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Q: The advantages of the new energy-saving mobile rotary tunnel kiln

Compared with the traditional ordinary tunnel kiln, the new energy-saving and environment-friendly mobile rotary tunnel kiln are stacked at the bottom of the ring kiln at one time, and the relative movement required in the brick-making process is completed by the movement of the kiln body, so the kiln car and its supporting facilities are not required. The section of traditional tunnel kiln is generally 2.7-4.5m. The construction cost of tunnel kiln larger than this section is very high, while the section of circular rotary mobile tunnel kiln can reach more than 12M, and the construction cost is far lower than that of tunnel kiln.

Burning bricks requires coal or other fuels. How to maximize the thermal efficiency is the technical key of brick kiln design. The sintering temperature of brick is between 850 ° C and 1050 ° C. In order to save coal, the heat insulation effect of the kiln must be improved. The rotary tunnel kiln is stacked with refractory fiber cotton, which not only reduces the weight of the kiln body, reduces the thermal expansion and contraction stress of the kiln body, but also improves the thermal insulation performance of the kiln body. The kiln temperature is maintained for a long time, and the bricks consumed at one time increase in large area. The internal combustion heat energy can more effectively improve the kiln temperature and save fuel.

In ordinary tunnel kilns, in order to prevent high-temperature flue gas from flowing into the kiln car and burning out the wheels and bearings, it is also necessary to set up a gas source under the kiln car. In the whole heating system, the air supply pressure at the bottom and surface of the vehicle must be kept balanced, and the high temperature flue gas and cold air at the bottom of the vehicle must not rise to reduce the kiln temperature.

The bricks of the rotary tunnel kiln are directly stacked on the ground, without air supply under the vehicle, and the ground temperature is directly fully utilized. It is found that the aluminum silicate fiber blanket can still be calcined normally after 48 hours of coal and air shutdown in actual production, which is impossible for ordinary tunnel kilns. In the annular rotary tunnel kiln, when the firing temperature of bricks is reduced to room temperature, the heat released is enough to dry wet bricks of the same volume, so there is no need to build a hot air furnace, nor need to use the superheat roasting process to consume more coal to dry the heat.

In the heating system of the annular rotary tunnel kiln, dry air enters from the kiln tail and cools the sintered bricks through the cooling section to reduce the temperature of the sintered bricks at the outlet of the kiln tail to room temperature, that is, all the heat emitted by the sintered bricks is carried to the roasting section and drying section through the air entering the kiln for combustion support and drying. The energy saving of circular rotary tunnel kiln is its remarkable feature. Its reasonable process design, layout and simple logistics route also greatly reduce the energy consumption of the whole brick factory.

The circular rotary tunnel kiln fully adopts mechanized operation and automatic digital control system. The temperature in the kiln is directly displayed on the display screen of the control system. There is no need to hire high-paying fire-watching teachers, which fundamentally eliminates brick-making and greatly increases production.

Compared with the traditional tunnel kiln, the new energy-saving and environment-friendly mobile rotary tunnel kiln has great advantages. It can be predicted that the production mode of the new energy-saving and environment-friendly mobile rotary tunnel kiln will be widely used in the field of sintered bricks by comparing the Helu aluminum silicate fiber blanket

Q: 7 steps for clients to help buyer start the new clay brick plant

Step 1 : Buyers visiting some running brick plants to get basic knowledge for clay brick production

Step 2: Buyers study the market what kind of brick is popular

Step 3: Buyers make a plan for how many bricks per day to produce roughly

Step 4: Buyers or we help buyer check raw material whether suitable for making the popular bricks . If buyer wants to build full auto tunnel kiln plant .Buyer need to supply the soil test report.

Step 5: Buyers check what fuel is available like coal,gas,heavy oil,wood,rice husk ect in his place

Step 6: What is the buyer budget for brick machine and kiln roughly .

Step 7: Recommend the right offer or proposal based on buyer raw material brick size,daliy capacity,fuel, budget

Q: Why most of tunnel kiln brick factories not successful

Reason 1: No raw material analysis

According to our survey of 100 failed brick factories in the past, more than 80% of the brick factories did not do any analysis on their raw materials before building the factory. They just purchased brick machine and kiln equipment based on their feelings. In fact, the raw materials of each brick factory is more or less different. The selection of the machine should also consider its raw materials, brick type, kiln output, etc., which requires a systematic design.

Reason 2: Without professional design

More than 90% failed brick factories do not want to pay the factory design fees before they start the brick projects. In fact, a perfect process design process is an important guarantee for the success of a brick factory. The design cost of different brick factories is about 30,000~80,000 USD. Because of different raw materials and brick types, daily output, kiln width and length and building materials and kiln equipment used in the kiln will be different too. In order to attract business, many companies will not charge customers for design fees, because they are temporarily hiring some unqualified kiln workers to design for them. and these kiln workers do not actually have the ability to design. Sometimes they just buy a set of drawings from other companies and use them in different projects. How can such kiln workers guarantee the success of the project? Therefore, if the client wants to achieve the success of the project, he must be willing to spend money on those professional companies. Any kiln that is not professionally designed will generally fail

Reason 3: Does not have enough budget

Part of the reason for the failure of some projects is due to the limitation of funds. When selecting equipment,they just want to save money without considering the performance of the equipment. This leads to the fact that the brick factory is always stuck in the operation process, and the kiln does not have enough bricks to Production.

The following process is the right way to build one fully automatic clay brick plant :

Q: How to open a clay brick factory？

Basic elements:

1. raw materials 2.water 3.electricity 4 land 5.fund

Step 1: Investigate the market and confirm the demand

To determine new plant production scale should refer to the local market conditions.First of all, we shall thoroughly investigate local brick and tile market conditions and grasp following situation:current market demand,actual production volume of existing companies, how big the market gap is,current selling price of brick and tile products and the demand and price trend.Besides,is there the same new brick factory to be built?What is the production scale?After mastering above conditions, the new plant can be determined.

Step 2: Confirm brick type

Formulate product production plan according to the condition of raw materials.When you build a new factory, you must have a clear understanding of the local production materials.After determining the dosing plan and selecting raw materials, we must determine the production plan and scale according to local market conditions. It is suitable for hollow brick or hole brick?Whether annual production scale should be 50 million or 80 million?

Step 3: Confirm the production process and equipment

Selected production process and equipment according to raw materials.Clarify your raw material properties before starting new plant.Please have experienced technical staff to plan the production route and conduct selection or design production equipment.Not all equipment can adapt to your raw materials.

Step 4: Infrastructure construction

After determining production scale, it is possible to determine area, process direction, equipment layout of production plant and the location of living area according to the size of production volume.Plan plant elevation based on local geological, hydrological and meteorological conditions.]Arrange various production workshops according to the wind direction.To determine the mode of production, shall it be labor-intensive companies or technology-intensive enterprises,requires whole careful plan and design by technicians based on the results of technical and economic analysis.

