How Auto bricks are Made?

CHINA BANGLA ENGINEERS & CONSULTANTS LIMITED
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Clay Brick Producing Equipments

Bricks are the only manmade building materials that testify to their use since the early human civilization. With their attractive
appearances and superior properties such as high compressive strength and durability, excellent fire and weather resistance,
good thermal and sound insulation, bricks are widely used for building, civil engineering work, and landscape design.

Bricks for building may be made from clay, shale, soft slate, calcium silicate, concrete, or shaped from quarried stone. However,
true bricks are ceramic, and therefore created by the action of heat and cooling. Clay is the most common material, with modern
clay bricks formed in one of three processes soft mud, dry press, or extruded.

Bricks may also be classified as solid (less than 25% perforations by volume, although the brick may be "frogged," having
indentations on one of the longer faces), perforated (containing a pattern of small holes through the brick removing no more than
25% of the volume), cellular (containing a pattern of holes removing more than 20% of the volume, but closed on one face), or
hollow (containing a pattern of large holes removing more than 25% of the brick's volume). Blocks may be solid, cellular or
hollow.

Clay Brick Producing Technical Process:

Most brickworks have some or all of the following:
  A kiln, for firing, or 'burning' the bricks.
  Drying yard or shed, for drying bricks before firing.
  A building or buildings for manufacturing the bricks.
  A quarry for clay.
  A pugmill or clay preparation plant

In a typical modern brickworks, clay is taken from the quarry, and then carried by conveyor belt or truck/lorry to the main factory,
although it may be stockpiled outside before entering the machinery. When the clay enters the preparation plant (Clay Prep) it is
crushed, and mixed with water and other additives which may include breeze, a very fine anthracite that aids firing. This process,
which is also known as pugmilling, improves the consistency, firing qualities, texture, and color of the brick. From here, the
processed clay can be extruded into a continuous strip and cut with wires, or put into moulds or presses (also referred to as
forming) to form the clay into its final shape. After the forming or cutting, the bricks must be dried, either in the open air, in drying
sheds, or in special drying kilns. When the bricks have been dried, they must then be fired or 'burnt' in a kiln, to give them their
final hardness and appearance.

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                   Brick making process, with clay as raw material

               Brick making process, with shale as raw mawterial

Clay Brick Producing Equipments

1. Box feeder
A box feeder is designed for storage, dosage and preliminary breaking up of materials used in clay brick production. Their basic
functionality is to dose and transport raw material for further production stages.
Model Capacity (m3
/h) Conveyor belt Conveyor width Conveyor speed Power (kw）


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(mm） (m/s）
GD650 935 Rubber 650 6 5.5
GD800 1540 Rubber 880 5.3 5.5
GD1000 2590 Rubber 1000 6 7.5

Plate feeder
Plate feeder is used to convey diferent kinds of particulate, lumpy materials in horizontal or inclined direction in building material,
metallurgical, coal and chemical industries, and it's suitable for feeding lumpy lime stone, gypsum or clay from the bottom of feed
bin to the inlet of crusher continuously and evenly.

Model Capacity (m3
/h) Conveyor belt Conveyor width
(mm）
Conveyor speed
(m/s）
Power (kw）
GL800 2035 Chain board 680 7 7.5
GL1000 2540 Chain board 880 7 7.5
GL1200 3050 Chain board 1080 7 7.5

2. Rubber belt conveyer
Belt conveyor is used in the transmission of sections like Clay Preparation, Molding, Loading & Unloading, etc.


