china Henan Ruiyao Intelligent Environmental Protection Co., Ltd Company News

We all know that during the process of extrusion, cutting and pushing of the clay strips by the brick machine, brick slag will adhere to the cut hollow brick blanks. If these brick blanks are loaded on the kiln car without being treated with brick slag, it will have an adverse effect on the quality of the bricks fired.   After the hollow brick clay strips are cut by the steel wire, brick slag will adhere to the holes of the brick blanks. These brick slags stick to the holes and the edges of the brick blanks, which reduces the porosity of the hollow bricks or causes the edges of the brick blanks to be not smooth. During the drying and baking process, the edges of the hollow brick holes are adhered to brick slag, which blocks the air from flowing into the holes, slowing down the drying speed of the brick blanks.  If the speed of the car is fast, the blanks cannot be completely dried, which seriously affects the quality of the blanks. During the baking process of the blanks, since the oxidation of carbon also requires oxygen to enter the blanks for reaction, the presence of brick slag causes oxygen to react with brick slag first, delaying the time for oxygen to enter the holes, slowing down the baking reaction speed. Due to the incomplete oxidation reaction, the internal black core of the brick increases, affecting the internal stress and compressive and flexural strength of the brick, thus affecting the brick's progress to a higher level. Practice has proved that the reduction of brick slag can improve the quality and output of bricks.  

The rapid development of the new chemical materials industry has placed higher demands on the heat treatment processes for chemical products such as powders, catalysts, functional ceramics, and composite materials. As a representative of modern continuous firing equipment, roller hearth kilns, with their advantages of high efficiency, energy saving, and precise temperature control, have been widely used in key processes such as drying, roasting, calcining, and heat treatment of chemical materials, becoming a vital piece of equipment for improving product quality and production efficiency.   In the chemical industry, many materials, such as lithium battery cathode precursors, catalyst carriers, electronic ceramic powders, alumina microbeads, and molecular sieves, require precise thermal decomposition, crystal phase transformation, or sintering processes. Roller kilns are equipped with advanced PLC control systems and multi-point temperature measurement devices, which can precisely control the temperature of each temperature zone (usually up to 1200°C or above) and adjust the atmosphere (such as air, nitrogen, reducing atmosphere, etc.) according to process requirements to ensure that the material completes physical and chemical changes under a specific temperature regime, thereby obtaining the ideal crystal structure, specific surface area, and catalytic activity. Modern roller hearth kilns commonly utilize waste heat recovery technology, utilizing heat from the cooling section for preheating or drying processes. This significantly reduces overall energy consumption and helps chemical companies achieve a green, low-carbon transition. Roller hearth kilns also feature excellent sealing and exhaust gas treatment interfaces, effectively collecting volatile substances released during the heat treatment process and reducing environmental pollution. Their modular design also facilitates adjustment of kiln length, heating method (electric or gas), and atmosphere system to the process requirements of different chemical materials, enabling multiple uses of a single kiln and improving equipment utilization. Roller hearth kilns, with their high stability, high degree of automation, energy conservation, and environmental protection, play an irreplaceable role in the heat treatment of chemical materials. They not only improve product performance consistency and batch stability, but also promote the development of chemical materials towards high-end, large-scale, and intelligent production. In the future, with the advancement of new materials technology, roller hearth kilns will have broad application prospects in the heat treatment of more specialty chemical materials.