1. Civil work: including Chenhuachi, workshops, doors, windows, and roofs of aging workshop.Meet installation requirements of reversible spreaders, multi-bucket excavators and conveyor belts.At the same time, water supply and drainage and heating are completed.

2. Aging workshop:The crushing workshop completes all civil construction tasks inside and outside the crushing room and feeding room.Complete the plant closure work.Meet installation requirements of feeder boxes, belts, crushers, vibrating screens, back-feed belts, and aging conveyor belts etc.

3. Molding workshop:including the feeding box, mixer, clay machine, extruder, cutting and transportation construction, as well as the kiln base after pouring belt,top car machine, tractor, kiln channel pavement, cushion and other construction.

4. The civil construction scope for air compressor stations, plumbing, substations, fire pump rooms, etc. includes drying kiln, roasting kiln, ferry car,hydraulic pusher,return tractor,traction machine, winch, tidal fan, blower, kiln cooling fan,pipeline , heat exchanger,kiln car production, track and so on.

Step 5:Preparation before production

1. organization construction

2. Make plans and regulations

3. Maintain and add equipment

4. Clean up the existing dry site and drying supplies

5. Maintain kiln

6. Maintain electrical equipment

7. Prepare sufficient fuel

8. Preparation of auxiliary items for production

9. Construct road and drainage

10. Prepare raw materials in advance

11. Ensure safety precautions

12. Run a test

13. Prepare spare parts

Entry arrangement for overall equipment:

1. box feeder,crusher,roller screen,mixer,belt,precipitator etc in crushing workshop

2. Multi-bucket excavator, reversible spreader

3. Box feeder , mixer, vacuum extruder, cutting and transporting equipments

4. Ferry car,hydraulic pusher,return tractor and hoist.

Q: How to make bricks from clay ?

A brick is building material used to make walls, pavements and other elements in masonry construction. Traditionally, the term brick referred to a unit composed of clay, but it is now used to denote any rectangular units laid in mortar. A brick can be composed of clay-bearing soil, sand, and lime, or concrete materials. Bricks are produced in numerous classes, types, materials, and sizes which vary with region and time period, and are produced in bulk quantities. Two basic categories of bricks are fired and non-fired bricks.

Block is a similar term referring to a rectangular building unit composed of similar materials, but is usually larger than a brick. Lightweight bricks (also called lightweight blocks) are made from expanded clay aggregate.

Fired bricks are one of the longest-lasting and strongest building materials, sometimes referred to as artificial stone, and have been used since circa 5000 BC. Air-dried bricks, also known as mudbricks, have a history older than fired bricks, and have an additional ingredient of a mechanical binder such as straw.

Bricks are laid in courses and numerous patterns known as bonds, collectively known as brickwork, and may be laid in various kinds of mortar to hold the bricks together to make a durable structure

https://en.wikipedia.org/wiki/Brick

Q: How to make red bricks?

The production process of sintered bricks is generally composed of four parts: raw material preparation, blank body forming, wet blank drying, and finished product firing.After raw materials are excavated, some can be processed by adding water, stirring and grinding equipment,while others will not work.Raw materials,such as mountain soil, coal gangue and shale,are to be broken and finely chopped, then followed by water mixing and grinding.The choice and preparation of raw materials directly affect the quality of the finished product.As the saying goes, raw materials are fundamental to making sintered bricks,showing the importance of the raw materials preparation and raw materials.

After the selected brick raw materials are processed, they enter the molding workshop for molding.Blank forming method basically uses plastic extrusion molding in China.There are three methods for plastic extrusion. That is plastic extrusion molding,semi-hard plastic extrusion molding and hard plastic extrusion molding.

These three extrusion methods are based on the difference in the moisture content of the molding.When the moisture content more than 16%,wet billet molding is plastic extrusion molding. When the moisture content equals 14-16%, it’s semi-hard plastic extrusion molding. When the moisture content equals 12-14% ,it’s hard plastic extrusion molding.Blank forming includes: feeding material , mixing,adding water and grinding equipment processing before raw materials entering the molding shop not brick extruding machine.After passing through the molding brick machine, the qualified mud and wet billet are formed.Forming process should fulfill the requirement of the shape and structure.Forming is the foundation of the brick making process.The quality of the formed body is directly related to the appearance quality of the finished tile.

After the wet billets formed from the molding plant, they need to be dried by dehydration.In the production process of sintered bricks, there are two ways of drying wet blank: natural drying and artificial drying.

The natural drying is to place the wet billet on the billet stalk in the natural drying place,manually invert the code and use the atmosphere to wet the cold billet into a dry billet.Artificial drying is to use equipped artificial drying chamber to dry wet billet.The artificial drying room is divided into three types: large-section tunnel drying room, small-section tunnel drying room and chamber drying room.Whichever type is adopted, it is manually or mechanically placing wet billet on a drying truck,then put it into drying chamber.The heat medium in the drying chamber generally comes from the waste heat of the sintering kiln or the hot blast stove.Whichever drying method is adopted, it must be ensured that the blank will not be deformed or chapped during the drying process.If the wet billet can’t guarantee the appearance quality of the product during drying, it will cause high reject rate, falling output,increasing cost of the finished brick, which are definitely harmful to company economic efficiency.This shows the importance of drying wet billet in brick making process.

If the residual moisture rate after drying is less than 6%,the wet billet could be fired in the baking kiln.Hoffman kiln and tunnel kiln are normally used for roasting.When using Hoffman kiln, the brick code is manually placed in the kiln and the fire is roasted in the kiln.When using tunnel kiln,the brick code is manually or mechanically placed in the kiln cart.The kiln car enters kiln head and exits from the kiln tail. The brick blanks on the kiln car are roasted into bricks.The roasting flame in the kiln doesn’t move just the kiln cart.Whether using Hoffman kiln or tunnel kiln,this two conditions must be followed:1.never use underfire to produce unburnt brick.2.never use big fire to produce coke brick.It is often said that roasting is the key of the brick making process,which explains the importance of roasting in the brick making process.

Sintered brick process is composed of four parts.To sum up,it is said that the raw material is fundamental,molding is the basis,drying is ensure and roasting is the key. These four parts are interdependent.

Q: Four key factors in the production of sintered clay bricks

Generally speaking, the production process of sintered bricks consists of four parts: the preparation of raw materials, the formation of blanks, the drying of wet blanks and the production of finished products.
Preparation of raw materials
After the brick raw materials are extracted, some raw materials can be processed by adding water to stir and milling equipment, while some raw materials cannot be processed. \"Raw materials such as mountain soil, coal gangue and shale can also be crushed and finely crushed and then mixed with water and ground. The selection and preparation of raw materials directly affect the quality of finished bricks, so the raw materials are the basis for the preparation of sintered bricks. Explains the importance of raw materials and raw material preparation.
Billet formation
A workshop for processing and forming brick materials. The blank molding method of winding bricks in my country is basically plastic extrusion molding. There are three plastic extrusion molding methods, namely plastic extrusion molding, semi-rigid plastic extrusion molding and hard plastic extrusion molding.

