Brictec's High-Quality Extrusion Brick Machine Powers Shaoxing Ultra-Low Emission Sintered Brick Project
Brictec's Advanced Extrusion Brick Machine Powers Shaoxing 35% Solid Waste Utilization Sintered Brick Project
In May 2022, Brictec successfully undertook the construction of the new lightweight composite integrated assembly panel project for Shaoxing Green Exhibition Environmental Protection Co., Ltd. This project, positioned in the field of high-end sintered wall materials for green environmental protection and solid waste utilization in China, aims to create a modern clay sintered brick demonstration base through the construction of a fully automated intelligent production line.
Project Engineering Excellence
During project implementation, Brictec demonstrated profound professional expertise. Using Computational Fluid Dynamics (CFD) simulation technology, the company optimized factory layout to ensure efficient material flow for processes including raw material transportation, aging, forming, and roasting. The double-helical raw material aging silos strictly adhere to GB 50528 design standards, providing a stable and homogeneous raw material base for green body forming.
Thermotechnical Engineering Innovation
The tunnel kiln system construction showcased Brictec's technical prowess with modular construction techniques and precise control over kiln lining flatness (error ≤1.5mm). The self-developed Italian-technology regenerative pulse burners, integrated with intelligent temperature control and staged combustion technology, achieve roasting temperature fluctuation of ±5℃ while enhancing energy efficiency by 28% and meeting GB 29620 emission standards.
In raw material processing, multi-stage crushing and screening systems and vacuum extrusion molding equipment ensure precise control of particle size distribution (0.1-2mm proportion ≥90%) and vacuum degree (≥92%), guaranteeing density and strength indicators of green bodies.
Project Success Metrics
The Shaoxing Green Exhibition project achieves an industrial solid waste blending ratio of over 35% and annual production capacity of 120 million standard bricks. Product quality meets compressive strength ≥MU20 with qualified frost resistance, establishing a benchmark case for green wall material production in China.
The Importance of Process Design in Clay Brick Project Planning
Process Design Perspective
Process design serves as the project's blueprint, determining overall layout and equipment selection. Key considerations include raw material properties, product specifications, capacity coordination, and energy efficiency through integrated thermal system design.
Raw Material Processing
- 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 & Forming
- 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
Drying Technology
- Multi-stage drying with preheating and fast drying phases
- Airflow design: Vertical airflow to maintain temperature difference <5°C
- Waste heat recovery: Reuse tunnel kiln cooling zone heat
Tunnel Kiln Firing Curve
- Preheating zone (200-600°C): Heating rate ≤50°C/hour
- Firing zone (900-1050°C): Hold for 2-4 hours under oxidizing atmosphere
- Cooling zone: Slow cooling to <80°C to prevent cracking
Failure Cases vs. Good Design Comparison
| Issue |
Poor Design |
Good Design |
| Brick Cracking |
Single-stage drying |
Multi-stage gradient drying |
| High Fuel Consumption |
No kiln waste heat recovery |
Integrated drying-firing heat recovery system |
| Low Production Capacity |
Mismatched crusher and extruder capacity |
Holistic equipment capacity coordination |
| Spiral Mark Defects |
Insufficient extruder compression ratio |
Optimized die L/D ratio (≥4:1) |
| Material Waste |
No homogenization causing inconsistency |
Enclosed aging shed + automated batching system |
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 and refractory spalling contaminating bricks.
Sealing Vitality
Ineffective sand sealing between cars and kiln walls leads to heat loss (8-12% higher energy consumption) and flue gas crossflow disrupting firing curves.
Mobility Foundation
Wheel systems must feature high-temperature bearings (>400ºC) and self-adjusting rail alignment to prevent derailment.
"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.
- Stringent Refractory Standards: Kiln walls use high-load-bearing bricks (>60% Al2O3) while roofs adopt lightweight insulation composites
- Millimeter Precision: Kiln straightness tolerance <3mm/10m
- Dynamic Validation: CFD simulation + physical kiln testing
The Critical Role of Tunnel Kilns
Quality Determinant
Kiln temperature control directly affects bricks with ±5ºC variation causing >10MPa strength difference and determining water absorption rates.
Energy Center
Consumes >70% of total energy. Brictec solutions achieve >65% waste heat recovery and <90m³ gas/10k standard bricks.
Production Hub
Kiln width and car speed coordination ensures uninterrupted production (>95% capacity utilization) with minimal 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.
Your message must be between 20-3,000 characters!