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Rubber belt conveyor
width (mm)
Conveyor
length(mete
r)/Powder
(kw)
Conveying
speed
(meter/secon
d)
Capacity
(MT/hour)

500 ≤12/3 1220/45.5 2030/5.57.5 1.31.6 78191
650 ≤12/4 1220/5.5 2030/7.511 1.31.6 131323
800 ≤6/4 615/5.5 1530/7.515 1.31.6 278546
1000 ≤10/5.5 1020/7.511 2040/1122 1.32.0 435853
1200 ≤10/7.5 1020/11 2040/1530 1.32.0 6551284

3. Double roller crusher
Double roller crusher is mainly used for the crushing of medium or lowerhardness mines and rocks with medium or lower rigidity
in the cement, metallurgy, chemical industry, electric power, coal and other industry. The crushing materials include limestone,
slag, coke and coal.
Item SGP500 SGP600 SGP800
Manufacturing capacity, m3
/h 1318 1723 2326
Roller specifications, mm 500×500 600×500 800×500
Rollers interval, mm 35 35 35
Power, KW 7.5/10 10/13 18.5/22

4. Double shaft mixer
Double Shaft Mixer efficiently mix dry to very wet materials, or blend liquids and sludges with dry solids. Materials can range from
wet and sticky clays, sludges, or filter cakes to silty, sandy soils and other abrasives. These machines can be used as pugmills
for mixing liquids or sludges with dry solids, especially when a greater tub volume is required for longer retention times. Most
often, they are used for the intensive blending of two dissimilar wet or dry materials.


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Item SJ2m SJ2.5m SJ3m
Mixing length, mm 2000 2500 3000
Power, KW 22 2230 3037

6. Brick extruder

For extruded bricks the clay is mixed with 1015% water (stiff extrusion) or 2025% water (soft extrusion). This is forced through a
die to create a long cable of material of the proper width and depth. This is then cut into bricks of the desired length by a wall of
wires. Most structural bricks are made by this method, as it produces hard, dense bricks, and suitable dies can produce holes or
other perforations. The introduction of holes reduces the volume of clay needed, and hence the cost. Hollow bricks are lighter
and easier to handle, and have thermal properties different from solid bricks. The cut bricks are hardened by drying for 20 to 40
hours at 50 to 150 °C before being fired. The heat for drying is often waste heat from the kiln.

Vacuum extruder, double stage, hard plastic

Vacuum extruder of hard plastic are mainly used to produce bricks with low plastic materials as raw materials, such as coal
gangue, fly ash, shale, sandy soil of poor quality, etc., and produced bricks strength can reach 3.54 KG/cm2
.

Model Capacity,
pcs/hour
Moisture
content
Vacuum degree
(Mpa)
Extrusion
pressure (Mpa)
Power (KW)
JZK90Y4.0 2000025000 1114% ≦0.092 4.0 132+315
JZK75Y4.0 1500020000 1114% ≦0.092 4.0 110+250
JZK60Y4.0 1100013000 1114% ≦0.092 4.0 90+160

Vacuum extruder, double stage, Split type


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Model Capacity,
pcs/hour
Moisture
content
Vacuum degree
(Mpa)
Extrusion pressure
(Mpa)
Power (KW)
JKY60/604.0 1600022000 15%18% ≦0.092 4.0 200+90+22
JKY55/554.0 1400019000 15%18% ≦0.092 4.0 200+75+22
JKY50/504.0 1200016000 15%18% ≦0.092 4.0 160+75+22
JKB55/553.0 1200016000 17%19% ≦0.092 3.0 160+55
JKB50/503.0 1000015000 17%19% ≦0.092 3.0 132+55
JKB45/453.0 800012000 17%19% ≦0.092 3.0 110+45

Vacuum extruder, double stage, Integral type

Model Capacity, pcs/hour Moisture
content
Vacuum degree
(Mpa)
Extrusion pressure
(Mpa)
Power (KW)
JZKE503.0 1200016000 17%19% ≦0.092 3.0 160+7.5
JZKE453.0 1000015000 17%19% ≦0.092 3.0 132+5.5
JZKE403.0 800012000 17%19% ≦0.092 3.0 110+5.5
JK352.0 60008000 18%22% ≦0.092 2.0 75
JK302.0 50007000 18%22% ≦0.092 2.0 45

7. Cutter, automatic


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8. Automatic unfired brick stacking machine

Automatic Unfired Brick Stacking Machine are used to pick up the grouped billet automatically (wet billet or dry billet) and put
down them to the assigned position of the kiln car, and Suitable for both once brick setting system and twice brick setting system.
There are many ways to putting down the billet ,such as putting down billet in face up or putting down billet in side face. The type
of brick stacking machine can be designed according to user’s demand.