These three extrusion molding methods are distinguished based on the molding with different moisture content. When the moisture content of the wet billet is greater than 16% (dry basis and below are dry basis), it is plastic extrusion molding. When the moisture content of the wet billet is 14-16%, it is semi-rigid extrusion molding. When the moisture content of the wet billet is 12-14%, it is a hard plastic extrusion molding.

Billet forming includes: feeding, mixing, adding water and grinding equipment before the raw material enters the forming workshop; after forming, the qualified mud stick and wet billet are formed. Molding to achieve the shape and structure of the product is the composition of the shape and structure of the product.

Therefore, it is often said that molding is the foundation. In other words, the external shape and structure of the product are both shape and shape. In other words, molding is the basic meaning of the brick making process. Because the quality of the molded body is directly related to the appearance quality of the finished brick.

Drying of wet billets
When the wet billet is formed in the forming workshop, the wet billet should be dehydrated and dried. There are two ways to dry sintered brick wet body: natural drying and artificial drying.

The wet billet natural drying method is to place the wet billet conveying code on the ridge of the natural drying part to form a stack, and manually invert the frame, use the atmosphere for natural drying, so that the wet billet is cold sun-dried into a dry billet.

The wet billet is dried by hand, and there is an artificial drying chamber to dry the wet billet.

The artificial drying chamber is divided into three types: large section tunnel drying chamber, small section tunnel drying chamber and small section tunnel drying chamber, which are used for artificial drying of wet billets. These three drying methods, whether manually or mechanically, put the wet billets on the drying cart to form a pile. At this time, the dryer enters the dryer coded as a pile of wet billets into the drying room to dry the wet billets.

The heat medium in the drying chamber usually comes from the waste heat of the sintering kiln or hot air furnace. Regardless of the drying method and the artificial drying method, the drying process of the wet body must be followed to ensure that the body is not deformed or cracked.

If there is a problem with the drying of the wet body, the appearance and quality of the product cannot be guaranteed, the reject rate is high, the output is reduced, the cost of finished bricks increases, and the economic benefits of the enterprise are not good. Therefore, it is often said that green body drying is a guarantee. This illustrates the importance of wet green drying in the process of making bricks. When the wet billet is dry and the residual moisture is less than 6%, the billet is fired into the baking kiln.

Production of finished products
Kilns used for roasting are generally called wheel kilns and tunnel kilns. In the baking kiln, the bricks are manually placed in the kiln to form a stack. Roasting is carried out in the kiln. When the tunnel kiln is roasted, the bricks are placed on the kiln car by manual or mechanical means, and the bricks stacked from the tunnel kiln head to the kiln end are stacked on the kiln car. From the tunnel kiln head to the kiln tail Baked into bricks. The calcining flame in the kiln does not run, but the billets are transported on the kiln and then roasted in the kiln.

No matter whether you use a wheel kiln or a tunnel kiln to bake the bricks, you cannot burn green bricks; secondly, you can\\'t burn them over fire, or burn overheated bricks, or burnt bricks. Therefore, it is often said that roasting in the brick making process is the key to explaining the roasting ratio in the firing process.

The four important components in the process of sintering bricks are: raw materials are the foundation, molding is the foundation, drying is the guarantee, and roasting is the key. These four parts are interdependent.

Q: The main reason for the high damage rate of sintered clay bricks

Nowadays, the technology of sintered brick enterprises is also becoming mature with the improvement of the level of kiln construction technology, but there is still a common phenomenon in some enterprises that the damage rate is relatively high. In order to further improve the quality of sintered bricks and reduce the damage rate of finished products, we need to start from the following aspects:

1. Raw material selection and matching
The selection of raw materials is basically determined when the kiln is built and the site is selected, so it is a bit impractical to discuss the selection of raw materials after production. If the determined raw materials have low plasticity or too high drying sensitivity coefficient, it is easy to cause more fractures in the finished bricks. At this time, it can only be achieved through the matching of particles, the outsourcing and aging of raw materials, and the pressure of extrusion molding. Make adjustments.

2. Blending of internal combustion
The blending of internal combustion must be accurate and stable. The demand for internal combustion varies depending on the performance of the kiln, the climate, the moisture content and other factors. Therefore, there is no absolute uniform standard in the production process. The trial blending trial firing should be carried out according to the actual situation, and the trial blending should be accurate. According to the record of the fired temperature and the fire color of the finished brick, an accurate blending standard is determined and strictly implemented. If the internal combustion is too low, it will cause a large amount of external combustion input and even produce unqualified products. If the internal combustion is too high, it is easy to cause excessive roasting fire and increase the damage of finished bricks.

3. Moisture control and mechanical damage in production
The requirements in production are also quite strict, and the moisture content is the most important link. If the water content is too high, the hardness of the brick will decrease, and the general tunnel kiln is about 14-18 layers. If the brick hardness does not meet the requirements, it will cause the bottom brick to break and deform, and in severe cases, it may even lead to inverted bricks and affect normal firing. In the production, if the water content is improper or the water content is unevenly mixed, uneven mixing, etc. will cause poor healing of the bricks and bring difficulties to the drying and roasting.

4. Brick drying
Drying is the most difficult part to master. If the moisture content is too high, a large amount of vaporized water is easily produced during drying. If the temperature is too rapid in the initial stage of drying, it will cause cracks when the vaporized water passes through the surface of the body. In severe cases, the bricks will break. . Excessive moisture content can also easily cause the bricks to regain moisture and soften under the influence of the climate environment, which brings great difficulties to the baking work.

5. Cooling of finished bricks
During the firing process of bricks, the temperature in the kiln will generally rise to above 1000 degrees Celsius, and the body will become a solid solution. If it is suddenly cold, it will cause the body to solidify and shrink too quickly and cause fracture. Therefore, a reasonable heat preservation time must be determined according to the change of outdoor temperature, and the heat preservation length is sufficient to effectively control the occurrence of cooling fracture.

6, the code billet force
After the bricks are formed, depending on the hardness and plasticity of the raw materials, the bearing capacity is also the same. If the pressure is too large or the force is uneven, it will cause crushing. This phenomenon generally occurs within six hours after the completion of the bricks. It is already broken when incorporated into the dry. Therefore, it is necessary to ensure that the surface of the kiln car is flat, the stack must be straight and stable, the contact points are in good contact, and the billet is not inclined. Raw materials with too low plasticity can even consider choosing an appropriate amount of additives.
There are many other reasons that cause high damage. According to actual analysis and proper adjustment in all aspects, the problem of high damage rate of sintered bricks can be solved.

Q: Analysis of clay brick cracks and solutions

1. Structural cracks

Brick structure cracks are caused by the molding process or improper raw material handling. This type of crack is different from the cracks caused by regular molding equipment (machine mouth). The biggest distinction is: molding cracks are regular to follow, while structural cracks are regular. It is not strong, but it is easy to misjudge such cracks as forming cracks in actual work. Pay attention to observation and judgment.

