High-Efficiency Vertical Screw Extruder 30% Energy Saving for Tunnel Kiln Brick Plants

Equipment Introduction:
This series of machines is manufactured using advanced European technologies, specifically designed for the extrusion molding of high-end ceramic materials, cement fiber products, and semi-rigid plastic viscous materials. The equipment's materials, technical structure, electrical systems, and operating systems are all produced in accordance with European standards.

Vertical Double Helix Vacuum Extruder is a core forming equipment in clay sintered brick production, mainly used to extrude homogenized clay materials into brick blanks with specific cross-sectional shapes. Its structural features include:
Vertical double helix structure: Two screw shafts are arranged vertically, rotating in opposite or same directions to apply continuous extrusion and shearing forces on materials, ensuring uniform mixing and air discharge.
Vacuum system: A vacuum chamber is set at the front of the extrusion section, removing air bubbles from materials by vacuuming (typically with a vacuum degree of -0.08MPa to -0.095MPa) to improve the density of brick blanks.
Mold components: Replaceable extrusion molds determine the cross-sectional shape of brick blanks (such as standard bricks, perforated bricks, hollow bricks, etc.), adapting to different product requirements.

Efficient double-helix mixing:
The shearing action of two screw shafts crushes agglomerates in materials and enhances plasticity, especially suitable for high-viscosity clay or clay with impurities.
High-vacuum forming: The vacuum system effectively removes gas from materials, increasing the density of brick blanks by 10%-15% and reducing shrinkage deformation after sintering.
Automated control: Equipped with a PLC control system, enabling real-time adjustment of screw speed, vacuum degree, and extrusion pressure to adapt to different material humidity (optimum humidity 15%-20%).
Multi-functional mold adaptation: Supports quick mold replacement for switching between standard bricks, KP1 bricks, perforated bricks, etc., with mold change time ≤30 minutes.
Large-capacity design: Conventional models have a capacity of 80,000-150,000 bricks per shift (8 hours), and large equipment can reach 200,000 bricks per shift to meet large-scale production needs.

Main technical parameters:

Core Forming link:
Transforms mixed materials into uniform brick blanks, providing standardized blanks for subsequent drying and sintering.
Improve product quality: Vacuum extrusion eliminates air holes in materials, making the density of brick blanks uniform. After sintering, the strength of bricks is improved (MU10-MU25), and impermeability and frost resistance are significantly enhanced.
Connect production processes: (Interacts) with upstream crushing and mixing equipment and downstream cutting and drying equipment to form a continuous production line, improving the degree of automation.
Reduce material waste: Precisely controls the extrusion amount, reduces errors in manual forming, and the material utilization rate can reach over 95%.

Technical advantages:
The double-helix design increases extrusion pressure by 30% compared with single-helix, suitable for high-hardness materials (such as shale and gangue mixed with clay).
The vacuum degree is stable and controllable, the porosity of brick blanks is reduced, and the thermal conductivity after sintering can be decreased by 15%-20%, meeting the standards of energy-saving bricks.
Economic advantages:
High degree of automation, reducing operators by more than 60% and lowering labor costs (compared with traditional manual extrusion).
Significantly improved production capacity, with unit energy consumption (kWh/10,000 bricks) reduced by 12%-18% compared with traditional equipment.
Maintenance advantages:
The screw shaft is coated with wear-resistant alloy (such as tungsten carbide), with a service life of 8,000-10,000 hours and convenient replacement.
The vacuum system is equipped with an automatic dust removal device to reduce dust blockage, extending the maintenance cycle to 3,000 hours per time.

● Company profile

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.

Business Scope

(1) Design and engineering
Xi’an Brictec offers process design and engineering service for clients to have a fully automated modern bricks and tile factory, including chamber drying, tunnel drying, rapid drying and tunnel kiln and other process design and technical consultation, among which the dryer and kiln constructing and engineering is the utmost importance in our general contracting program. This part is the key to achieve production targets by using key technologies in the project.

(2) Machinery manufacturing and supply
Xi’an Brictec Machinery Equipment Manufacturing Co., Ltd. introduces the latest European brick machinery technology for smooth production domestically. In 2018, Xi’an Brictec built cooperation relationship with Shandong Mine Machinery Cosmec Materials Machinery Co, Ltd, jointly R &D and manufacturing automation equipment for brick making.
1.Cutting machine, setting machine, automatic unloading and packing machine and automatic packaging machine;
2.Ferry car, cone blower, stepping machine, pulling machine, kiln car and other kiln automation equipment;
3.Gas burning system (natural gas/liquefied petroleum gas / coal gas), liquid burning system (heavy oil/waste tire oil), solid fuel burning system (pulverized coal, petroleum coke, rice husk, palm kernel husk, coconut husk, cottonseed husk, etc.)

