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Terca Bricks N.V.Thermal energy-saving production of „snelbouwblocks“ in Belgium

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Thermal energy-saving production of„snelbouwblocks“ in Belgium

From the press through to the packaging station, thenew plant of the Terca Bricks N.V. in Zonnebeke, WestFlanders, was built completely by Lingl. It produceshighly pored backing bricks with a daily capacity of345 tonnes in a 12-hour single-shift operation onseven days per week.

With extensions to the dryer and the kiln as well asadditional production shifts, the works capacity can beincreased to 540 t/day. The use of plane-grinding machines is intended for theproduction of calibrated bricks.

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With a universal cutter for vertical cut, a doubleclay column (2 x 300 mm wide) or a 600 mmwide single column are cut and the greenproducts placed on the laths. The loaded drying supports pass through anautomatic weighing device, are collected in alifting frame and then transferred by a loadingrack into the waiting dryer cars.

DryingThe continuous dryer, which is fitted withrotary fans and controlled by process computer,is divided into four automatically regulatedzones. The control system takes into accountthe relative humidity, temperature, pressure andproduction time. The dryer is 56.8 m long with five forwardtracks. With a drying time of 30 hours, the dailycapacity amounts to 354 tonnes. Heating of thedryer takes place in a compound thermal oper-ation with hot air from the low-temperaturearea of the kiln and indirectly from the high-temperature area of the kiln via a thermal oilheat exchanger. Additional heating is possiblewith a pipe burner for natural gas.

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Grouping and settingThe dried bricks, after unloading of the dryer cars withanother loading rack, are cleared from the laths by atransfer gripper and placed on two supply belts. Here theyare tilted and grouped to setting layers, which are set onthe kiln cars in a crosswise bond in square stacks as two-brick turrets.

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1 Shaping plant2 Universal brick cutter, loading of drying

supports, automatic weighing device3 Dryer car loading4 Continuous dryer with 5 forward tracks5 Dryer car unloading6 Grouping of setting layers on 2 lanes7 Kiln car loading8 Preheater for 3 kiln cars9 Tunnel kiln 145/8.80/1.82 m

10 Control room for dryer, tunnel kiln,machines and transport systems

11 Kiln car unloading12 Kiln car cleaning13 Grouping of shipping pack layers14 Lower film supply15 Plateau car circuit16 Shipping pack stackers 1 and 217 Horizontal strapping18 Packing slip supply19 Shrink film packaging on 4 sides20 Vertical strapping21 Shipping pallet supply22 High-/low voltage distribution

1 Formgebungsanlage2 Universal-Abschneider,

Formlingsträgerbeladung,automatische Waage

3 Trocknerwagenbeladungmit Laderechen

4 Durchlauftrockner5 Trocknerwagenentladung6 Setzlagengruppierung

auf zwei Bahnen

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N.V. Steenbakkerijen van Zonnebeke

B-8980 Zonnebeke

7 Ofenwagenbeladung8 Vorwärmer für 3 Ofenwagen9 Tunnelofen 145/8,80/1,82 m

10 Leitstand für Trockner,Tunnelofen, Maschinen undTransportanlagen

11 Ofenwagenentladung12 Ofenwagenreinigung13 Versandpaketlagengruppierung14 Unterfolienaufgabe15 Plateauwagenumlauf16 Versandpaketstapler 1 und 217 Horizontalumreifung18 Packzettelaufgabe19 Schrumpffolienverpackung 4-seitig20 Vertikalumreifung21 Versandpalettenaufgabe22 Hoch- und Niederspannungsverteilung

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FiringThe natural gas fired tunnel kiln is 145 m long and has avery low energy consumption. The atmosphere and temper-ature gradient in the kiln are controlled and automaticallyregulated via process computer. With a firing temperatureof 1020° C, the passage time through the kiln amounts to35 hours, whereby firing can be carried out in oxidizing orreducing atmosphere. The raw material has a high carboncontent, so that special precautions have to be taken forthe oxidization of the opening materials.

UnloadingThe fired bricks are unloaded in layers by a transfer gripperand placed on two chain conveyors.

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Pack-forming and packagingThe supplied bricks are regrouped to form shipping packlayers by layer compensating and aligning grippers.

On a plateau car circuit, rotary transfer grippers stack thebrick layers in a crosswise bond or header-stretcher bond,with or without shipping pallet, on a base foil to formshipping packs. Three different types of shipping pack canbe formed: with works pallet, with Euro pallet, and withoutpallet but with grip holes for the fork-lift truck.

In the subsequent packaging plant, several combinationsof horizontal and vertical strapping , insertion of packinglabels, and shrink-film wrapping with the film on foursides are possible. Vertical strapping serves to secure thefinished packs on the shipping pallets.

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Product: Backing bricks(snelbouwblocks), 41 formats

Capacity: 345.5 t/calendar day

Reference size: 288/138/138 mm, 4.28 kg fired weight

Working time: 12 hours on 7 days/week

Personnel: 3 men (from press to packaging)

Continuous dryerAir recirculation by rotary fans

Dryer length: 56.8 m

Tracks: 5 forward, 1 return track

Drying time: 30 hours

Tunnel kilnKiln length: 145 m (23 cars)

Preheater/lock: 18.9 m (3 cars)

Exit lock: 6.35 m (1 car)

Firing channel: 8.80 m wide, 1.82 m high

Fuel: Natural gas

Firing temperature: 1020°C oxidizing/reducing

Passage time: 35 hours

Plant controlThe machines, transport systems, continuous dryerand tunnel kiln as well as the adsorption filter andthermoreactor plants are controlled automatically bya Simatic S5-155 U process computer as a central unit,the Fix-DMACS visualization system based onWindows NT and joint Terca/Lingl software.

Technical Data

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Hans Lingl Anlagenbau und VerfahrenstechnikGmbH & Co. KGA.-Berblinger-Straße 6 · D-89231 Neu-UlmPostfach 1629 · D-89206 Neu-UlmTelefon +49 (0)731 9751-0 · Telefax -210http://www.lingl.com · e-mail: lingl@lingl.com 12.00

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