A complete installation with a production capacity of 150.000 t/year.
Production: 150.000 t/year.
Product: Hollow bricks.
Dryer: Rapid dryer Celeris.
Kiln: Tunnel kiln Gaudí.
Location: Chief, Algeria.
The Rahmoune Group, one of the most important Algerian investment groups and owner, among other, of El-Ouarsenis and El-Heumis brickworks, entrusted Equipceramic with the construction of its new brick factory in Chlef. This new brickworks has been designed for the production of 150,000 tons of hollow bricks per year and it is the company’s fourth production line.
Equipceramic and SARL Comep worked together to lay down the technological basis for the project. It foresees the installation of a Celeris rapid dryer for the drying process and of a Gaudí sealed tunnel kiln for the firing process. Both of them have been provided with state-of-the-art automation systems. The factory has been equipped in order to admit a wide operation range allowing adaptability to particular production needs so as to obtain a high quality final product. Fired ware is unloaded by means of rotary grippers that make 900×900 mm packs to be directly loaded on trucks.
The drying is performed in a Celeris rapid dryer consisting of a metallic structure with an exterior masonry enclosure housing two overlapped canals. Products are dried inside these canals by applying a counter flow drying system in which hot drying air flows in the opposite direction to the product flow.
In this type of dryers racks are used as drying supports. They are drawn through canals by means of a chain driven by motor and frequency inverter. This handling system also includes a counterweight device to keep the chain at the right tension.
Among the advantages of this type of dryer, particular attention must be drawn to the ones below:
- High quality and rapid drying.
- Very precise regulation of the drying cycle.
- Mechanical simplicity and low maintenance.
DRYER LOADING AND UNLOADING SYSTEM
Dryer racks are simultaneously loaded and unloaded by means of an automatic pusher that allows for loading green ware while the opposite edge pushes dry products out of the rack and sets them on a an intermittent conveyor.
The firing process is performed in a Gaudí sealed tunnel kiln dessigned by Equipceramic. This kiln is provided with a comprehensive automated regulation system and it is equipped with state-of-the-art technology to obtain the best results in terms of product quality and to ensure efficient means of regulation to guarantee operating flexibility as well as a wide range of possibilities to customize the drying cycle.
In terms of design, priority has been attached to obtain a simple operation and regulation system, to select the most suitable equipment for each firing section and to provide the kiln with a comprehensive interior duct system.
The Gaudí kiln consists of a robust and sealed construction which allows for high pressure applications and for the rapid cooling of its metallic beams and roof, thus avoiding the use of forced ventilation.
Every section of the kiln is constructed and provided with the refractory and insulating materials that adapt best to the stage of the process being performed and always pursuing the best results.
It has an undulated roof built with refractory pieces suspended by means of INOX anchors.
It has an exterior metallic structure consisting of folded plates welded to each other to guarantee its sealing function.
Kiln cars are used as firing supports. They are provided with refractory support settings to obtain a better firing of the base layer and with double flange wheels for the perfect alignment of joints.
KILN CAR HANDLING
Kiln cars are handled through the prekiln and the kiln by means of hydraulic pushers.
Kiln cars loaded with fired products are headed to the dehacking area by means of a hauler. After being unloaded, empty kiln cars are automatically driven to the setting area by means of a hauler that pulls them in a one-by-one sequence under the setting area.
Kiln cars loaded with dry or fired products are handled and stored by means of automatic winches.
KILN CAR SETTING AND DEHACKING
Products conveyed by kiln cars are set and dehacked in an automatic way by means of pneumatic grippers.
The dehacking line consists of rotary grippers that make 900×900 mm packs to be directly loaded on truck.