Type Production Capacity (Pieces/Hour) Weight (Kg) Dimension (mm)
ZMP460×2 4600 13500 8000×5980×7570
ZMP690×3 7400 14000 11500×6010×6610
ZMP460×2×2 8615 16500 12440×6010×6610
ZMP923×4 8615 16500 12440×6010×6610
ZMP731×3×2 11270 9000 11850×3782×5000
ZMP3×2A 12960 16264 17390×6680×6453

9. Clay brick making machine, Manual


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Clay bricks making machine, manual (DW01)

Clay bricks press, manual (DW02, mainly produce bricks of special shapes)

9. Supplemental equipments for clay brick plant


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Wet adobe car

Dry adobe car


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Automatic lifting and transporting vehicle

10.Hoffman kiln

The Hoffmann kiln is a series of batch process kilns. Hoffmann kilns are the most common kiln used in production of bricks and
some other ceramic products. Patented by German Friedrich Hoffmann for brickmaking in 1858, it was later used for
limeburning, and was known as the Hoffmann continuous kiln.
A Hoffmann kiln consists of a main fire passage surrounded on each side by several small rooms. Each room contains a pallet of
bricks. In the main fire passage there is a fire wagon, that holds a fire that burns continuously. Each room is fired for a specific
time, until the bricks are vitrified properly, and thereafter the fire wagon is rolled to the next room to be fired.
Each room is connected to the next room by a passageway carrying hot gases from the fire. In this way, the hottest gases are
directed into the room that is currently being fired. Then the gases pass into the adjacent room that is scheduled to be fired next.
There the gases preheat the brick. As the gases pass through the kiln circuit, they gradually cool as they transfer heat to the brick
as it is preheated and dried. This is essentially a countercurrent heat exchanger, which makes for a very efficient use of heat and
fuel. This efficiency is a principal advantage of the Hoffmann kiln, and is one of the reasons for its original development and
continued use throughout history. In addition to the inner opening to the fire passage, each room also has an outside door,
through which recentlyfired brick is removed, and replaced with wet brick to be dried and then fired in the next firing cycle.
In a classic Hoffmann kiln, the fire may burn continuously for years, even decades. Any fuel may be used in a Hoffmann kilns,
including gasoline, natural gas, heavy petroleum and wood fuel. The dimensions of a typical Hoffmann kiln are completely
variable, but in average about 4 m (height) x 15 m (width) x 150 m (length).


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Tunnel kiln
In modern brickworks, clay bricks are usually fired in a continuously fired tunnel kiln, in which the bricks move slowly through the
kiln on conveyors, rails, or kiln cars to achieve consistency for all bricks.

Tunnel kiln is a long structure in which only the central portion is directly heated. From the cool entrance, ware is slowly
transported through the kiln, and its temperature is increased steadily as it approaches the central, hottest part of the kiln. From
there, its transportation continues and the temperature is reduced until it exits the kiln at near room temperature.

The tunnel kiln is composed of of furnace body, traction system, rail, kilncar, and firing system, hot air ventilation system, control
system, etc. The design and manufacture of the tunnel kiln could be negotiated based on customers' request, including chamber
dimension, working Temperature, controlling method and number, traction way and speed as well as heating power. Basically, a
brick kiln consists of two main parts. One is drying chamber. The other is tunnel kiln. There is no special burning system for
drying chamber. The extra heat used in tunnel kiln will be feedback to drying chamber through a pipe system.


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How Auto bricks are Made?

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How Auto bricks are Made?