1. Two or more raw materials are not uniformly mixed, and the moisture content, plasticity, and particle gradation of various raw materials are different, and cracks appear after molding.

Solution: The raw materials must be mixed evenly before entering the crushing equipment, and do not place the raw materials mixing work on crushing, mixing, and screening equipment.

2. The influence of impurities in raw materials, such as tree roots, grass roots, plastic ropes, large hard materials, etc.

Solution: Check the screen frequently to prevent damage to the screen. After the subsequent equipment maintenance of the screen, the debris on the site should be cleaned up.

3. The water content of the mud entering the brick machine is different. The most typical case is that the mud in the belt and equipment is not cleaned up before the machine stops. After several hours of water volatilization of the mud, the mud moisture is uneven after the brick machine is turned on. Use the brick machine to stir and temporarily add water. Can\\'t solve it.

Solution: When the forming work is completed, strictly follow the shutdown procedure to ensure that there is no excess mud in the belt and related equipment.

4. The knives of the mixer are severely worn or the mixing and adding water is unreasonable.

Solution: Regularly check the gap between the stirring knife and the box, and adjust the method of adding water.

5. The abrasion of the screw cutter of the brick machine is too large, the speed of each part of the extruded mud stick is unbalanced, and the density of the green body is inconsistent, resulting in different drying shrinkage and cracks.

Solution: Regularly check and replace the stirring knife in time.

6. Core frame problem. One is the unreasonable installation, and the other is the manufacturing problem of the core frame.

Solution: Adjust the core frame and replace the unqualified core frame.

7. After the mud stick is extruded, the machine mouth and the belt, the belt and the cutting machine and other transportation equipment are not evenly connected, which causes the mud stick to bend and produce cracks.

Solution: Adjust the balance of each equipment, and often clean up the mud attached to the belt idler.

2. Compression and tension cracks

It mostly occurs in the lower layer of the billet stack and on the horizontal billet, and this kind of crack generally appears large-mouth fracture on the surface of the billet. Causes and solutions of compression and tension cracks:

(1) The water in the green body is too high, and the green body strength is insufficient and fracturing.

Solution: reduce the forming moisture and increase the strength of the green body.

(2) The molding temperature of the green body is low. After entering the drying room, it absorbs moisture and softens, and then it rises sharply and shrinks and cracks.

Solution: Check the temperature of the green body frequently, especially the temperature of the mud bar during the extrusion of the machine mouth, and adjust the thermal parameters accordingly.

(3) The blank has poor plasticity, and the blank has low strength and fracturing.

Solution: Incorporate high-plasticity materials or add additives to improve the strength of the blank, or reduce the number of layers of the code blank.

(4) Uneven blending of plastic raw materials and other raw materials, resulting in uneven shrinkage of the green body and cracks.

Solution: Strengthen the pre-mixed processing of raw materials, make the blending uniform and consistent, so that the shrinkage is basically uniform.

(5) The plasticity of the mixture is too high, the linear shrinkage is too large, and it cracks after rapid drying.

Solution: Incorporate barren materials, such as coal gangue, slag, hard shale, etc. to reduce plasticity and reduce shrinkage.

(6) The number of kiln cars is small or the temperature of the bricks out of the kiln is high, and the bricks are stacked on a kiln car with a certain temperature, and rapid dehydration causes cracks.

Solution: Increase the number of kiln cars or adjust the sintering operation to reduce the temperature of the kiln. Kiln cars without pads can also add pads with large holes and easy heat dissipation.

(7) The uneven surface of the kiln car causes the brick to crack.

Solution: tidy up the countertop of the kiln car.

(8) The tunnel kiln or the turnover track is uneven, and the transportation of the kiln car is unstable, and fracturing due to shaking and shaking.

Solution: adjust the track.

(9) The jacking staff was inadvertently operating, and the car collided with the car during jacking, and the green body was broken or collapsed due to vibration.

Solution: Improve and improve operating skills.

Three, wind crack

Wind crack: This kind of crack usually occurs after the brick is formed before entering the drying kiln. The crack generally cracks laterally on the edge of the brick, such as hollow bricks around the hole and on the hole wall. There is also the upper windward side of the billet stack and the edge of the brick air duct with a large gas flow rate in the drying room.

The reasons and solutions are:

The main reason is the higher drying sensitivity of the mud. There are many plastic particles of this kind of mud, and its plasticity is high and it is easy to form. However, due to the unreasonable particle gradation, its sensitivity is relatively strong. When it is formed in strong wind, high temperature, and dry environment, wind cracking will occur. .

1. To solve wind cracks, first start with raw materials, adjust raw materials or proportions, and increase coal gangue or hard shale with low plasticity to adjust particle gradation and plasticity. Secondly, according to climate change, measures such as closing the doors and windows of the molding workshop and spraying water in time. The production line with conditions can also be set up with temporary or permanent drying and static stop lines, so that the bricks with high drying sensitivity can survive the \"dangerous period\" in an ideal environment.

2. The green body cracks as soon as it enters the drying kiln. The main reason is that the gas humidity in the drying kiln is low or the flow rate is high. It can reduce the exhaust air volume or lower the exhaust gas temperature and increase the humidity.

3. The gap between the upper blank in the drying chamber and the top of the drying chamber is too large, so that the hot gas in the drying chamber is concentrated on the upper part, causing the upper wind speed to be too high, and the temperature is too high to cause the blank to crack. The treatment method is to erect or artificially heighten the top bricks on the top of the billet stack. If the number of billet layers is not increased, add a windshield (board) on the top to reduce the upper gas velocity and flow. The windshield can be made of corrosion-resistant materials such as felt or concrete slabs.

4. The dry kiln is not tightly sealed, causing cold air to enter the kiln. It is necessary to check whether the kiln door, sand seal, kiln car bumper, etc. are tightly sealed at the entrance door. Do not open the dry kiln door for a long time. Close and seal immediately after entering the car.

5. The driving speed of the drying kiln is uneven, and the driving time is not controlled strictly. When the car is not driven for a long time, the temperature in the kiln is high and the humidity is low, which causes the green body to quickly dehydrate and crack. It is required to enter the vehicle regularly and evenly, and not to increase or decrease.

Q: Reasons for green clay bricks to collapse easily

1. Determine the process according to the raw materials
The one-time burning process of the tunnel kiln has the advantages of saving space, reducing manpower, high degree of automation, and saving investment. However, whether the one-time burning process can be used depends on the performance of the raw materials. The raw materials suitable for the one-step burning process include coal gangue, shale and raw materials with a high content of coal gangue and shale. For soft raw materials with high content of fly ash, clay and laterite, soft shale and large drying shrinkage, and low critical moisture, use the one-time burning process with caution. Even if one-time burning is used, the drying time should be prolonged and reduced. The heating rate of the green body. Strictly control the height of the pallet truck, and generally should be controlled below 12 floors. For those manufacturers who plan to build a production line of a fired tunnel kiln, the raw materials should be tested and analyzed, and the opinions of experts should be listened to to prevent such problems from continuing to occur.