01 Overview of Tunnel Kiln Calcination Process   By drawing on the mature tunnel kiln technology, aluminum ash, calcium aluminate and other industrial solid wastes are pressed into shape and then calcined at high temperature in a static manner, which not only improves the calcination efficiency and product quality, but also achieves the goals of clean production and resource utilization.   02 Process Features Pressing and Forming The material needs to be pre-treated before entering the kiln, and then pressed into a block, hollow or porous structure through high-pressure forming equipment. This not only improves the air permeability and heat conduction efficiency of the material, but also helps the subsequent calcination process to be evenly heated and fully reacted.   Static calcination mode Different from the dynamic stirring calcination of the traditional rotary kiln, the tunnel kiln adopts a static calcination mode, which avoids the wear and dust problems caused by material turning, and is more conducive to controlling the calcination temperature curve and improving product stability and consistency.   Highly sealed design   Double kiln door design, the entire calcination process is carried out in a closed environment, effectively preventing the leakage of harmful gases such as chloride ions, nitrogen oxides, and carbon dioxide, reducing the risk of environmental pollution, and also reducing the problem of agglomeration and blockage inside the kiln body.   Waste heat recovery and purification The high-temperature flue gas discharged after calcination can be used to preheat new materials through the waste heat recovery system to achieve energy recycling. At the same time, the flue gas is discharged in compliance with the standards through a unified purification system (such as dust removal, desulfurization, and denitrification), further ensuring environmental safety. Highly automated control With the help of modern sensing technology and intelligent control systems, the entire production line can achieve full-process automated operation from raw material mixing, pressing and molding, automatic stacking, kiln calcination to finished product kiln discharge. This not only greatly reduces labor costs, but also improves the continuity, stability and safety of production.    

01 Overview of Tunnel Kiln Calcination Process   By drawing on the mature tunnel kiln technology, aluminum ash, calcium aluminate and other industrial solid wastes are pressed into shape and then calcined at high temperature in a static manner, which not only improves the calcination efficiency and product quality, but also achieves the goals of clean production and resource utilization.     02 Process Features Pressing and Forming The material needs to be pre-treated before entering the kiln, and then pressed into a block, hollow or porous structure through high-pressure forming equipment. This not only improves the air permeability and heat conduction efficiency of the material, but also helps the subsequent calcination process to be evenly heated and fully reacted. Static calcination mode Different from the dynamic stirring calcination of the traditional rotary kiln, the tunnel kiln adopts a static calcination mode, which avoids the wear and dust problems caused by material turning, and is more conducive to controlling the calcination temperature curve and improving product stability and consistency. Highly sealed design   Double kiln door design, the entire calcination process is carried out in a closed environment, effectively preventing the leakage of harmful gases such as chloride ions, nitrogen oxides, and carbon dioxide, reducing the risk of environmental pollution, and also reducing the problem of agglomeration and blockage inside the kiln body. Waste heat recovery and purification The high-temperature flue gas discharged after calcination can be used to preheat new materials through the waste heat recovery system to achieve energy recycling. At the same time, the flue gas is discharged in compliance with the standards through a unified purification system (such as dust removal, desulfurization, and denitrification), further ensuring environmental safety.   Highly automated control With the help of modern sensing technology and intelligent control systems, the entire production line can achieve full-process automated operation from raw material mixing, pressing and molding, automatic stacking, kiln calcination to finished product kiln discharge. This not only greatly reduces labor costs, but also improves the continuity, stability and safety of production.      

In today's rapidly developing industrial fields, especially in the manufacturing industries of ceramics, refractory materials, and electronic components, the demand for heat treatment processes is growing and the requirements are becoming more stringent. With the advancement of science and technology and the upgrading and transformation of the manufacturing industry, finding more efficient, energy-saving and thermal equipment that can accurately control the temperature curve has become one of the key directions for the development of the industry. In this context, push-plate kilns, as an important sintering and heat treatment equipment, play an indispensable role in many industries.   The pusher kiln is a continuous high-temperature heating equipment. Its working principle is to carry the materials to be processed through a series of push plates made of refractory materials, and push these materials from one end of the kiln to the other end at a certain speed. In this process, the materials pass through the preheating zone, the firing zone (or reaction zone) and the cooling zone in turn, thereby completing the required physical and chemical changes. According to different heating methods, it can be divided into electric heating push plate kiln and gas heating push plate kiln; according to the atmosphere environment, there are many types such as air atmosphere and nitrogen atmosphere.  

