The Spanish company Beralmar has received an order to supply a new production line for the Boshan ceramics company, a few miles from Astana, the capital of Kazakhstan.
The order includes a Llevant direct kiln car stacking dryer and a Presthermic airtight tunnel kiln. The three tunnels (two for drying and one for firing) are designed with the following dimensions:
106 m length
4.70 m useful width
1.54 m useful height
The low height is to cater for the kiln car stacking equipment. Nominal production is 30 mill. NF/year (around 325 t/day) of various solid, hollow and thermoclay formats.
It is not always possible to install production lines with dryers for directly stacked green material on kiln cars as it depends on the suitability of the clay available and the formats to be manufactured. But when it is technically viable, as in this case, it has numerous advantages, above all:
Low energy consumption: the combined energy consumption anticipated for drying and firing is 330 kcal/kg
Low automation and therefore lower investment costs, fewer production stoppages
The only fuel available for the project is coal with a low calorific value (> 4500 kcal/kg). To meet this technical challenge, a Promatic firing facility for the kiln and a GBS/1500 heat exchanger will be installed. On the other hand, the price of this fuel is moderate and this, combined with the low energy consumption of the planned line, will lead to energy bills that will undoubtedly be one of the keys to the competitiveness of this new ceramics plant.
Beralmar Tecnologic S.A.