Fully Automatic Twice Stacking Ceramic Face Brick Tunnel Kiln
Working Principle of Tunnel Kilns:
1. The working principle of a tunnel kiln is based on a continuous production mode.
2. Green bricks are placed on kiln cars, which enter the kiln body via tracks or rollers.
3. The green bricks are gradually heated in the preheating zone to remove excess moisture, and the exhaust gases from the kiln can be recirculated to improve thermal efficiency.
4. The green bricks reach the highest temperature in the firing zone and complete the sintering process.
5. The fired bricks are gradually cooled in the cooling zone to a temperature suitable for unloading.
6. Kiln cars move continuously through the kiln, with new green bricks entering and fired bricks being unloaded, achieving continuous production.
Structure of Tunnel Kilns:
1. A tunnel kiln typically consists of the following main parts:
(1) The main structural part of the tunnel kiln, usually an elongated passage with tracks or rollers inside to support and move the green bricks.
(2) The first zone that the green bricks enter after entering the kiln body, where the temperature gradually increases to remove moisture from the bricks.
2. Firing Zone: The core area of the tunnel kiln, with the highest temperature, where the bricks are sintered.
3. Cooling Zone: The zone where the fired bricks are cooled down gradually to a temperature suitable for unloading.
4. Combustion System: Provides the heat required for firing, usually including burners, fuel supply systems, and exhaust systems.
5. Ventilation System: Controls the airflow inside the kiln to ensure complete combustion and uniform temperature distribution.
6. Drive System: Used to move the green bricks through the kiln, usually including motors, chain drives, or roller drive devices.
Maintenance and Care of Tunnel Kilns:
To ensure the efficient operation and long service life of tunnel kilns, regular maintenance and care are necessary:
1. Regularly inspect the kiln body for cracks, deformations, or other damage, and repair them in a timely manner.
2. Clean the combustion system regularly, including burners and fuel supply systems, to ensure complete combustion.
3. Ensure that the ventilation ducts are unobstructed and check the normal operation of fans.
4. Inspect the operation of the drive system, including motors, chains, or roller drives, and lubricate and replace worn parts in a timely manner.
5. Regularly calibrate temperature sensors and control systems to ensure accurate temperature control.
Since the end of the 1990s, China has been faced with the problems of high investment, complex process and difficult maintenance, and the advantages of the secondary yard burning process are difficult
In order to give full play to it, the domestic sintered wall materials are also greatly limited by the one-sided use of one-step code burning technology to improve the quality of products;
At present, domestic high-end public buildings, such as hospitals, schools, museums, libraries, cultural tourism centers and other clean bricks and green bricks are gradually used, but the second batch burning of clean brick factories
The vast majority of processes still rely on manual operation, and the degree of automation is extremely low, which is no longer suitable for the current shortage of labor resources;
We follow the trend of the world today, innovates boldly, and independently develops a new type of secondary code burning system for the pain point. Its main features include:
1. The drying tray is canceled, greatly simplifying the process;
2. The drying vehicle has been redesigned to make the connection between vehicle products and upper and lower level systems more smooth;
3. The efficient ceramic tile conveying technology is used for reference, and a large number of servo motors are used to control the operation, marshalling and connection of green bodies and vehicles;
4. The upper shelf and lower shelf are concentrated on the same side of the dryer, simplifying the process and greatly saving space;
5. The newly developed DSC discrete integrated control platform integrates variable frequency servo, photoelectric, proximity travel and other position and time sensors through PLC and configuration software;
Technical Parameters:
| Tunnel inside width | Height of above kiln car surface |
Daily capacity | 10,000 brick firing fuel consumption |
| 2.4 m | 1.6~2 m | ≥80,000 pieces | < 49×10⁶ KJ |
| 3.5 m | 1.6~2 m | ≥150,000 pieces | < 49×10⁶ KJ |
| 4.6 m | 1.6~2 m | ≥200,000 pieces | < 49×10⁶ KJ |
| 6.9 m | 1.6~2 m | ≥300,000 pieces | < 49×10⁶ KJ |