Purpose

Production of ceramic brick, grade 200

Trademark owner

Hong Kong Mega

Developer

Spain

Licence owner

Government of PR China

Kitting up and process

list of machines

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)
14Turn 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.  

Processing

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

General info

Operation regime

22  hrs/day, 300 days, year

Productivity/year

25 000 000 pcs

Productivity/hr

Min - 3 900 pcs

Personnel

15 persons

Total energy consumption

185 kW

Heat energy demand

4 250 000 kcal/hr

Completeness of the equipment

All included

Warranty

2  years since leaving the territory of China .

Space

Production area

9000 m²

The production line is divided into shops

--Raw materials preparation shop

3000 m² outdoors

Functions

Scarfing of clay – breaking of large pieces - transportation – stone removal – transportation –lifting to hopper

Equipment

Clay scarfer (see photo 13)
Stone removal (see photo 15)
Vertical bucket elevator  (see photo 25)

--Attrition and mixing shop .

300 m² indoors

Functions

storage-transportation-batching-transportation-grinding-mixing with water-transportation-slab preparation

Equipment

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)

--Compression shop

400 m² Indooors

Function

Transportation – feeding to press-feeding to mold - pressing-transportation –unloading of press  – loading on trolley

Equipment

Press (see photos  1, 2, 3, 4, 5, 7, 8, )
Discharge table (see photo 6)
Mold. unloader (see photos 9, 10, 11, 12)

--kiln house

2300 m². Separate building

Functions

– transporation to kiln on trolleys – kilning

Equipment

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

--Warehousing

3 000 m² Outdoors

Function

transportation– finished products warehouse

Equipment

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)

Specifications of products and raw materials

Raw materials

Clay

The fraction used

Max- 0,5 mm

Clay consumption per 1000 bricks

1,728 m³

Clay consumption per 2000  bricks

3,456 m³

Clay consumption per 3000  bricks

5,184 m³

Annual water requirement

Water 4 500 m³

Annual clay requirement

44 000 m³

Additives

natural pigments and additives can be added

Standard brick size

240 × 115 × 53 mm

max size of the brick

1200х250х300 mm.

Breaking into wild stone

Yes see photos (ceramic bricks )

Facing bricks

Yes see photos (ceramic bricks )

Wall blocks

Yes seephotos (ceramic bricks )

Supporting walls of 25 storied-buildings

Yes see photos(ceramic bricks )

Kilns

Number of kilns

4 units

parameters of kilns

Combustion space

72 m³.

Production space

1.38 × 2.2 × 1.32 × 3 = 12 m³х 4

Desing temperature of the kiln

1400 ⁰С.

Outer size of  kiln

6.5 × 3.2 × 3 m

Gas consumption

600 m^3/hr

Operation firing temperature

1350 ⁰С

Inner size of the kiln :

5.3 × 2.34 × 1.43 m

Press

LU-HDP-15-300 presses

1 unit.

Press parameters

Diameter of reinforcing cylinders

no less than 300 mm

Hydraulics

PR China

Oil amount

1 000 kg

Changeout of oil

Once a year

Single pressing

10 pcs

Air venting/min

3

Productivity

Min - 60 pcs/min

System pressure

300 кNт

Pressure on each brick

Min. 200 кNт

Pressing cycles/min

6.5 cycles/min

Duration of the cycle

9 seconds

Power

62 kW

Outer size

3300 × 1500 × 1800 mm

Weight

18 tons

Permissible defects

1 %

Is not in the set

Complete set

To be purchased on the spot

ISO N46 hydraulic oil

Readjustment of the press for other size

Readjustable

Changeability of molds

Any molds can be prepared by order

Other units

Unloader

Unified 5-25

Conveyors

Unified 5- 100

Hoppers

Unified 5-25

Mixers and attritors

Unified 5-25

rails

Unified 5-100

Trolleys

Unified 5-100

Carts

Unified 5-100

Traction mechanisms

Unified 5-100

Clay scarfers

Wheeled or crawl