Abstract: The selection and implementation of technological transformation plan of sintered brick production line must be based on the market demand for products and the actual conditions of enterprises in order to improve the drying yield, reduce the production cost, reduce the consumption of products, and meet the industrial policies and regulations, improve the enterprise and social benefits. main target.

　　Guizhou Province, a sintered brick business, the original production line with an annual output of 1800 to 20 million sintered ordinary brick production capacity, raw materials to mine-based shale, the use of power plant fly ash as internal combustion blending ingredients, cast raw coal. In June 2014, in view of the new wall materials industry in Guizhou Province policy requirements, the annual output of less than 50 million (ordinary brick) shale fired brick production line is not suited to the sustainable development of wall materials business requirements, The production line can not produce sintered hollow brick, the product grade is lower, the market coverage is limited. Therefore, the company decided to carry out technological transformation.

　　Before and after the technical transformation of the enterprise profile and part of the economic indicators analysis is as follows.

　　1. Survey of the Technological and Economic Indicators before the Technical Renovation

　　1.1 Overview of technological transformation process

　　The sintered brick enterprises to use shale and fly ash as the main raw material, cast raw coal.

　　Shale by the box feeder, hammer crusher, rotary sieve screening, and fly ash mixed, through the mixer, a 50 two-stage vacuum extruder extrusion molding, cutting, cutting blanks, belts Dry billet into the drying chamber by the top six, the qualified dry blank through the frame car to send 22-wheel kiln, artificial yards kiln, artificial look at the fire, Add outside the cast coal, roasting qualified, the artificial kiln, artificial stacking and loading.

　　Wheel kiln exhaust gas using 12 centrifugal fan out into the drying room as a drying medium to use, drying room exhaust from the high 45m smoke garden emissions. Process equipment in Table 1.

　　1.2 Economic and technical indicators

　　The main economic and technical indexes before the technical transformation are shown in Table 2.

　　1.3 technical transformation of the original production line conditions

　　Since the construction of the production line in 2002, the continuous production of more than 200 million pieces of high quality sintered wall materials to meet the needs of regional construction. With the shale mine consumption of raw materials, factory area increased, has reached the basic requirements of technological transformation. Coupled with the introduction of new wall materials in 2014, Guizhou Province, industrial policy norms, technological transformation is also time.

　　Figure 1 ~ Figure 4, respectively, the original production line in the main production processes. Technical transformation program to determine the old facilities for the demolition of all, in the construction site with an annual output of 50 million (ordinary brick) sintered hollow brick production line.

　　Good wet blank kiln car code in the indoor 2 lanes on the static stop, time is about 40h, and then give two dry kiln.

　　Dry kiln exhaust, the axial fans by 18 on the original sent to the original 45m bacon, exhaust into the smoke before the need for desulfurization device for dust and desulphurization, discharge standards.

　　Dry billet into a firing tunnel kiln roasting, to be qualified products. Sintering process to set kiln temperature, pressure, air flow monitor, the roasting for automatic monitoring.

　　Fired tunnel kiln flue gas all by 16, 12, two centrifugal fan into the dry tunnel kiln, as a drying medium.

　　Finished out of the pit, respectively, parked in the three parking lines, of which two finished products by the staff directly from the kiln car unloading bricks, yards into the car transport factory. Another stop line of the finished product, can be mechanized unloading brick forklift for holding folder transport, stacking and loading transport.

　　2.2 Process equipment

　　Process equipment in Table 3.

　　2.3 After the production line process parameters

　　After the implementation of technological transformation and production line operation, the production line technology parameters in Table 4.

　　2.4 after the technological transformation of production processes

　　After the technical transformation, the main link of the production line is shown in Fig. 5 to Fig

　　3.Discussion on the implementation of technological transformation

　　3.1 Production scale

　　According to the “wall material industry in Guizhou Province norms” restrictions, the implementation of technical transformation program called for annual production reached 50 million. After the technological transformation of the production practice shows that the main thermal equipment, two cross-section of 3.48m , Length 77m dry tunnel cellar and a cross-section 3.48m, length 123m firing tunnel kiln, monthly output of 4.5 million ordinary brick, according to The local annual production time of 11 months, to achieve the wall material industry in Guizhou province specifications. If the production of hollow brick, the scale of production can exceed the specifications requirements.

　　The annual output of sintered bricks can meet or exceed the specification requirements, and the following technical measures are worthy of analysis and summary.

