brick making plant clay brick Hoffman kiln project

Ibrick China brick making plant clay brick Hoffman kiln project  Big capacity semi automatic clay brick hoffman kiln  Coal fired clay brick hybrid hoffman kiln  Oil fired system africa clay brick hoffman kiln  Hoffman kiln This producing line adopts the new type hoffman kiln. This hoffman kiln have the impeccable firing system, exhausting system and afterheat system. It will produce the regular clay sintering bricks through adjusting all the systems and make the firing temperature more reasonable. Hoffman kiln adopts the reinforced concrete foundation, the wall be built by the normal sintering brick, the fire hole and heat suction mouth be adopted the heat proof concrete. The 30% heat source of hoffman kiln come from internal combustion, 70% come from out injection. Basic requirement for the field Factory can not build in caving zone or fracture zone. Factory should be above 300 meters apart from residential area and on downwind position, because in mass production process, a few noise and dust will be produced. Layout principle: On the premise of meeting the requirement for the production technology, try to make the layout compaction, with short transportation line, transportation easy and smooth, passengers and goods transportation separate and not disturb each other. It accord with the demands of clean, fire proofing and safe etc. with green planting arrangement and environment protection, so that to make economic and reasonable layout and practical total graphic design. This should make good use of the landform, if necessary make the layout in vertical direction, so that to reduce the ground works. Electric power: Facilities normal power matched is 380V, 50HZ, Four-wire three-phase alternation current. (can adjust according to local requirement.) Energy Hybrid Hoffman Kiln (HHK) REPORT: In response to these aspects of local air pollution effects as well as to global climate change issues related to GHG emissions, brick kilns have come under close scrutiny from citizens groups, environmentalists and as well as the government. In order to resolve this issue, Government of different counties with support from donors intends to facilitate the adoption of cleaner technologies and practices in the brick manufacturing sector in Bangladesh. This initiative is focused on the replacement of old technology kilns and retrofitting older kilns for cleaner and more energy efficient operation. The combination of energy saving and reduction in pollution is a ‘win-win situation’, in which industry benefits because of savings in energy costs and better working conditions. On the other hand, the country and the society gain due to reduction in pollution as well as savings in precious natural energy resources. What is the brick hoffman kiln (HHK)? The HHK is a hybrid version of the Hoffman kiln technology that was developed in Germany in the mid-nineteenth century. Since then it has been redesigned to improve heat retention in the kilns and to capture waste heat for recirculation in the drying tunnel. In addition to improving kiln efficiency, the process also reduces CO2 and other emissions since it employs coal fuel technique to create better thermal bonding,reducing fuel usage. It has been claimed that the HHK technology improves energy efficiency through internal combustion of injected fuel through the application of heat optimization techniques in a minimum heat-loss chamber in the combustion zone of the kiln. The design capacity has claimed that one 18-door HHK will enable production of 16.5 million bricks of the size commonly used whereas the traditional Fixed Chimney Kiln (FCK) produces about 2 million on the average. This means that each new HHK will replace 7.5 of the older energy inefficient kilns in equivalence. It has also been alleged that the fuel, coal, consumed in the HHK is about 10 to 12 tones per hundred thousand bricks compared to 22 to 24 tones in the traditional kilns. It follows, therefore,that the new kilns are about 50% more energy efficient. The HHK is a hybrid version of the Hoffman kiln. Structurally, it is built like the Hoffman but, unlike the traditional Hoffman in Bangladesh,Nepal and India, the fuel used is coal. The kiln can be made from firebricks or from green bricks. In the latter event, the green bricks get “cooked” during kiln operation. The inner and outer kiln linings are made with bricks and the space in between them packed with clay to create a solid inner chamber from which heat escape is almost absent. In this version, the firing chamber can be filled manually or automatically with dried green bricks, usually about 8,000 to 9,000 units at one time in line stacks of around 1,000. There are about 8 line stacks in each firing chamber. Each line stack is fired for about half an hour so that total firing time is about six hours. The fuel, granulated coal, is fed into the firing zone in the kiln through stoke holes on the roof. A centrifugal blower forces from behind air required for the combustion process; and, as it reaches the line to be fired, it is already preheated from the previous firing zone thus reducing firing time and energy usage. The temperature in the firing zone is about 9000C. In the HHK system, green bricks are pre-dried in a “dry tunnel” with waste heat captured from the kiln through elaborate flow mechanisms and pumped into the tunnel by the centrifugal blower which performs two functions simultaneously, blows out hot air from the kiln and feeds it into the dry tunnel.At this background, it has been claimed that in overall consideration, the HHK type kilns are more environmental friendly, energy efficient and cost effective than the existing FCK or BTK technology when it is compared in respect of production and quality. However, all claimed advantages in brick manufacturing processes are very much raw materials and technology implementation specific. A more complete knowledge of raw materials and their properties, better control of firing, improved kiln designs, properties of fuel used and more advanced mechanization, all contribute to advancing the brick industry. As HHK is a new technology, no information is available regarding its emission and specific energy consumption under brick condition. So, it became important to measure the essential environmental parameters of HHK to ascertain whether the adoption of this technology will advance the brick sector towards the desired ‘win-win situation’. Manufacturing Process: Clay Extraction, Transportation and Preparation: The clay is excavated by hydraulic excavator or by hand from nearby riverbeds or surface clay mined from open pit and transported to plant stacking yard by trucks. The clay is crushed by means of roller mills and then by double shaft mixer where water and granulated coal is added in such a manner as to ensure moisture content of 15% Coal Crushing and Pulverizing: Coal is crushed using steel sieve type crushing machine to pulverize the coal. Brick Shaping: The tempered material is fed into vacuum extruder for continuous column production. The column is then cut by Clay bar cutting machine. The green bricks are set on wood planks that are manually loaded on the drying cars for drying. Brick Drying: The green brick is then manually loaded on to the drying car, which is then transported into the drying tunnel by means of hydraulic pusher. Hot air for drying is funneled into the tunnel from the annular kiln. The drying cycle is about 24 hours. Brick Firing: The dried green bricks are unloaded manually into the annular HHK (Hybrid Hoffman kiln). The speed of firing is 1.25 m/h at a sintering temperature of about 950-1050 C. The fired brick are unloaded and conveyed manually in carts to stacking Yard. Main technical data includes: Clay Particle size after roll mill: 2mm. Brick Moisture content for shaping: 18%-20%. Dry chamber temperature:  120 o C. Sintering temperature: 950 o C –1050 oC.  Raw Materials: The major raw material brick production is clay. However, coal is also a major raw material for bricks. Coal will be partially mixed with clay for internal burning (~70%) and the rest of coal will be externally applied (~30%). (a) Clay Initial analysis of the clay brick materials by Xian Institute indicates that thE available clay is suitable for brick production in the proposed kiln. The  (b) Coal  Yearly estimated requirement of coal for 16,500,000 bricks is 1,750 tons. The actual coal requirement is currently observed to be higher than the estimates. 
Comparison with other kiln Technologies The Specific Energy consumption of the HHK Universal Kiln was compared with available data for other technologies commonly used in Bangladesh. These are the MC BTKs and the FC BTKs. The comparison of specific energy consumption in these technologies is shown in Table 8 below.  In general, FC BTKs will perform better than MC BTKs, however, in the data above, the operational practices of the FC BTK during monitoring by TERI in 2002 was found to be very poor and this is reflected in the results in Table 8. Additionally, the FC BTK was being monitored; it was only in its 2nd round of firing compared to the MC BTK, being in its 7th round of firing.   These findings further indicate that to evaluate the realistic performance of a particular brick manufacturing technology in terms of energy efficiency stabilization time of the firing kiln should be systematically studied.The project design combines a highly efficient kiln technology, the Forced Draft Tunnel Kiln (FDTK) with a unique technique of forming green bricks: granulated coal is injected for internal combustion. This approach results in lower energy usage, higher quality bricks and reduced pollution. Bricks of any size, shape and pigmentation can be produced at the plant with minor modifications. All bricks will be of uniform quality and will meet international standards for strength, quality and appearance.
Clay brick dryer chamber with brick hoffman kiln of production capacity 

