Bricks are commonly used for centuries for protecting houses from natural elements, for instance raining and storms, as well as sustainable housing development. The components of bricks come from natural raw materials which are environmentally friendly and contribute to a healthy indoor climate. These bricks products are non-toxic and do not emit volatile organic compounds. Besides benefits inherent in natural properties of bricks, bricks are highly resistant to fire, electricity, ionizing radiation and static electricity. Furthermore, bricks are able to isolate transmission of sound and vibration.
In the common bricks manufacturing process, there are 8 steps to make the bricks from raw material to finished products in modern brick production facilities. Raw materials are crushed and grind to achieve suitable particle size through separators and jaw crushers. Raw material of right size will be sent to silos for storage and prepared for the next production stage. Those over-sized raw materials will be delivered to the hammermill for further pulverising with moving steel hammers. According to specific batch specifications, these raw materials are filtered and sent to moulding processes. There are three types of moulding processes, for instance, extrusion, moulding and pressing in bricks manufacturing processes. The most common type of moulding processes is extrusion which is widely applied in most modern brick production plants.
These three forming methods are used to form raw materials into bricks:
- Moulding- Raw clay is mixed with 25% to 30% sand which will help to reduce shrinkage in later brick manufacturing processes. To achieve desired consistency, these raw clay is ground and mixed with water. Hydraulic press is used to press the clay into the steel mould and form the shape of brick.
- Pressing- A thicker clay mixture is used to form sharper edged bricks. Due to the longer kiln burning time required for pressing bricks method, it is costly to perform compared to the other two forming methods mentioned.
- Extrusion- The clay and mud are mixed with water in a pugmill. The mixture is forced through a mould to produce a big piece of clay mixture with specific overall dimensions. Then these big pieces of clay mixtures are cut through by wire into individual brick dimensions. Extrusion forming produced dense bricks and perforations which reduced cost which make this method the most popular in brick manufacturing plants.
After the bricks are formed, the next important step is to remove the moisture from the bricks. If the excess moisture in the bricks is not removed, it would crack during the following firing process. The cracking happens because water on the bricks burn off too quickly.
Two types of dryers are commonly used in the brick drying process:
- Tunnel dryers
Bricks are moved slowly through a long chamber with hot air blown into the tunnel by external industrial fans to speed up the drying process. The moving of the bricks are done by using customised pallet cars with heavy duty rollers to withstand the heavy load and high temperature of hot air. The high temperature in the furnace is called kilns. The kilns are continuously monitored and maintained at a temperature range at required rate according to the material of bricks.
2. Automatic chamber dryers
Automatic chamber dryers are commonly used in Europe brick manufacturing plants. Special racks with finger-like devices hold the bricks in multiple layers and transfer the bricks to dryers by rail-mounted cars.
Once the moisture is removed, these bricks are moved to kiln and heat up for 48 hours. Finally after cool down, the finished bricks are moved to the packaging section for stacking and packing, wrapping with steel tape.
One of the applications where the Ferrari ceramic and brick industry fans are largely used in brick production. In the process of brick production, the Ferrari industrial high temperature fans are mainly used in the drying kiln, in the furnace and in the combustion systems. Belt driven Ferrari industrial axial fans and belt driven centrifugal fans are commonly used in drying kilns and furnaces. High-pressure direct driven Ferrari industrial centrifugal fans are used to perform air injection in the combustion stage of combustion systems.
Industry: Brick and Ceramic industry
Fan type: High pressure Ferrari industrial fan
Fan quantity: max 22 kW
Description: Ferrari industrial high pressure fans applied at ceramic factories to pressurise the drying system and remove moisture from the dryer system.
Ceramic Industry Fan
Ferrari Asia Ventilation
Offering ceramic and brick industry fans to meet your exact specifications.
lin is one of the typical applications that used in the ceramic and brick industry fans. Continuous kiln is a typical tunnel kiln with both ends open and designed to generate heat at the central portion. Bricks and other building materials pass through the tunnel kiln continuously. Kiln is turned on uninterruptedly to proceed several batches of bricks.
ryer application is commonly utilised in many fields of industries. It is typically used in building materials or, more generally, clay or shale based on construction materials.
Clay drying is the most essential part of producing brick. This phase defines the shape, size, and quality of the clay. With proper settings of the dryer system, air flow and drying speed, it assures the ability to dry the clay without forming cracks on the surface. Most common dryer methods used are rapid dryers, continuous dryers and static dryers. For this process, Ferrari industrial high temperature construction fans direct air on the manufactured products to obtain uniformity of the drying process.