　　3.1.1 Implementation of low forming requirements of water forming.

　　Using 55 double-stage vacuum extruder, the extruder lower motor is 200 kW, can achieve 12.5% ??~ 15% of the molding water, squeeze out the speed of 14 to 15 per minute, mud strength, appearance quality Preferably, to provide a strong guarantee for shortening the drying cycle and reducing the rate of dry rejects. More importantly, low-forming moisture can ensure the success of a code burning process, the wet blank bricks of the kiln wet blank billet the next layer of wet billet will not be deformed, but also to determine the code 16-story high technical decision to create a prerequisite. ( “One code burning” process, to determine the high wet blank blank 16, the decision has a greater risk, such as raw material performance and other unfavorable factors, resulting in only 14 yards high wet blank code or 12 layers, Plane from the kiln car plane height can not be arbitrarily changed, making the gap between the brick stack and the kiln is too large, when the use of car to increase the pad brick to adjust, the ventilation efficiency of the Kazakh air outlet will be adversely affected.Therefore, Is too large, will inevitably make firing output, quality, fuel consumption and so will be a greater impact.

　　3.1.2 code up to 16 layers, increase the kiln car code blank capacity

　　Compared with the same specification kiln car code put 14 layers, each kiln car ordinary brick loadings reached 6912. Code blank capacity increased, the same into the car time, the daily net output of 1.7 to 19,000, the maximum monthly net increase of 570,000. It can be seen that increasing the amount of code blanks is of great significance to improve the yield and quality of fired tunnel kiln.

　　3.1.3 the role of the implementation of the program stop

　　In the technological transformation, the length of the two hydrostatic blanking stops is the same as the length of the 77m dry tunnel kiln, and 21 kilns are parked in each static stopping section, and the static blanking time of the wet blank is about 40h.In addition, the regional environmental average temperature is 13.7 ℃? 16.2 & lt; 0 & gt; C. In this condition, the moisture content between the dry and wet particles in the green body can be transferred from the wet particles to the dry particles during the static process of the indoor wet blank, so that the quantity of the water heterogeneous particles in the blank body is gradually reduced, And the water homogeneity in the green body is improved. At the same time, due to the difference between water vapor partial pressure and water vapor partial pressure on the surface of the buried body, the surface of the green body can be dehydrated slowly and increase the wet billet strength. The total amount of water to reduce the wet billet into the dry tunnel kiln, help to improve the appropriate drying rate. When the drying cycle is longer, the residual moisture of the dry billet can be lower, which is beneficial to the improvement of tunnel kiln production.

　　3.1.4 Set up two dry tunnel kilns

　　In the production process of sintered bricks, to improve the dry yield is the basis to increase the output of sintering kiln, but also improve the basic conditions of enterprise efficiency. Technical innovation will focus on drying links, set up two dry tunnel kiln, to ensure that dry production reached or exceeded the scale of production requirements. In addition, the dry tunnel kiln adopts 1 set of 16 #, 1 set of 12 # boiler centrifugal induced draft fan as the hot air of 2 dry kilns, 1 set of No. 18 axial flow fan, 3 turbines work together to strengthen the kiln ventilation Capacity, improve the drying efficiency, to avoid dry kiln into the car side condensation and condensation of water vapor condensation. As the code blank height of 16 layers, such as residual moisture within the brick stack uneven, will result in lower firing rate of qualified products, waste increased. Therefore, the structure of drying kiln to send hot air holes must be in close co-ordination with the stacking form of the mechanical code blanks, the hot air can reach the middle of the brick stack evenly and ensure the residual moisture of the dry blanks inside and outside the brick stack is basically the same.

　　3.1.5 fired tunnel kiln wall thickness

　　Tunnel kiln in operation, the heat from the inside out, therefore, need to emphasize the maintenance of the furnace structure insulation, fiber-like soft light material compared to compact material thermal conductivity is small, can be used as a kiln insulation material. As the use of thin insulation material thickness, after a period of operation, the furnace insulation reliability is poor, coal consumption increased. For ordinary sintered brick materials, its thermal conductivity is inversely proportional to the wall thickness, the thicker the kiln wall maintenance structure, the smaller the heat transfer coefficient. Technical transformation, firing tunnel kiln flue system is designed in the kiln wall, an increase of kiln wall thickness, the furnace insulation can be improved. Production practice, the internal combustion blending only 220kcal / kg ~ 270kcal / kg, kiln surface cast a small amount of raw coal, kiln brick stack fire color, the finished product strength is basically the same, very few appear fire brick.

　　3.1.6 Technical improvement to improve the degree of automation

　　Technical innovation in the industry with practical and reliable automatic ingredients, automatic water distribution, kiln furnace automatic kiln temperature monitoring, and other advanced technology. Molding workshop to achieve mechanization and automation. Using a special forklift clip mechanized unloading bricks and stacking code. This series of measures has greatly improved labor productivity and product quality, significantly reducing the number of post workers, to avoid human factors on the impact of production.

　　The above six technical measures are the basis for realizing the target output of the technical transformation. The production practice shows that the product quality of the production line is higher, the coal consumption is lower, and the production plan is arranged flexibly and smoothly.

