Custom Decorative Brick Project - Brictec Malaysia Facility with Automated Glazing System
Project Overview
The Malaysia CBT decorative bricks production line is Brictec's flagship model project in Southeast Asia, designed to produce 70,000 decorative bricks (215x100x67mm) daily. With a 6-day work week, actual daily output reaches approximately 85,000 pieces.
Production Process
This project utilizes a wet plastic extrusion process featuring:
- Single layer tunnel dryer with support bar recycling
- External firing tunnel kiln with flat ceiling of lightweight mullite
- Fully automated control systems for operating equipment
- Centralized control for drying chamber and tunnel kiln
Process Design in Clay Brick Project Planning
Process Design Perspective
Process design serves as the project blueprint, determining layout and equipment selection with key considerations:
- 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
Critical factors affecting 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 & 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
The most critical pre-sintering stage features:
- Multi-stage drying with preheating (40-60°C, 70% RH)
- Fast drying (80-120°C) for bound water removal
- Vertical airflow to maintain temperature difference <5°C
- Waste heat recovery from tunnel kiln cooling zone
Tunnel Kiln Firing Curve
- 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
Design Comparison: Failure Cases vs. Optimal Solutions
| 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" (>$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)
"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, embodying demands for quality and energy efficiency through:
- Stringent Refractory Standards: Kiln walls use high-load-bearing bricks (>60% Al2O3, refractoriness>1750ºC)
- 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:
- ±5ºC variation causes>10MPa strength difference
- Preheating-firing-cooling balance sets water absorption (optimal 6-10%)
Energy Center
Consumes>70% of total energy with Brictec solutions achieving:
- >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.
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