1. Ceramic industry Electronic ceramics: Used in the production of alumina ceramic substrates, ceramic capacitors, piezoelectric ceramics (such as buzzers, sensors), etc., requiring precise temperature control and atmosphere control (such as nitrogen protection). Structural ceramics: Sintering high-performance ceramic components such as silicon carbide and silicon nitride, such as sealing rings and cutting tools. Daily ceramics: Quickly firing glazed tiles, special ceramics (such as heat-resistant tableware).   2. Electronic components Magnetic materials: Sintering ferrite permanent magnets (such as speaker cores), soft magnetic materials (inductor components). MLCC (Multilayer Ceramic Capacitor): High temperature sintering of nano-scale ceramic powders requires a strict temperature rise and fall curve. Semiconductor packaging: Firing of ceramic packaging substrates (such as LED brackets). 3. Powder metallurgy Metal powder sintering: Hard alloys (such as tungsten steel tools), metal injection molding (MIM) parts, magnetic alloys (NdFeB). Heat treatment: Annealing and carburizing of stainless steel or special alloys.   4. New energy materials Lithium battery materials: Sintering of positive electrode materials (such as lithium iron phosphate, ternary materials), carbonization of negative electrode materials. Photovoltaic industry: Firing of ceramic crucibles for solar cells.

High efficiency: Due to the continuous operation mode, the push plate kiln can achieve uninterrupted feeding and discharging, greatly improving production efficiency. Compared with intermittent kilns, it reduces waiting time and makes the entire production process smoother. Good temperature uniformity: The advanced temperature control system ensures the precise control of the temperature in each area of ​​the kiln. Coupled with the reasonable structural design, the material is heated evenly throughout the sintering or heat treatment process, which helps to improve product quality. High flexibility: Whether it is processing small batch samples or large-scale production tasks, the push plate kiln can adapt. At the same time, for different types of materials, only the process parameters need to be adjusted to meet the diverse product needs. Energy saving and environmental protection: The new push plate kiln focuses on the effective use of energy in design, such as reducing heat loss by optimizing the insulation layer structure and reducing fuel consumption by using an efficient combustion system, thereby achieving the purpose of energy saving and emission reduction.

Newly built or overhauled large-section tunnel kilns must be baked according to the correct baking procedure before they are put into production, as the kiln body contains a large amount of moisture, so as to discharge the moisture in the kiln body, so as to ensure the service life of the kiln and meet the requirements of normal production.   The quality of baking of large-section tunnel kilns not only directly affects the service life and normal production of the kiln, but also affects the quality and output of the products. Even if a large-section tunnel kiln is reasonably designed and of excellent construction quality, if it does not pay enough attention to the baking process and does not bake according to a reasonable kiln baking system, it is very likely to cause cracking of the kiln body, structural deformation, and partial collapse in severe cases. Once the kiln body cracks (multiple cracks or severe cracks), the sealing of the kiln body is damaged, air leakage will occur during use, and the atmosphere, pressure, temperature, etc. of the kiln are difficult to control, which also greatly reduces the service life of the kiln. In addition, errors in kiln baking will also affect the curved seal and sand seal of the kiln, which can affect the service life of the kiln car. Therefore, baking in a large-section tunnel kiln is a rigorous and meticulous job that requires serious preparation and operation.

The large-section multi-joint tunnel kiln can realize multiple rows of kiln cars entering the kiln at the same time. The kiln system consists of: drying kiln, roasting kiln, air duct system, flue gas re-firing system, automatic roasting system, flue gas purification system, etc. The large-section multi-joint tunnel kiln design realizes factory-based modular production, with the characteristics of small footprint, high output, environmental protection and energy saving.   1. High efficiency and energy saving It eliminates multiple kiln walls and reduces the heat loss of multiple kiln walls. Compared with a single tunnel kiln, it can reduce heat consumption by 30%. At the same time, a double-channel sealing design is adopted between kilns to ensure the smooth and reliable operation of the kiln. The new fast drying system solves the production and manufacturing problems of high-moisture raw materials and reduces investment costs. 2. Low-carbon and environmental protection The flue gas discharged from the low-temperature preheating section and the high-temperature drying section of the drying kiln is reused in the cooling section of the roasting kiln through the flue gas re-firing system. The moisture discharged from the constant-speed drying section is sent to the flue gas treatment system for treatment, which reduces the treatment volume and oxygen content of the exhaust flue gas and ensures that the emission meets the standards. 3. Scientific planning The architectural form of a large-scale joint plant is adopted to form a large-area and large-space joint workshop. The kiln body design uses international large-size steel to make the overall structure of the kiln strong and durable, saving maintenance costs. The construction period is short. It reaches production and standards quickly, and the investment benefits are high.