Factory for king size products

 1.000 Tm/day production capacity of king size hollow products.

EQUIPCERAMIC, S.A., received a request from CERANOR, S.A. to design an unprecedented plant with a production capacity of more than 1.000 Tn/day of king size hollow bricks to be built in Valencia de Don Juan (León).

The design of the plant developed by EQUIPCERAMIC, S.A., was the result of cooperation between the technical staff of CERANOR, S.A. and of EQUIPCERAMIC, S.A.

The proven experience and technology of EQUIPCERAMIC, S.A., has been the key factor in bringing this installation to a satisfactory end.

As it is the largest factory in the world producing king size hollow bricks, it has been necessary to develop new machinery and new lines whose performance surpasses the usual equipment in the sector. This new machinery has also been provided with the necessary flexibility to automatically adapt to the different types of bricks to be produced, since the plant has been designed to manufacture a wide range of products.

The success achieved in such a huge project is due to a new conception of mechanisms to cope with the high production/hour requirements, which have also been equipped with the most sophisticated control and command electrical items and drives in the market. This is to enable a maximum quality product, reflected by its flatness and strength.

A new sealed tunnel kiln” has been designed to fire all kinds of products. It has been named Gaudí Tunnel Kiln after the brilliant architect.

The installations comply with Ceranor's requirements regarding resources optimization, energy efficiency and quality of final products.

Cutters

The slug cutter can copy the correct speed of the slug.

The cutting car rive is provided with a servopositioner that enables downwards cutting. The electric cam created by the servopositioner allows the cutting car to accelerate and overtake the slug after it has been cut, and then rises before the slug.

The slug is then speeded up and, when processing small hollow bricks or ceiling blocks it is shifted to a multiple cutter for stationary clay column with vertical cut. This cutter consists of two independent frames, each one bearing several groups of wire. They have a cutting capacity of up to 2mts length. 

When producing king size hollow bricks, the slug is shifted to a pulse multiple cutter. Ware is fed by means of a belt and it emerges at 90º, on conveyor straps with a lifting drive

Tray loading and unloading

At the cutter exit, already cut products are gathered together to form a layer that will be loaded on the dryer tray.

This process is carried out from the programming table, which leaves enough space between the pieces for them to be dried.

The layer is split into rows according to the different speeds between the two slatted tables. It is then loaded onto trays by a set of straps which comb the tray of the dryer.

Racks

Trays loaded with wet ware are conveyed to the dryer car loader.

This loader has a loading capacity of 6 trays with a size of 3 x 2.4mts. per minute and it is equipped with a pit where dryer cars are introduced to facilitate the loading on each rack. .

Racks loaded with dry ware are conveyed to the unloading area where they are unloaded in reverse procedure to the loading process.

Setting area

Dry ware is then unloaded from trays by means of a chain table which rises between the ribs of the tray. The unloaded tray is re-routed towards the loading area by means of a chain table. At this point, a gripper collects empty trays and regroups them forming 4 mts. high columns. These columns are stored by an electric transfer lifter in a buffer with a capacity for 2,500 trays.

There are two setting machines designed by Equipceramic, S.A.. One is for the vertical loading of ware onto trays, and the other is for flat loading of king size bricks on trays.

Kiln car loading

Unloaded dry ware is regrouped and, in the case of vertically set products, rows are programmed to be supplied by a triple gripper which distributes them onto three different belts. At this point, 1m x 1m layers of dry ware are programmed. A triple full width setting gripper equipped with a pneumatic drive and intermediate tongue, loads 12 layers onto the kiln car.

When setting in a vertical position, ware is programmed in rows onto a slatted table. They are then conveyed towards three turning device lines equipped with automatic wire-tying units.

Prekiln and kiln

The pre-kiln is in line with the kiln and contains 12 kiln cars, 77.70 meters. Hot air coming from the kiln air recovery system is driven by a centrifugal fan through 8 different injection areas. The heating input is adjusted by means of an in-duct gas-fired device when required. A recirculation group consisting of two centrifugal fans is included. 1 centrifugal fan commands the draught.

The Gaudí Tunnel Kiln designed by Equipceramic, S.A. at Ceranor, S.A. is a kiln especially designed and equipped to reach high production of a wide range of king size products, while guaranteeing the correct firing curve for each product..

It is undoubtedly the largest tunnel kiln ever built in the world for this type of product, being 9mts. wide by 199.30mts. long and 1.70mts. high.

Thanks to its long size and its advanced control system the Gaudí Kiln is a high quality, flexible and reliable machine.

Its robust construction, built on site, its perfect sealing thanks to a welded metallic casing, its innovative design and its metallic structure, which supports the roof above the casing, together constitute what can justly be called a “Great kiln”, not to mention its many well designed circuits and equipment and a broad range of fans, burners and sensors.

Dehacking

The dehacking designed by Equipceramic, S.A. consists of two double lines: one for standard products and the other for king size products and ceiling blocks. When dealing with products which are not tied with wire, there are four pneumatic grippers in charge of unloading four packages and transferring them onto two unloading lines with a production capacity of 130 packages/hour.

Products tied with wire are unloaded, layer by layer, by means of 8 full width setting grippers. Units are placed on conveyors to be sorted. Afterwards, units are strapped vertically by means of other grippers to make packages of about 1 metre high. These packages are then shifted to a double conveyor which is the same as that used in dehacking.

 

 

Ceranor

 ceranor map

Production: 1.000T/day.
Products: Multiple products and king size hollow products.
Dryer: Semicontinuous.
Kiln: Sealed tunnel kiln  “Gaudí”.
Location: Valencia de Don Juan, León, Spain.