FLOWCHART / GUIDELINES FOR HANDMOULDED BRICK PRODUCTION IN VSBK FIRING SYSTEM
SOIL
Remove
Cut the soil
Roots/Stones
and build up a pile
Check for lime
and large
granular stones
STONE DUST /
FINE SAND
Sieve through
Measure a fixed
3mm mesh
volume of sand/stone dust
Check for lime
with acid
BURNT COAL
Sieve through
Measure a fixed
ASH
3mm mesh
volume of burnt coal ash
e.g. sponge iron
Sieve through
Measure a fixed
waste, foundry
3mm mesh
volume of internal fuel
DRY MIXING
Cut the pile and mix the
INTERNAL FUEL
waste, coal dust
AGEING
Add water - mix thoroughly
materials at least twice
and cover with plastic sheet
in dry state before
to prevent evaporation.
adding water
Store wet mix for minimum
1 day, preferably 3 days +
Check CV of each
batch of internal fuel
delivered and record
RICE HUSK
Measure a fixed
volume of rice husk
WATER
Ensure floor is
EXCESS CLAY
clean and level
FROM MOULD
Check plasticity and
Sand to be sieved
moisture content
through 2mm mesh
STOCK
ROLL CLAY IN
FILL MOULD
APPLY PRESSURE
CUT OFF EXCESS
SHOVEL
MOIST CLAY ON
SAND AND MAKE
WITH SOIL
BY HAND AND
SOIL WITH
AND SMOOTH
HAND CART
HANDMOULDING
A WEDGE
UNDER PRESSURE
STRIKE ON FLOOR
BOW CUTTER
SURFACE BY HAND
FLOOR
Use red burning
Clean mould after
sand
every 50 bricks
Mould dimensions to
Experiment with
be checked weekly
different frog designs
to reduce brick weight
Sprinkle interior
with clean, dry
sieved sand
SPRINKLE DRY SAND
Dried bricks going to kiln
Weigh and measure brick dimensions
to be <5% MC (dry basis)
Ensure that loading trolley /
content and record. Compare bricks
made by different moulders
Ensure weekly maintenance
of belts, wire rope, motor.
daily before going to kiln. Check moisture
Calculate % wastage and
conveyer belt is not
causes of waste.
overloaded
DRY TO
STACK BRICKS
DEMOULD
LEATHER
IN DRYING
DRY GREEN BRICK
LIFTING OF
ONTO FLOOR
HARD STATE
STACKS
TRANSPORT
GREEN BRICKS
Ensure floor is
Keep distance
Reject broken or
Transport green bricks by
clean and level
as short as
damaged bricks
mechanized means
possible and
- Lift
clean and level
- Winch
Wherever possible avoid
Handle green bricks with
handling the brick more than
care to avoid damage.
once. Preferably the trolley for
Stack bricks at least 1 cm apart.
transporting the bricks should
Drying stacks should be
be used from drying area to
on a burnt brick layer.
top of the kiln
- Conveyer belt
Any changes to the clay mix amount of
internal fuel and its current CV to be
notified to the firemaster.
Always maintain a dense loading pattern at the
centre after stabilization.
Compare quantity of bricks loaded
Spread coal uniformly at the periphery only.
Check weigh
Check fired brick for size,
into kiln and quantity going into
colour and ring to
stockyard to calculate process
establish if coal additions
wastage and determine causes of
need adjustments.
wastage.
scale accuracy
Check CV of each
delivery of coal
Monitor fire position and
Weigh and
Determine loading,
EXTERNAL FUEL
flue gas temperature prior
measure 10
transportation and
(COAL)
to unloading and loading.
and record
bricks daily
unloading breakage and
and record.
determine causes
VERTICAL
LOADING OF
LOADING OF
SHAFT
UNLOADING
PLATFORM
SHAFT
BRICK KILN
OF BATCH
Keep the brick stack
Ensure correct
Rate of loading and unloading
height at the same
setting pattern is
to be set to stabilize the
level with shaft top to
followed and coal
position of the fire and as per
ensure good ventilation.
is added to the
quality desired
Ensure that the structure
layer as instructed
not overloaded
Open dampers and lid when
Maintain proper coal
loading. After loading is complete
size and quantity
close lid and dampers
STOCKYARD
DESPATCH