How to prevent green bricks from collapsing in the dryer kiln?
Regarding the common problem of bricks collapse, our company has the following suggestions:
- Strictly control the moisture content of the brick blanks: Control the amount of water added to the mixer. Too much water will make the brick blanks too soft with excessive moisture, while too little will cause the blanks to fail to form properly and block the extruder machine. Brick factories can adopt an automatic water addition system, which can monitor soil moisture and adjust the water volume accordingly.
- Moisture content upon entering the drying kiln: Brick blanks should have 1-3 days of natural drying time to reduce the dehumidification pressure in the drying chamber, thereby decreasing the probability of brick inversion. If the customer is building a tunnel kiln, it is recommended to have 3-5 blank storage lines. For rotary kilns, the diameter of the rotary kiln should be over 130 meters.
- Optimize the blank stacking structure: The plan should be arranged reasonably according to the brick type and raw materials to ensure uniform airflow penetration.
- Select appropriate exhaust fans: The air pressure and air volume of the exhaust fans should be suitable based on the kiln's stacking plan; unsuitable fans will significantly reduce the dehumidification effect.
- Precisely regulate ventilation and temperature in the preheating zone: Change "relatively centralized dehumidification" to "relatively dispersed gate-opening smoke exhaust" to lower the relative humidity of the flue gas. When selecting a kiln design plan, avoid outdated centralized dehumidification schemes and choose our latest dispersed dehumidification scheme.Additionally, hire experienced kiln technicians who can correctly operate the fans and valves on the kiln when the humidity in the kiln is too high.
- Install a humidity monitoring system: Our recently developed humidity monitoring system can effectively monitor the humidity in the kiln's drying section. It will issue an alarm for excessively high humidity values, allowing kiln operators to intervene early before brick collapsing occurs.
- The insulation of the kiln, especially in winter, is crucial. If the outside temperature is too low and no insulation measures are taken for the bricks, the bricks will freeze, leading to their collapse.
针对常见的砖坯倒塌问题,我司有以下建议:
- 严格控制砖坯的水份:要控制好给搅拌加的水量,加水太多,会造成砖坯子过软,水分过大.太少,又会造成砖坯不成型,堵挤出机机器.砖厂可采用我司鸿运窑炉最新研发的自动加水系统,此系统可以监测土壤水份,根据土壤水份来调节水量.
- 入烘干窑水份:砖坯要有一到三天的自然晾晒时间,从而减小烘干室的排潮压力,进而减小砖坯倒塌的概率.若客户建设的是隧道窑,建议客户有3~5条存坯线,若是旋转窑炉,则旋转窑炉的直径要在130米以上.
- 优化码坯结构:方案要根据砖型和原料,合理的布置,确保气流均匀穿透.
- 选择合适的排潮风机:根据窑炉的码坯方案,排潮风机的风压和风量都要合适,不合适的风机会导致排潮效果大打折扣
- 精准调控预热带通风与温度:相对集中排潮”为“相对分散开闸排烟”,降低烟气相对湿度.在选择窑炉设计方案的时候,尽量要避免集中排潮的落后方案,要选择我们最新的分散排潮方案.另外要雇佣有经验的窑炉师傅从而可以在窑炉湿气过高的时候能正确的操作窑炉上的风机和阀门.
- 安装湿度监测系统:我司鸿运窑炉最近最新研发的湿度监测系统,可以有效的监测窑炉烘干段的湿度,对过高的湿气值会给予报警提示,从而再让窑炉师傅在砖坯倒塌之前过早的介入.
- 窑炉的保温工作,尤其在冬天,如果外界温度过低,砖坯没有采取保温措施,砖坯就会受冻,从而导致砖坯倒塌.