(3) Installation, maintenance and production guarantee service
Xi’an Brictec provides production, commissioning and maintenance services to brick making factories, helping clients to make bricks easily.

● Project reference from Xi’an Brictec

1.Shaoxing Lvzhan environmental protection technology Co., Ltd

Xi’an Brictec designed this Lvzhan project in 2023. The project has annual output of 300,000㎡ of sintered bricks and prefabricated brick wall by using local solid waste such as chemical contaminated soil, construction residue, printing and dyeing sludge as the main raw materials, etc. so as to make high quality sintered bricks making, and 60%-70% of electricity needed for production line is from the photovoltaic power generation on the factory roof. Xi’an Brictec provides whole package service from the preliminary planning and design of the project to the supply of core equipment in the later stage. Single layer tunnel dryer process is adopted with natural gas burning system for tunnel kiln (7 meters inner width). Xi’an Brictec has delivered a very satisfactory EPC project to our client, and also set a new benchmark for the solid waste recycle and utilization in the industry.

2.Najmadin project in Iraq

This project was jointly designed and implemented by Xi’an Brictec and China National Building Materials Co., Ltd. in 2023, with a daily output of 750 tons of sintered bricks. It is located in Sulaimani Province, Kurdish region of Iraq, and the raw material is shale. Xi’an Brictec has participated in project planning, design, construction and commissioning. Single layer tunnel dryer process is adopted, and Heavy oil/liquefied petroleum gas dual fuel serve as the fuel for dryer and tunnel kiln (9 meters cross-section) . In this project, Xi’an Brictec competes with European production line on the same platform and wins honor for the country. So far the project has been put into production, expecting to meet the production target in May 2024.

3.Antique Bricks Project for Yan'an Green Building Material Recycling Industrial Zone

The project was designed and implemented by Xi’an Brictec as a whole in 2022, mainly to produce antique bricks, facing bricks and paver, etc.. The raw material is high-quality shale and purple sand soil, and the fuel is natural gas. The entire production line combines two shaping methods (extruding and pressing), and uses chamber dryer for drying and tunnel kiln for burning, and integrates three shuttle kilns for antique bricks production. Xi’an Brictec was fully engaged and offer excellent package service in the project in the preliminary process design, dryer construction and core equipment supply and production commissioning. This automatic degree applied in this project is the highest domestically, also meets the advanced international level.

4.Guangdong Baolihua Electric Power Co. Ltd. brick making project with high content fly ash as raw material

Xi’an Brictec designed the whole project and led multiple raw material batching experiments, and finally got the result of 65% fly ash content being the perfect ratio to produce qualified sintered bricks. And because of this project, Xi’an Brictec has obtained the invention patent for making bricks with high content fly ash added.

5.ECO CERMICS project in Bangladesh
This is an EPC project by Xi’an Brictec. Single-layer tunnel drying process is adopted with two 4.8-meter tunnel kilns in use. Bongianni soft plastic extruder from Italy, roller and pulverized coal burner invented by Xi’an Brictec are also applied in this project. Invested by GPH, the 3rd largest cement enterprise in Bangladesh, the production line has the characteristics of highest automation and largest production scale. The factory roof is laid with solar photovoltaic, offering 60% power generation for production line.

6.Uzbekistan Project

The project is for the high-grade brick making production, ranking top three in Uzbekistan. It has two production lines and Xi’an Brictec is responsible for the whole set of cutting, loading & unloading automation system and the natural gas burning system. Client thinks highly of Xi’an Brictec and compliments it as the most reliable partner, offering the easier natural gas burning system with lower energy consumption than European burning system. With the assistance of Xi 'an Brictec, the client uses tire pyrolysis oil to make bricks in its Phase II project, producing high quality bricks under low cost.
Xi 'an Brictec will continue to make breakthrough in every aspects, continuously providing all various tailor-made brick making solutions for our valuable clients!

● Business region

Over 30 countries and regions including China, Russia, Kosovo, Kazakhstan, Uzbekistan, Tajikistan, Vietnam, Malaysia, Iraq, India, Bangladesh, South Africa, Zimbabwe, Peru, Colombia...
In addition, the company has local offices and after-sales service centers in countries such as Iraq, Kazakhstan, Bangladesh, Uzbekistan, Zimbabwe and other.
Adhering to company’s culture and spirit “ Struggle-oriented and customer-centered”, Xi’an Brictec is here to help you make bricks easily!