　　3.2 technical transformation planning

　　In the technological transformation, the firing tunnel kiln, the dry tunnel kiln, the carriage unloading brick line, the forming workshop and the double aging depot are arranged in parallel. Raw material preparation workshop according to the terrain conditions independently arranged close to the shale mine, reducing the floor height of the excavation of earth and earth to achieve the layout of the layout of compact and saving land, improve the overall efficiency.

　　The technological transformation plan emphasizes the technical measures such as mechanical code blank, artificial drying, tunnel kiln roasting, pit furnace insulation, fan frequency control and other technical measures to meet GB50528-2009 “sintering brick factory energy-saving design specifications” standards related to energy saving requirements.

　　The establishment of raw materials and product testing part to meet the “sintered brick tile enterprise quality management procedures” and “sintering brick enterprise inspection room basic conditions” requirement.

　　3.3 Product quality and energy consumption standards

　　After the transformation of the quality of the production of ordinary bricks in line with GB5101 - 2009 “sintering ordinary turn” standards.

　　Sintered brick energy consumption per unit of product to meet GB30526- 2014 “sintered wall materials per unit of product energy consumption limits”, the sintered solid products <51kgce / t (converted energy consumption of 357kcal / kg) requirements.

　　At present, the local market needs less hollow brick, inconvenience to organize large-scale production.

　　3.4 Pollutant Emissions

　　After the transformation of raw materials and preparation of the workshop, set up a Taiwan-made bag filter. According to observation, a hammer crusher feed, there is a small amount of dust, dust particles of pollutants emissions can not meet the GB29620-2013 “brick and tile industry air pollutant emission standards” requirements. The bag filter line has been prepared for further improvement.

　　The tunnel kiln's hot flue gas enters the tunnel kiln. As a drying medium, it contains particulate matter, SO2 and nitrogen oxides. After the heat exchange of the flue gas, the 18-axial fan delivers the bacon. In the fan outlet pipe and chimney installed at the bottom of the desulfurization device, the use of lime as a desulfurization agent for dust particles and SO2 gas processing, after treatment by the chimney exhaust emissions.

　　Production, in order to SO2 emissions of atmospheric pollutants, has been selectively used in Hunan Province and the province of high-quality low-sulfur coal (heat up to 5000kcal / kg above the sulfur content of less than 1%), Amount, improve desulfurization efficiency.

　　3.5 Investment in technological transformation

　　This technical transformation will be the original production line removed, the construction of a complete annual output of 50 million (standard bricks) shale hollow brick production line, using a code burning process, two dry tunnel kiln, a firing tunnel kiln, mechanization The higher the number of post workers, the whole plant is only 53 the total number of employees, with the original production line number of employees is basically the same. However, a significant reduction in labor intensity, full labor productivity reached 940,000 / year? People, a substantial increase in labor productivity.

　　At present, the hollow brick market demand for less, inconvenience the organization of large-scale production, the company decided to use the original 50 two-stage vacuum brick extruder, cut and cut blank unit to establish an independent whole brick production line, as the technical complement, To facilitate the flexible arrangements of hollow brick production.

　　It is estimated that the investment in this technological transformation will reach 8 million yuan and the investment in every 10,000 bricks is only 1,600 yuan. Compared with the same type of sintered brick technological transformation projects, the total investment will be reduced by more than half.

　　4 Conclusion

　　Before the implementation of this technological transformation, the company organized a number of process, equipment research, a code burning process for a detailed and in-depth analysis and summary, combined with existing production experience and raw material conditions, put forward a practical transformation of the route and the tunnel Kiln structure, the better to achieve the goal of this technological transformation.

　　After the implementation of the program, production scale by an annual output of 20 million pieces of ordinary brick, raised to an annual output of 50 million or more, to achieve large-scale production, optimize the product structure, improve product quality, to meet the Guizhou Province in April 2014 promulgated The implementation of the “wall material industry in Guizhou Province norms” requirements, business efficiency and social benefits simultaneously improved.

　　Second, according to market demand and raw material conditions, the use of a code burning process, technical measures complete, to meet the market demand for different products, expanding the market coverage of the product is conducive to improving business efficiency.

　　Third, technological transformation planning and business site conditions better, technology, roads, green, auxiliary facilities such as compact layout, saving land.

　　Fourth, technological transformation investment of about 8000000 yuan, better to achieve the investment, large-scale, mechanization and other targets.

　　In addition, the implementation of technological transformation, product energy consumption, product quality and other indicators to meet the relevant national standards. At the same time, corporate employees monthly wage income increased by 16%.

　　With the “brick and tile industry emission standards for air pollutants,” the implementation of environmental protection facilities in the production line also needs to be further improved to meet the production process of air pollutants discharge standards. SO2 desulfurization in the exhaust gas of dry tunnel kiln needs to adopt more perfect measures to achieve the standard discharge.

　　The production practice shows that this technological transformation is a successful example, worthy of similar conditions of small and medium-sized enterprises sintering brick reference.

　　- From the “brick” magazine

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