Specification Model	Numbers	Output Capacity (Pcs/day)	Land Covering Required	Outer Size (m)
Hoffman Kiln + Dryer	24 gates	80,000	130×70m	90×17×3.5
	10 Channels			67.6×16×1.5
	36 gates	150,000	150×90m	110×17×3.5
	12 Channels			67.6×20×1.5
	48 gates	200,000	150×120m	130×17×3.5
	16 Channels			67.6×25×1.5

  Shaanxi Ibrick brick making plant clay brick Hoffman kiln project  We supply following brick making machine and brick making equipment 1. Belt type box feeder, plate type box feeder  2.  Primary roller crusher, fine high speed rolling crusher, jaw crusher , hammer crusher 3. Double shaft mixer , double shaft mixer and extruder  4. Energy saving vacuum extruder, double shaft vacuum extruder  5. Automatic brick cutter system  6. Green bricks separation machine  7. belt conveyor  8. Brick dryer  9. Brick tunnel kiln  10. kiln automatic control and monitoring system  11. Brick kiln equipment  12. Automatic brick loading and unloading machine  13. Automatic brick packaging machine 14. Automatic robot brick setting machine  15. Automatic brick stacking machine  16. Brick dryer and tunnel kiln design and construction  17. Technical provide and technical supervision   18. Undertake turn-key project    If you want to set up a new brick plant or plan to purchase automatic brick making machinery and brick equipment, please contact with us at any time . Welcome to contact with us online :  1. Skype id : jerylee00 2. Facebook id :  Ibrick China 3. Phone Number: 0086-15991710216 (Viber,Whatsapp,Wechat) 4. Company Wetchat : ibrick / ibricktechnology  5. Website: www.ibrick.cc 6. E-mail: info(@)ibrick.cc IBRICK Company Introduction : http://youtu.be/ItIqVJuR5mM