2. Raw material processing
In addition to higher raw material performance requirements, the one-time burning process also requires raw material processing, and the raw material particle gradation is more reasonable. For coal gangue or hard shale, although it is suitable to use the one-time burning process, if the raw material processing fineness is unreasonable. If the aging effect is not good, the forming of the bricks cannot be guaranteed. Strength of wet billet and drying effect. When the green body enters the drying kiln and heats up, it becomes soft and its strength decreases. The bottom body cannot withstand the pressure of the upper body and collapses. Therefore, the fineness of raw materials must meet: ∠0.5mm accounted for more than 55%, 05.mm-1mm accounted for 20%-25%, and 1mm-2mm accounted for less than 20%. The lower the plasticity index of the raw material, the higher the proportion of fines should be.

Raw material aging is the key to ensuring the quality of brick molding. For coal gangue, shale, especially industrial waste slag, the raw materials for brick making, which are mixed with multiple raw materials, raw material aging is an indispensable process because of low plasticity and low plasticity. When there is no aging process for mostly granular raw materials, it takes only a few minutes from the time the raw materials are crushed and mixed with water to enter the brick machine to discharge the blanks. The added moisture is only on the surface of the raw material particles, and does not penetrate the inside of the particles. The quality of the formed body cannot be guaranteed. Only when the raw materials are mixed with water to the molding moisture content and sent to the aging warehouse, after more than 3 days of aging, and then crushed by a pair of rollers or wheel mills, can the quality of the molded body be ensured. The raw material should not add water as much as possible in the upper part of the extruder, because the water added by the upper level stirring does not have enough time to penetrate into the raw material. This surface water is rubbed with the brick screw auger under the action of strong extrusion pressure. The formation of a water film between the laminar flow of mud will cause delamination and cracks in the green body during the drying process, which not only affects the drying quality of the green body, but also reduces the strength of the green body, leading to the collapse of the green body. What must be explained here is that the aging raw materials must be mixed with water and then sent to a closed and moisturizing aging silo for aging. The moisture content of the raw materials entering the aging silo is basically equal to the moisture content required for molding, not like some brick factories. It\\'s just that the powdered and fine dry materials are piled up to say that they are aging, in fact, the dry materials that are not stirred with water have almost no aging effect.

3. Using semi-hard plastic molding
The use of the one-time sintering process requires high strength of the molded body. Therefore, a semi-rigid plastic molding machine with high extrusion pressure should be used to ensure that the green body has high strength and dry quality. The output of semi-rigid plastic molding machine is relatively low, the extrusion pressure is relatively high (generally, the extrusion pressure is 40kg/cm2), and the molding water content of the green body is about 13%-15%. The diameter of the mud tank is more than 500 mm. The semi-rigid plastic molding machine mentioned here is not the 50-50-35 two-stage vacuum extruder produced by most machinery manufacturers at present. It is a high-output extruder, and a single machine can meet the annual output of 60 million to 70 million sintering. Brick production line, this kind of brick machine has good comprehensive performance, high pressure and high output, and the water content of the green body is about 14%~17%, which is suitable for manual drying wheel kiln roasting or tunnel kiln double-stacking process. If you must choose this type of brick machine in the one-time code burning process, you must inform the machinery manufacturer to customize it. When manufacturing, reduce the spindle speed of the brick machine and increase the extrusion pressure to meet the one-time code burning process.

For the existing one-time sintering process, the brick factory that uses a two-stage vacuum extruder below 50-50-35 and the phenomenon of blank collapse can replace the lower-level 4-level motor with a 6-level motor and increase the motor pulley by 15%-20 %, or do not change the motor, only reduce the original motor pulley by 10%-15% to reduce the extrusion speed and increase the extrusion pressure, which can effectively improve the strength and appearance quality of the formed body, and ensure that the blank does not collapse during drying. kiln.

4. Drying kiln structure
The structure of the drying kiln is determined according to the properties of the raw materials and the pressure of the brick machine. The main factors that determine the length of the drying kiln are the drying sensitivity of the raw materials, the shrinkage rate, the critical moisture, and the forming moisture. Regardless of whether the top air supply or the combined top and side air supply are used, the air supply position has a great influence on the drying effect of the green body. The position where the hot air is sent depends on the critical moisture and drying sensitivity of the raw material. For raw materials with low critical moisture and high drying sensitivity, before the air supply position is unreliable, generally the first air supply point at the front end should be more than 15m away from the car inlet, otherwise dry cracks will occur. The total length of the drying kiln should be more than 70m for raw materials with high molding moisture and large shrinkage, otherwise it may cause excessive heating and excessive water vapor and collapse of the billet.

5. Code kiln car
The kiln car must ensure that the fuel is evenly distributed across the kiln section and the airflow must be evenly distributed across the kiln section. A few days ago, almost all brick factories use internal combustion bricks. The principle of the kiln car yard should be the tying method of medium-sparse side and dense bottom, so that it not only satisfies the concentration of heat in the middle of the kiln, the sparse bricks and the less heat, but also satisfies Because of the large gap in the middle, the moisture can easily flow out. However, it is difficult for many manufacturers to understand that solid bricks are easier to collapse than hollow bricks during the drying process. This is due to the fact that solid bricks use more raw materials, heavy weight, and more total water under the same volume. The tidal volume is large, and if the moisture is not exhausted, the billet will collapse. Therefore, the density of solid bricks should be sparser. The total density of solid bricks is controlled at (standard bricks) 240 blocks/m3—260 blocks/m3, and 90 porous bricks are controlled at 160 blocks m3-170 blocks/m3.

Q: How to distinguish clay brick、cement brick and interlock brick

Type	Raw material	Forming method	Burned or not	Brick type
Clay brick	Clay、shale、coal gangue、slag、fly ash etc.	Screw extrusion	Burned	Solid brick、Hollow brick、Multi-hole brick
Interlock brick	Soil、cement etc.	Molding press	No	Solid brick、Multi-hole brick(2-3 holes)、Paver
Cement block	Cement、fly ash、slag、sand etc.	Molding press	No	Solid brick、Hollow brick、Multi-hole brick、Paver、Curbstone


clay brick	cement brick	interlock brick

Q: Advantages of sintered clay hollow bricks in modern building applications

--1--- Buildings constructed with high-performance thermal insulation blocks can guarantee long-term economic advantages, long-term energy saving, and minimum maintenance costs during the service life.

---2---

Houses built with high-performance thermal insulation blocks have a long-term use value due to the very good durability of sintered materials, which can ensure that the investment can serve several generations. High-quality sintered brick masonry buildings can be sold at high prices.

---3---

The comfort of the living room is good. A house built with high-performance thermal insulation blocks can make the interior feel very comfortable. Because of the countless micropores in the sintered product, it can adapt to the change of indoor and outdoor humidity very well, so it can ensure that it has a very good storage capacity for water vapor and a very good release capacity. The sintered building materials have a warm-colored surface, which can buffer the changes in humidity and heat. The sintered building materials have very few harmful substances, which can ensure a healthy indoor environment and make people feel comfortable indoors.

