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Purpose
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Production of ceramic brick, grade 200
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Trademark owner
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Hong Kong Mega
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Developer
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Spain
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Licence owner
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Government of PR China
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Kitting up and process
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list of machines
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1.Feeding clay scarfer -1 unit
2.Roll stone crusher and separator - 1 unit
3. Aerated hoppers -2 units
4.Bucket lifiting conveyors ,2 units
5. Raw materials electronic doser ,1 unit.
6. Fine-fraction attritor ,1 unit.
7. Mixer, 1 unit.
8. Raw materials feeding machine , 1 unit.
9. Double side pressing device 25 000 000 pcs/year
10. Unloader 1 unit.
11. Kiln , 4 units
12.Rails , about 400 m . (exact length can be agreed upon depending on shop plan and engineering factors )
13.Trolley 52 units. (Number of trolleys depends on number of pressure chambers amd length of the railway tracks)
14.Turn rails - 200 m. (exact length can be agreed upon depending on shop plan and engineering factors)
15. Turning carts 16 units. (Number of trolleys depends on number of kilns and length of railway tracks )
16.Traction mechanisms 3 units.
17.Brick molds 1 units.
18. Conveoyrs 9 units.
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Processing
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Scarfing of clay-breaking of large pieces, transportation-stone removal-transportation-lifting to hopper-storage in hopper-transportation-batching-transportation-grinding-mixing with water-transportation-preparation of slabs-transportation-feeding to press-feeding to mold-pressing-transportation-unloading of press-loading on trolley-transportation to kiln -kilning-transportation- finished products warehouse
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General info
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Operation regime
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22 hrs/day, 300 days, year
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Productivity/year
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25 000 000 pcs
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Productivity/hr
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Min - 3 900 pcs
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Personnel
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15 persons
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Total energy consumption
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185 kW
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Heat energy demand
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4 250 000 kcal/hr
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Completeness of the equipment
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All included
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Warranty
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2 years since leaving the territory of China .
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Space
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Production area
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9000 m2
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The production line is divided into shops
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--Raw materials preparation shop
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3000 m2 outdoors
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Functions
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Scarfing of clay – breaking of large pieces - transportation – stone removal – transportation –lifting to hopper
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Equipment
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Clay scarfer (see photo 13)
Stone removal (see photo 15)
Vertical bucket elevator (see photo 25)
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--Attrition and mixing shop
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300 m2 indoors
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Functions
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storage-transportation-batching-transportation-grinding-mixing with water-transportation-slab preparation
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Equipment
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Hoppers 2 units.(see photo 14)
Electronic meter (see photos 22, 23, 24)
Attritor (see photos 19, 20, 21)
Mixer (see photos 28, 29)
Slab preparation (See photos 26, 27)
Conveyors 4 units.(see photos 16, 17, 18)
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--Compression shop
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400 m2 Indooors
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Function
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Transportation – feeding to press-feeding to mold - pressing-transportation –unloading of press – loading on trolley
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Equipment
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Press (see photos 1, 2, 3, 4, 5, 7, 8, )
Discharge table (see photo 6)
Mold. unloader (see photos 9, 10, 11, 12)
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--kiln house
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2300 m2. Separate building
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Functions
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– transporation to kiln on trolleys – kilning
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Equipment
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Rails (see photos 33, 37, 40)
Trolleys (see photos 34, 36, 38)
Kiln (see photos 40, 41, 42, 43, 44, 45)
Turn rails, traction mechanisms
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--Warehousing
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3 000 m2 Outdoors
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Function
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transportation– finished products warehouse
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Equipment
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Rails (see photo 33, 37, 38)
Turn trolleys (see photo 38)
Hyraulic elevator (see photo 39) or diesel autoloader (not in the basic set)
Breaking of bricks into wild stones (supplementery function) (see photo 49)
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| Photo of the equipment |
Main machines and units |
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Specifications of products and raw materials
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Raw materials
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Clay
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The fraction used
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Max- 0,5 mm
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Clay consumption per 1000 bricks
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1,728 m3
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Clay consumption per 2000 bricks
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3,456 m3
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Clay consumption per 3000 bricks
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5,184 m3
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Annual water requirement
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Water 4 500 m3
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Annual clay requirement
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44 000 m3
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Additives
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natural pigments and additives can be added
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Standard brick size
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240 × 115 × 53 mm
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max size of the brick
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1200х250х300 mm.
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Breaking into wild stone
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Yes (see photo ceramic bricks )
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Facing bricks
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Yes (see photos ceramic bricks )
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Wall blocks
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Yes (see photos ceramic bricks )
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Supporting walls of 25 storied-buildings
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Yes (see photos (ceramic bricks )
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Kilns
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Number of kilns
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4 units
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parameters of kilns
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Combustion space
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72 m3
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Production space
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1.38 × 2.2 × 1.32 × 3 = 12 m3 х 4
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Desing temperature of the kiln
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1400 0С
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Outer size of kiln
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6.5 × 3.2 × 3 m
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Gas consumption
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600 m3/hr
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Operation firing temperature
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1350 0С
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Inner size of the kiln
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5.3 × 2.34 × 1.43 m
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Press
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LU-HDP-15-300 presses
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1 unit
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Press parameters
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Diameter of reinforcing cylinders
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no less than 300 mm
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Hydraulics
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PR China
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Oil amount
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1 000 kg
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Changeout of oil
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Once a year
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Single pressing
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10 pcs
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Air venting/min
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3
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Productivity
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Min - 60 pcs/min
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System pressure
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300 кNт
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Pressure on each brick
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Min. 200 кNт
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Pressing cycles/min
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6.5 cycles/min
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Duration of the cycle
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9 seconds
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Power
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62 kW
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Outer size
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3300 × 1500 × 1800 mm
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Weight
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18 tons
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Permissible defects
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1 %
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Is not in the set
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Complete set
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To be purchased on the spot
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ISO N46 hydraulic oil
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Readjustment of the press for other size
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Readjustable
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Changeability of molds
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Any molds can be prepared by order
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Other units
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Unloader
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Unified 5-25
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Conveyors
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Unified 5- 100
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Hoppers
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Unified 5-25
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Mixers and attritors
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Unified 5-25
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rails
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Unified 5-100
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Trolleys
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Unified 5-100
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Carts
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Unified 5-100
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Traction mechanisms
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Unified 5-100
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Clay scarfers
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Wheeled or crawl
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