Direct setting of clay bricks and blocks

The principle of direct setting on wagons consists of loading the dryer with raw bricks on kiln wagons, and is specially designed for clays with low drying shrinkage and high mechanical resistance, allowing extrusion with low humidity and high pressure (stiff extrusion).

This type of dryer uses the kiln wagons to transport the raw bricks to the drying installation, which allows a smaller number of loading and unloading devices.

In addition, this type of dryers allows to increase its capacity of simultaneous production, based on the acceleration of the kiln production rate, with a low investment in mechanisms, a reduction of the general maintenance of the plant and a better optimization of the production process.

Case Studies

Need:

In Algeria, our Customer El Rym needed to build a factory with a capacity of 800t/day, equivalent to 280.000t/year, with a direct setting on kiln car dryer process.

Solution and Results:
In order a get a granulometry in the preparation area, lower than 1mm, Verdés installed two hammer mills, each with 55t/h capacity, with screen system and storage in big silos (each with a capacity of more than 120m³). And in order to produce bricks with high mechanical strength which allow the direct setting on kiln car dryer, Verdés installed a COMBI 077 C-65 extruder which actually works with a pressure between 23 and 24 bars.
Need:

In Malaysia, Hap Kee, Verdés customer since many years ago, wanted to install a new direct setting line in his brick plant and was confident again in Verdés machines and experience.

Solution and Results:
This new line is designed in order to achieve a daily production of 700 tons. The preparation process is a semi wet process, using primary crushers 117FT and one 127C disintegrator. The homogenization in both, preparation and shaping areas, in done using 046C mixers, and the extrusion is done using two Magna 675, specially designed in order to be able to work with pressures above 30 bars. Actually the line produces solid bricks for direct setting on kiln cars and is prepared for hard extrusion process (Stiff extrusion).
Need:

In Portugal, the Preceram Group, SA; owner of three brick plants (Preceram F1, F2 and Preceram North), equipped with machines Verdés for dry and wet process preparation, wanted to build a factory in order to work with direct setting on kiln car dryer process.

Solution and Results:
At the Preceram F2 brick plant, the clay preparation is done using the wet process, with a Verdés 117-DT primary crusher, continued with a wet pan mill, storage with reclaimer, Verdés 045-C mixer, Roller mill and a 069-D extruder which actually works with a pressure between 22 and 24 bars and with a production higher than 300t/day of big format bricks and almost exclusively thermobricks.
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