---4---

Due to the pores formed when the sintered block is formed and a large number of microporous structures are left during sintering, the external wall constructed with it has excellent thermal insulation performance.

---5---

Since the sintered blocks can naturally absorb the energy of the sun, it can also absorb and store the heat generated in the room. The heat absorbed by the wall can be released into the room through the wall, but the release time is longer-the temperature delay time is long. In winter, this process of absorbing and releasing heat balances the fluctuation of indoor temperature, which saves energy for heating, and at the same time feels comfortable and warm indoors, and cool in summer.

---6---

Sintered blocks have ideal characteristics of absorbing and releasing moisture. It absorbs indoor moisture and releases moisture at the same rate as the block. The surface of the wall can be kept relatively dry in any season, which ensures the comfort of the indoor environment.

The sintered wall roofing material product is a product with a microporous system. Its moisture conduction function can adjust the humidity in the building, and the speed of moisture absorption and drainage is equal. The water absorption and drainage speed of bricks are higher than other building materials 10 The structural strength of the building is not affected in any way when water is absorbed and discharged. This alone can improve the living environment and make the human body feel comfortable. Moreover, the equilibrium moisture content of the brick masonry is very low, which enhances the heat insulation effect of the masonry.

The equilibrium moisture in the wall of a building refers to the balance between the moisture left on the wall after drying and the moisture in the atmosphere. For brick masonry, this equilibrium moisture only accounts for 0.3% to 0.7% of its volume. Compared with other building materials, this is a very low value. It is precisely because of this very low value that it provides a comfortable and healthy environment for people living in brick buildings. The water absorption speed and drainage speed of the brick masonry are almost the same, so it can adjust the humidity of the small environment in the living room, which is often referred to as the \"breathing\" effect. In addition, the very low equilibrium moisture content of brick masonry is also very important for energy saving.

Because of the increase in water content of building materials, its thermal insulation performance will deteriorate (or deteriorate). In this sense, the brick itself is a very good \"insulation body\", and it can also effectively protect the thermal insulation material layer compounded with sintered bricks or blocks, and will not reduce its thermal insulation performance due to moisture absorption. performance. The proper drying time for the main body of a newly-built building means that after the construction of a building in a specific area, it can be dried at an appropriate time without using a special heating method. Generally speaking, each type of masonry structure absorbs water directly from the mortar during construction.

The criterion here is: the speed at which the absorbed water is discharged from the material. Because brick buildings have a slight vapor diffusion resistance, they dry very quickly and the average drying cycle is very short, which provides time for the early delivery and move-in of new buildings. The drying cycle of the wall depends on different regions and seasons. And this drying process of some building materials often lasts for several years.

Therefore, the drying time should be specified in the design according to the selected materials and different regions. Our country is not sufficient for this time, often in order to shorten the delivery period, move in early, resulting in moldy and deterioration of the decorative materials; in addition, due to improper selection of materials, the materials are often dehydrated after the residents move in, causing problems such as wall cracks.

---7---

Thermal comfort is very important, that is, the temperature parameter of the indoor wall surface of the building. When the surface temperature is much lower or higher than the indoor air temperature, it causes a very uncomfortable feeling. The sintered block has very good thermal insulation performance, and the outer wall built with it ensures a higher temperature of the indoor wall, so it has a very superior thermal comfort.

In summer, and vice versa. The \"secret\" of good thermal insulation performance lies in the microporous structure, where there is air in the small micropores. Add micropore formers during the preparation of raw materials, such as sawdust. After being shaped and dried, it is fired at a high temperature of about 1000℃. The sawdust burns and volatilizes, leaving countless small and air-containing micropores, which greatly improves heat preservation. Thermal insulation performance. The porosity of the sintered block, combined with the well-designed hole geometry, has very good thermal insulation performance, which can greatly reduce the heat loss through the external wall.

The sintered block can be used as a heat storage body, and the sintered block wall can naturally absorb the heat from the sun and can store the heat from the room. When needed, the indoor heat it absorbs can then be transferred back to the supply room. This kind of performance can make the room feel comfortable. The characteristic becomes \"phase shift\". The house of sintered blocks does not cool too quickly in winter, and it can keep the interior cool in summer. Sintered building materials have relatively low equilibrium moisture content and fast drying characteristics. Therefore, the walls of sintered building materials can quickly form the best insulation layer, thereby saving energy consumption for heating and air conditioning.

---8---

Excellent fire resistance-sintered building materials products will not burn, they are sintered products, so they have \"immunity\" against fire. Sintered building materials will not produce any harmful gases in the event of a fire. When the thickness of the wall is 8cm or thicker, the wall can reach a fire rating of F90. That is to say, in the event of a fire, people have 90 minutes to escape or transfer property. When a fire occurs, the harm to the human body is generally not the direct impact of the fire, but the smoke generated by the combustion of flammable building materials and decoration materials. But sintered blocks are sintered at high temperature, they do not burn, and will not release any harmful gases when a fire occurs.

---9---

Sound insulation performance is good. Sintered hollow (porous) blocks are sound insulation. Buildings need to have sound insulation measures to prevent noise from the outside and noise from neighbors. The noise generated by ventilation, impact and structure should be reduced to a level that does not affect others. The walls and floors made of sintered blocks ensure a quiet living environment and prevent noise from outside and inside the building. The outer wall of sintered blocks has excellent sound insulation performance. For places with special uses, there are also special sound insulation hollow blocks.

---10---

High structural strength. Sintered blocks are safe houses. Sintered blocks have a variety of different compressive strengths, and effective quality control and monitoring in production. For builders and architects, sintered blocks are safe and reliable.

---11---

Good seismic safety: For earthquake-resistant areas, sintered blocks for earthquake resistance have been specially developed. The wall built with seismic blocks shows that its seismic capacity is ten times higher than that of conventional blocks. Therefore, in earthquake areas, seismic blocks can be used to build safe, economical and durable buildings. In high-earthquake areas, it is entirely possible to use sintered blocks to build walls. Because of every other building material, the wall structure and building structure selected in the earthquake-prone area must also meet the seismic requirements. Sintered blocks have high mechanical strength, and have very good bonding characteristics with mortar, so it can effectively improve the seismic performance of buildings.

Economical: Sintered blocks have the greatest quality and value retention. Although the choice of wall materials has little effect on the total cost of the building, it determines the quality of the building. Houses built with sintered blocks are economical, safe, and can maintain and increase in value, because the durability of sintered blocks is unparalleled. The use of sintered blocks can shorten the construction period of the building, significantly reduce the amount of mortar, and the maintenance cost during the use period is very low. The high thermal insulation performance and air tightness of sintered blocks greatly reduce energy consumption. The long-term service life can be preserved and increased in value, and houses can be built for several generations.

Q: What wear resistant material to repair brick-tile equipment ?

How to repair clay brick making machine,how to fix clay brick making machine ?

