Record-breaking
KELLER HCW GmbH sets up new brick factory in Yang Quan, Shan Xi Province, China
[April 2006] Yang Quan City is located in the East of Shan Xi Province, China. As with many other towns of this region, the coal industry plays an important role for the local industry. At Easter 2004, KELLER HCW GmbH received an order by the Nan Mei Coal Group in Yang Quan to deliver a shaping plant as well as a setting and a package unloading plant for a new brick factory.
A speciality of the order was seen in the fact, that more than 130 Mio. Chinese bricks per annum should be produced once it was put into operation. This corresponds to an hourly output of 28.600 Chinese bricks or 430 t burnt bricks respectively per day. The raw material that is going to be processed furthermore consists of a mixture of coal residues and shale, whose shaping behaviour cannot be compared to the one of traditional clay and which can also be referred to as very abrasive. Moreover, the plant had to be planned very flexible to allow the production of all kinds of bricks – ranging from German small-sized formats to large-sized hollow bricks.
The coal residues and the shale go through a dry preparation plant that was provided by a local company. As for the shaping, the grain size of the prepared material is once again milled down in a fine rolling mill – provided by the company "Petersen Service" – to a grain size of only 0,7 mm and is, in the following, being formed in a high-performance extruder with a double shaft mixer to an endless column. To achieve high performance, the extruder die was designed in such a way that it allows a simultaneous extruding of double clay columns.
The KELLER HCW high-performance machinery including transport devices, slug cutter and the approved push-through cutter, which is able to cut up to 80 bricks simultaneously, is affixed close behind the press die. After the double slugs have passed the slug cutter, they are fed to the push-through cutter, where they are being pushed off by a pushing device in angular direction. Front row slugs are pushed by back row slugs through the cutting wires, where they are being cut to final bricks.
On their way to the kiln car setting machine the bricks, still arranged in cohesive rows, are now formed to double layers before they are being fed by the conveying belt to the turn-over device. As the products contain a high amount of carbon, they have to be set very flat on the kiln car to ensure that the carbon burns out in the self firing kiln as much as possible so that only a very small "black core" remains within the bricks. For this purpose, the KELLER HCW turn-over device has already manifoldly proved its excellence. Products still in upright position, will be taken off by grippers, which, in a next step, stretch them, turn them over into a flat position, put them together and finally put them down again.
After they have been set in a flat position, the still close-packed bricks are fed to the patented Cellaflex. There, firing-suitable spaces are formed between the bricks. The bricks then move on on the take-off table, from where they are set on kiln cars by a total of 6 grippers.
The kiln car load runs through the double tunnel dryer and the double tunnel kiln in a self-firing manner. "Self-firing" means, that the energy required for firing and drying can be covered by the carbon content of the raw material itself without needing any further energy input from outside. This kind of kiln has already been widely spread in China, especially in those regions, where the usage of traditonally clay had been prohibited, and where raw materials such as coal residues and flue ash, which normally cause environmental pollution, are being used as alternative brick material.
After the firing process, the kiln cars are automatically fed to the kiln car unloading plant, where the bricks are being lifted by an package gripper and set down in packets on a chain conveyor. The packets are then carried from the chain conveyor to the package storage via forklift truck. The automatic package unloading plant replaces the ordinary manually operated unloading and by this means guarantees a failure-free operation of the powerful plant. The unloaded kiln cars are finally recirculated to the setting plant.
At the moment, this plant consisting of only one single production line represents the plant with the best performance throughout China. The erection and commissioning time is record-breaking in reference to every other import machinery. The product quality is the best in comparison to other products made of coal residues and shale fired in a self firing kiln. With this plant a new milestone has been reached in China at producing bricks on a grand scale, with state-of-the-art technology and in the highest quality.
Further information can be found under the following links:
Press Release 04/2004 »
Video 05/2005 »
Video 08/2004 »
Project data of the plant »
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