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What should be done if under-fired bricks or over-fired bricks appear?
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1. Under-fired bricks
During the production of sintered bricks in tunnel kilns, it is often found that there are serious under-fired bricks on both sides of the kiln car bottom, which appear white; their strength is very low, resulting in a high breakage rate of finished bricks.
Reasons:
1. The kiln car is not well sealed, allowing cold air to enter the kiln from the bottom, causing the temperature on both sides of the green brick stack to drop, which is the main reason for under-fired bricks;
2. The pressure, temperature, and atmosphere in the tunnel kiln are unbalanced, with the pressure inside the kiln being lower than that under the kiln car;
3. The internal heat value of the raw materials is insufficient;
4. In pursuit of output, the sintering time and insulation time are insufficient.
Solutions:
1. Check the sealing between kiln cars and the sand seals on both sides of the kiln wall, promptly repair any air leaks in the sand seal grooves, and ensure there is enough sand in the sand seal grooves to prevent cold air from entering the kiln;
2. Adjust the balance between positive pressure, zero pressure, and negative pressure in the kiln, maintain the temperature in each zone of the kiln, reduce the temperature difference between the upper and lower parts of the green brick stack on the kiln car, and ensure normal firing and insulation of the green body;
3. Analyze the internal heat value of the raw materials and appropriately increase the firing temperature;
4. Strictly control the firing and insulation time, ensuring to adhere to 'fixed zone, fixed temperature, fixed time' for firing and insulation, without compromising quality for the sake of output.
2. Over-fired bricks
During the production of sintered bricks in tunnel kilns, bricks in the middle and upper parts of the stack may show bending deformation or bubbles, commonly referred to as exploded bricks or over-fired bricks.
Reasons:
1. The heat formulation in the raw materials is too high;
2. The stacking of green bodies is unreasonable;
3. The firing zone moves forward, and the firing and insulation time is too long.
Solutions:
1. Analyze the mixing ratio of heat in the raw materials and reasonably configure the internal heat value;
2. Improve the stacking method and appropriately increase the gaps between green bodies and stacks;
3. Strictly control the firing and insulation time.
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