In brick tile machine, the parts where the soil goes through is easy to be worn out .If we do not repair

the easy wear parts timely, the production will be influeced.

But what materials we should use to repair the easy wear parts ?

Usually we use A3 Carbon steel to repair the extruder auger and liner, double shaft mixer blades etc.

However, we find that after the Carbon steel can not fit for long time wear resistant requirment. After

some time , we find that if we adopt Fe-Cr-B wear - resistant electrode to repair auger,we get can

1.8 million green bricks while previously we only got 400,000 green bricks by carbom steel one time

repairing. The auger service life extends 4.5 times. The 2/3 repairing material cost is saved.

It is proved by pratice that adopting wear resistant material to repair easy wear parts is an effective

way to improve efficiency,extend working life and reduce cost .

HRC	Usage	Diameter (mm)	Length (mm)	Current (A)	Note
≥65	Auger,mixer blades,rollers of roller crusher,blower blades	3.2	350	130~160	first time build-up welding for 500 model extruder need 6 kg,thickness 2~3 mm,one time repairing need 1.5~2 Kg, capacity 4million to 6 million green bricks
≥65	Auger,mixer blades,rollers of roller crusher,blower blades	4	400	180~230
≥50	Hammer of hammer crusher	3.2	350	130~160
≥50	Hammer of hammer crusher	4	400	180~230

Q: Plasticity index of brick raw materials

The plasticity expressing in China’s brick and tile industry is now proposed by the Swedish A. Aterberg in 1911.Plasticity index is expressed as the range of water content when the clay is in a plastic state,whose value is equal to the difference between flow limit and plastic limit.Flow limit, also known as liquid limit, is water amount that clay enters a flowing state.Plastic limit is water amount that clay can be rolled into 3mm diameter.

According to this method, the plasticity index is used to classify clay as: high plasticity clay >15%; medium plasticity clay 7%-15%; low plasticity clay<7%.

This method has been widely used for many years in the fields of soil science and engineering geology.Although China's brick and tile industry has been using it for many years, it is only for soft and dispersed clay raw materials.For coal gangue, shale, etc., which rely on reducing particle size to obtain plasticity, there is a great deal of deviation in using this method.For example, the plasticity of raw materials such as coal gangue and shale depends on crushing to reduce the particle size to a certain degree, adding water to the particles after decomposing (aging), and it is changeable during processing.If the hard clayey shale or coal gangue rich in illite is ground to a sufficiently fine degree (such as cement fineness),the plasticity index may reach a pretty high level.And formed moisture content and drying shrinkage may be larger than common clay materials, which totally differ from common brick clay.

The plasticity index of common brick clay is relatively stable.In terms of this type of material, which depends on crushing process reducing particle size to obtain plasticity, its plasticity index is variable during processing.For example, when a certain coal gangue is crushed below 0.9 mm in the laboratory, according to geotechnical test method, the plasticity index is measured as only 7.2%.However, after adding 40% of excessively fired vermiculite (essentially no plasticity),then adding water, aging, and crushing on the roller, vacuum extrusion,plasticity index of the small sample actually reached 10.5%.For example, when other shales were crushed to less 0.9 mm, the plasticity index is measured as 8.4% according to geotechnical test method.However, after adding 40% (by weight) of fly ash,then mixing with water, aging, and crushing,plasticity index of the small sample extruded by the vacuum extruder reached 9.5%.This is still the result after revalidation according to the geotechnical test method,which fully demonstrates that the current geotechnical test method used in the brick and tile industry can’t correctly reflect the characteristics of raw materials such as coal gangue and shale during processing and forming.In order to further prove the fact that raw materials such as shale or coal gangue relys on reducing the particles size to obtain plasticity, the hard shale in a place near Shijiazhuang was crushed into two groups in the laboratory.One group all can pass 0.9 mm sieve; the other can all pass 0.5 mm sieve.However, the shale of the same mineral composition differs greatly in its plasticity index only due to its different grain sizes, one being 4.8% (0.9 mm) and the other being 8.9% (0.5 mm).In order to further verify this phenomenon, this two groups were blended together in different proportions to determine their plasticity index, drying line shrinkage rate and drying sensitivity index. The results are shown in the following table.

Blending ratio % Weight			Flow limit%	Plastic limit%	Plasticity index%	Drying sensitivity index	Dry linear shrinkage
0.5㎜	0.9㎜			Plastic limit%	Plasticity index%	Drying sensitivity index	Dry linear shrinkage
10	90	17.3		12.3	5.0	0.47	1.94
20	80	17.6		11.7	5.9	0.68	2.06
30	70	18.3		12.1	6.2	0.66	2.12
40	60	19.0		12.7	6.3	0.76	2.32
50	50	19.8		13.4	6.4	0.87	2.34
60	40	19.0		11.8	7.2	0.85	2.66

From the above table, it can be clearly seen that the plasticity index, dryness sensitivity index, and dry linear shrinkage of the mixture tend to increase with the increase of the particle composition below 0.5 mm in the mixture.This fully shows that the use of geotechnical test method can not fully evaluate the properties of plastic materials such as shale and coal gangue that rely on reducing particle size.From the above analysis, the plasticity degree has a great relationship with the particle size of clay minerals.

For example, assuming that the type and total amount of clay minerals contained in a kind of clay are exactly the same as that in a certain type of shale, plasticity index measured by the geotechnical test method is much higher than shale,because dispersed clay mineral particles in the clay are uniform and small.If the shale is fully crushed, so that the clay minerals in the shale reach a finely dispersed state like the clay mineral particles contained in the clay, it is possible that the plasticity index measured by the geotechnical test method will be the same as that of the clay.However, it can’t be achieved in actual production,causing a great plasticity fluctuation during processing raw materials such as coal gangue and shale.Which method should be used to describe and compare the plasticity of these raw materials?

First of all, it is necessary to limit the particle size composition of this kind raw materials after crushing.According to the practice and research of bricks and tiles produced by shale in USA for many years, shale crushing can provide 0.053 mm (270 mesh) or more particles.And it is thought that shale crushed should have three levels of particle grading:(1)The decorative coarse grain should occupy 0-3% (the grain size is generally 1.2-2.4 mm, sometimes it can reach 9.5 mm. It can be used without coarse grain decoration);(2)Filled granules should occupy: 20-65% (1.2-0.3 mm, this granules part is to limit the excessive shrinkage, cracks and deformation of the granules);(3)Plastic particles should account for 35-50% (below 0.053)

This indicates the minimum of plastic particles less than 0.053 mm after comminution,whether it is shale or coal gangue. The amount of particles smaller than 1 mm, or less than 0.05 mm, which was previously proposed in the design, is a very inaccurate method.If the gangue is completely crushed into 1 mm diameter pellets, it is possible that this material will not have the plasticity for forming.Before determining materials plasticity such as coal gangue and shale, the particles content less than 0.053 mm should be measured after the raw materials are crushed, and the content of this component should be controlled over 40%.This limit value can also be used as a basis for equipment selection during plant design and basic requirements for product quality control.In addition,this type of material relying on reducing particle size to obtain plasticity, whose particle size are falling in the processing of crushing, stirring, adding water, aging, milling, vacuuming, etc., or due to particles loosening caused by water effect.Therefore,determining this plasticity should be done at the outlet of the extruder or use other expression methods,in addition to the case where the limit after the comminution is less than 0.053 mm, the particle composition is greater than 40%.Another noteworthy situation is that when crushing hard or semi-rigid raw materials such as shale and coal gangue,the particle size distribution of the crushing material is very narrow,due to improper crushing equipment or processes.The direct results are poor strength of green body, or the difficulty in molding, or the poor frost resistance of the sintered product. Because unreasonable particle distribution will cause that the particles in the green body can’t reach the closest aggregation state.

