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[August 2005]
Keller Reproduces Traditional Effects on New Petersminde Plant
Reproducing the traditional colours and dimensions of the water-struck bricks at Petersminde Teglvaerk A/S (Stenstrup, Funen, Denmark) was a key requirement demanded of the modern kiln, now installed, which was ordered from Keller HCW GmbH (Ibbenbueren-Laggenbeck, Germany) to replace the decommissioned arched tunnel kiln.
Petersminde produces around 25 million Danish standard size water-struck bricks per annum, with further sizes such as German NF, DF and RF also being manufactured. The setting patterns employed are upright cross-bonded or double flat, a peculiarity being the disc-shaped rounded setting which is parallel to the tunnel kiln car transport direction.
The new Keller tunnel kiln, made of traditional brickwork with a gas-tight inner steel skin on three sides, has been designed for a firing temperature of 1200C and a firing time of approximately 50 hours. For the design of individual units, a reserve capacity of up to 30% had to be considered.
A warm storage for six tunnel kiln cars, heated by waste air from the preheater, is arranged in front of the kiln and the preheater is sited in front of the warm storage. The kiln is a closed system and as a result it is possible to adjust a defined pressure profile in the firing zone of the kiln. Apart from the usual sand seal and labyrinth design, the undercar has a special wheel cooling system.
For heating, high velocity gas side burners are provided as upper and lower burners with the burner control system working in cycles or pulses. This arrangement allows a multitude of setting methods with different format sizes. For the automatic initial heating-up of the kiln, ignition burners with flame control devices are installed at the end of the firing zone.
For colouring, an important part of the project, the reduction burner groups are also designed as high velocity side burners. A gas top burner is installed next to the side reduction burners. An oil burner group is provided for flashing the bricks. An automatic coating plant with several injection lances is provided for the special colour effects. Dosing of coal to each lance is controlled by a special reduction programme in the Keller HCW K-Matic automation programme in order to achieve individual colour effects.
www.keller-hcw.de
ENDS