase
• 40% lower maintenance costs

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)

Ineffective sand sealing between cars and kiln walls leads to:

• Heat loss (8-12% higher energy consumption)
• Flue gas crossflow disrupting firing curves

Wheel systems must feature:

• High-temp bearings (>400ºC)
• Self-adjusting rail alignment (derailment prevention)

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:

Kiln walls use high-load-bearing bricks (>60% Al2O3, refractoriness>1750ºC), while roofs adopt lightweight insulation composites for maximum thermal efficiency.

Kiln straightness tolerance <3mm/10m, eliminating temperature deviation or product color variation caused by deformation.

CFD simulation + physical kiln testing to optimize firing curve stability.

Kiln temperature control directly affects bricks:

• ±5ºC variation causes>10MPa strength difference
• Preheating-firing-cooling balance sets water absorption (optimal 6-10%)

Consumes>70% of total energy. Brictec solutions achieve:

• >65% waste heat recovery (industry avg. 40%)
• <90m³ gas/10k standard bricks

Kiln width and car speed coordination ensures:

• Uninterrupted production (>95% capacity utilization)
• <15min/car cycle time deviation