Data of product

Benefits of Using Natural Gas Combustion Systems in Brick Factories

In Terms of Product Quality

1. Precise Temperature Control

• Natural gas combustion systems can achieve precise temperature control.The natural gas combustion system, through advanced burners and control systems, can accurately adjust the flame size and temperature to ensure that the brick blanks are in a suitable temperature environment at each stage, making the quality of the bricks more stable.
• Compared with the traditional coal combustion method, the temperature fluctuation of coal combustion is relatively large and difficult to control precisely. This may lead to quality problems such as cracks and deformation of the bricks, while natural gas combustion can effectively avoid these situations.

2. Good Firing Uniformity

• The flame generated by natural gas combustion is relatively uniform. The combustion process involves fully mixing air and natural gas in the burner before combustion, and the flame can be evenly distributed inside the kiln. This ensures that the brick blanks are heated evenly at all positions inside the kiln, avoiding local overheating or underheating.
• For example, when using a natural gas combustion system in a tunnel kiln, the brick blanks slowly pass through the kiln on the conveyor belt, and the uniform flame can ensure that each brick is fired to the same extent, thereby improving the quality consistency of the entire batch of bricks. The performance indicators such as the color and strength of the products are more uniform.

3. Beautiful Product Color

• Natural gas combustion produces fewer impurities. When firing bricks, it will not have a large amount of coal ash and other impurities adhering to the brick surface like coal combustion does. This makes the brick surface smoother and the color more pure.
• For example, for some colored bricks or fair-faced bricks used for the exterior decoration of buildings, using natural gas for firing can better present the colors required by the design, improving the aesthetics of the products and enhancing their competitiveness in the building materials market.

In Terms of Environmental Protection

1. Reduction of Pollutant Emissions

• Natural gas is a relatively clean energy source. The combustion of natural gas mainly produces carbon dioxide and water, and hardly generates pollutants such as sulfur dioxide, nitrogen oxides, and particulate matter. Compared with coal combustion, the sulfur dioxide emissions during natural gas combustion can be reduced by more than 90%, the nitrogen oxides emissions can be reduced by 50 - 60%, and the particulate matter emissions are significantly reduced.
• This is very important for improving the air quality around the brick factory. Especially with increasingly strict environmental regulations, using a natural gas combustion system can make it easier for the brick factory to meet environmental standards and reduce the risks of fines and rectification due to environmental pollution.

2. Potential for Greenhouse Gas Emission Reduction

• Although the combustion of natural gas also produces carbon dioxide, from a life-cycle perspective, the carbon dioxide emissions per unit of energy generated are lower than those of traditional fuels such as coal. Moreover, with the continuous progress of natural gas exploration and transportation technologies, its carbon footprint has the potential to be further reduced.
• In the context of the global response to climate change, the use of natural gas combustion systems in brick factories helps to reduce greenhouse gas emissions, fulfill the corporate social responsibility, and enhance the green image of the enterprise.

In Terms of Production Efficiency

1. High Combustion Efficiency

• Natural gas and air can achieve good premixing in the burner, making the combustion more complete. The combustion efficiency can generally reach more than 90%. In contrast, the combustion efficiency of coal is usually around 60 - 80%.
• This means that under the requirement of the same heat output, less fuel is needed when using natural gas, which can reduce production costs. Meanwhile, efficient combustion can also heat the kiln to the required temperature more quickly, shortening the firing cycle of bricks and improving production efficiency.

2. High Degree of Automation

• The natural gas combustion system can be equipped with advanced automatic control equipment. Through sensors, controllers, and actuators, automatic adjustment of the combustion process can be achieved, including real-time monitoring and adjustment of parameters such as gas flow, air flow, flame size, and temperature.
• For example, when the temperature inside the kiln deviates from the set value, the control system can automatically adjust the supply amounts of natural gas and air to quickly restore the temperature to the normal range. This automatic control not only improves the stability of the production process but also reduces the need for manual intervention, lowers the labor intensity, and makes the production management of the brick factory more convenient and efficient.

In Terms of Safety and Stability

1. Stable Supply

• Natural gas is transported through pipelines. As long as a stable supply contract is signed with the gas supplier, generally there will be no situation like the interruption of coal supply affected by transportation, weather and other factors. This can ensure the continuity of the brick factory's production and avoid production losses caused by insufficient fuel supply.

2. Good Safety

• The natural gas combustion system itself has certain safety designs. For example, natural gas pipelines usually have complete leakage detection devices. Once a leak occurs, it can give an alarm in time and take measures. Moreover, the safety during the storage and transportation of natural gas is relatively high. Compared with the risks such as spontaneous combustion during coal storage, the potential safety hazards of natural gas are relatively small.

● 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!