Q: What percentage of water contained in the brick can be sintered?

Less than 8% of dry brick can be sintered, if the water moisture is too large, the brick will be easy to crack at the sintering time.

Q: Reasons and solutions of affecting bricks quality

why clay brick break, why clay brick crack ,why does brick crack?

Most of brick factory owners spent a lot of time and fianace to start their brick factories, however,not all of them get success, the reasons is that before starting clay brick factory, they did not conduct enough study and servey. To avoid investment loss for clay brick production, we have made the following summary for the common phenomenon of poor quality bricks and common mistakes the new clay brick facotry owners always make.

1, Malformed adobe, appears large cracks. In more serious cases, the whole adobe will split.

Reasons: the plasticity index of pug is too low, almost no plasticity.

Solution: to increase the plasticity index of raw materials, such as clay, coal slime or clay agent, etc.

For raw materials of low plasticity index, it can also be improved after aging, watering, stirring, rolling, extruding and other methods.

2, The body of adobe is not smooth, the obvious particles, more sand pits, and horns or flutes are missing.

Reasons: The shatter of raw materials does not meet the requirements of making bricks because there is much large particles.

Solutions: Install fine grinding equipment, as required for crushing the raw materials to make particles 3 mm or less.

Some kiln owners are not willing to spend money in equipping the machinery of raw material pre-treatment, such as roller crusher,double shaftmixers. Some kilns are only equipped with a pair of rollers, some only with mixers, some even neither of them. How can we get good bricks if there are bricks, tile, stone and other debris in the mud raw materials? Even if it is hard to send someone to pick them out clean. The fundamental way to solve the problem is equipped with auxiliary equipment.

3, The quality of adobe is unstable, sometimes good and sometimes poor.

Reasons: uneven mixing of raw materials

Solutions: Increase the mixer and feeder

Some brick factories are not equipped with rollers and mixers, even without the feeders, all by artificially feeding into the brick machine with shovel, which inevitably occurs two major drawbacks.①, raw material soil cannot be stirred and mixed well. The plasticity of raw soil is not exactly the same, and sometimes the disparity is very great, the Yellow River sludge is like that.②, the inside fuels such as coal, coal gangue, slime and others cannot be stirred evenly. The two heterogeneous, will inevitably lead to the instability of adobes’ quality.

4, malformed adobe and mud column, will spread immediately after cutting.

Reasons: Failure of the vacuum chamber

Solutions: a, improve the maintenance, service, repair technology of brick machine to ensure the normal function of brick machines’ properties. b, make the necessary technical transformation

b, Another reason for resulting in failure of the vacuum chamber, is the sand-based raw material, so the closed mud layer of the upper auger is too thin, easy to be drawn through, causing the vacuum failure, so the adobe could not be molded. The best way to solve this problem is to change the ratio of raw materials, to increase the plasticity index of raw materials. The other way is to cut the front end of the superiors auger to 2-10 centimeters according to the material properties of soil (must be conducted under the guidance of skilled technical personnel, don’t do it by yourself).

5, Many brick cracks on adobes or broke into two sections, more wastes after sintering.

Reasons: There are too many viscous ingredients in raw materials, so the plasticity index is too high.

Solutions: change the ratio of raw materials, reduce the plasticity index. The plasticity index of clay can be up to 25, can be properly incorporated into the coal ash, slag, fly ash or waste of brick powder to make it thin.

6, Soft adobe, easy to form, or crack after cutting.

Reason: the improper control of moisture in the mud.

Solution: soft adobe, easy to be deformed, showing that the water of sludge is too much, should reduce water. If the mud column quickly occurs crack or split of mud column after molding, which is caused by too little water in mud, it can be solved by increasing appropriate water.

7. Brick production capacity not stable

Reason: Not equip with box feeder

Solution : Some brick factory owners in order to save money, they refuse to use box feeder but some labors to feed soil manually .Therefore, soil feeding amount is not stable,sometimes more than what the extruder need, some times, less what extruder need, thus greatly influencing production capacity.

All in all, there are all kinds of raw materials to make bricks, in addition to the different climate, some abnormal situations inevitably occur in the production and it is really hard to avoid. If there are problems, knowing the following two points will be easy. One isto havea team with a strong sense of responsibility and a technical team ofprofessional mechanics. Two is to timely communicate high and difficult technical problems with industry colleagues.

Q: If the soil contains stone, such soil can be used to make bricks?

No,the stone must be removed, otherwise the machine will accelerate wear and tear, or even damage to the machine. Generally based on the size of stone, you can choose the following machines: stone removing roller machine, roller sieve, thrust sieve.

Q: Any kinds of soil can be used for making bricks?

Most of soil can be used for making bricks, but soil plasticity must be between 5 to 17. If the soil plasticity is too big or too small, you need to add additional material in the soil.

Q: How many types of vacuum brick extruder based on vacuum extruding pressure?

●This equipment is for vacuum extruding and molding the products of fired common brick, fired perforated brick, fired hollow brick, hollow block and etc.

●Our extruder has three forms: soft plastic vacuum extruder, semi hard vacuum extruder and hard plastic vacuum extruder.

●Soft plastic vacuum extruder is suitable for the raw materials with moisture content higher than 19%;the allowed extrusion pressure is 0.4~1.8 MPa.

●Semi hard vacuum extruder is suitable for the raw materials with moisture content between 16%~19%;the allowed extrusion pressure is 1.8~2.5 MPa.

●Hard plastic vacuum extruder is suitable for the raw materials with moisture content lower than 16%;the allowed extrusion pressure is 2.5~4.5 MPa.

Q: What is difference between single stage and double stage vacuum extruder

DZK series clay brick making machine is divided into Double stage vacuum extruder and single stage vacuum extruder:

1) Double stage Vacuum brick extruder can make three kinds of brick, solid brick, porous brick and hollow bricks. To produce different kinds of bricks, usually, only need to fix different brick die. It is composed of upper stage mixing parts and lower stage extruding parts;

2) Single stage vacuum extruder usually can produce solid bricks. It has only lower stage extruding parts;

You can get hollow bricks too if your soil quality is very high.

3) Double stage vacuum extruder has higher capaicty ,higher vacuum pressure than single stage vacuum extruder . Also double stage extruder green bricks contains less moisture

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