Description of the Technology: The HHK is a hybrid version of the Hoffman Kiln technology that was developed in Germany

in the mid-nineteenth century. Since then, it has been redesigned to improve heat retention in the kilns and to capture waste heat for recirculation in the drying tunnel. n addition, coal consumption is reduced by introducing pulveri!ed coal into the wet clay in each brick which then bakes the brick from the inside. The designed production capacity of a Hybrid Hoffman Kiln may vary from minimum "#,### bricks per day to several multiples of "#,### bricks per day. The si!e and scale of each $new technology% kiln is such that it replaces &." kilns of the older technology.. The energy consumed per brick for the HHK is "#' less than those produced for the ()K. Hence, for each operational HHK, the assumed )*+ emissions reductions were calculated to be ","," tonnes. -nergy savings from each HHK installed .and replacing &." ()Ks/ is in the order of &0 tera1oules or +# G2Hr. The energy efficient Hybrid Hoffman Kiln .HHK/ improves energy efficiency in two ways3 through internal combustion of in1ected fuel in green bricks and the application of heat optimi!ation techni4ues in the combustion !one of the kiln. *n the one hand, granulated coal is in1ected into forming the green bricks resulting in lower energy usage, higher 4uality bricks and reduced pollution and on the other, the kiln is designed to combust the dried green bricks at predetermined temperatures in a minimum heat loss chamber. 5ricks of any si!e, shape and pigmentation can be produced at the plant with minor modifications. 6ll bricks are e7pected to be of uniform 4uality and will meet international standards for strength, 4uality and appearance, which cannot be achieved in the energy inefficient kilns .- Ks/. The HHK is a hybrid version of the proven Hoffman kiln. Structurally, it is built like the Hoffman but, unlike the traditional Hoffman, the fuel used is coal. The kiln can be made from firebricks or from green bricks. n the latter event, the green bricks get $cooked% during kiln operation. The inner kiln lining is made from refractory bricks and then plastered over by refractory cement. The firing chamber can be filled manually or automatically with green bricks, usually about ",### to ,### units at one time, in line stacks of around 8,###. Thus, there are " line stacks9 and the firing time for each line stack is about half an hour. The fuel, granulated coal, is fed into the firing !one in the kiln through stoke holes on the roof. 6ir re4uired for the combustion process is forced from behind9 and, as it reaches the line to be fired, it is already preheated from the previous firing
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!one thus reducing firing time and energy usage. The temperature in the firing !one is about :###). The process is e7tremely simple and is carried out manually. n addition to kiln efficiency, green bricks are in1ected with pulveri!ed coal, a techni4ue commonly used in )hina to make bricks. This techni4ue enables improved thermal bonding and reduces fuel usage, and hence )* + and other emissions. )lay is premi7ed with granulated coal and then e7truded to produce the green bricks. This is a uni4ue process that is fundamental to the energy efficiency achieved in brick making in )hina. 6lmost :#' of the total energy re4uired is in1ected into the bricks and only about +#' is fed e7ternally into the firing chamber. ;ost of the fuel mi7ed into the bricks is almost completely burnt during firing. The Production Process Clay Extraction, Transport and Preparation - The clay is e7cavated by hydraulic e7cavator or by hand from a nearby area and transported to the plant-stacking yard by trucks. The clay is then crushed by means of roller mills, followed by a double-shaft mi7er, where water is added to ensure 8"' moisture content. Introduce pulverized coal and shape the brick - <ulveri!ed coal is mi7ed with the clay which is fed into a vacuum e7truder. 6 column of clay is pushed out=e7truded. This is then cut into the green bricks which are then manually loaded onto a drying car for drying. Brick Drying - The drying car is then moved into the drying tunnel. The drying cycle lasts for about +, hours. The hot air in the drying tunnel is sucked in from the annular kiln. Brick iring - The dried green bricks are then removed from the drying tunnel and loaded manually into the annular HHK kiln. The speed of the firing is 8.+"m=h at a sintering temperature of about >"#o) - 8#"#o). The fired bricks are unloaded and conveyed manually in carts to the stacking yard. (igure 83 Graphical representation of HHK brick manufacturing process

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Step # $: ;i7ing of coal with clay

Step # !: pouring coal for firing

Step # ": (inished bricks

coal
Mi#er

-7haust smoke are being channali!ed through this underground smoke tunnel to dryer to dry Green bricks inside. Automatic Brick Making Machine

Step # : dried bricks in kiln for firing

?ried bricks

Step # 23 Green brick putting into the dryer Step # 33 5rick are being dried

)lay stack
Seasoning of clay

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