1. REFRACTORY BRICK INDUSTRY DESIGN Presented By  Kazi Mahmudul Haque Bhadhon (0611012)  Md. Tanvir Faisal (0611022)

2. TOPICS Introduction Different types of refractory Product selection Reason for selection Market General shapes of products Process layout Raw Materials & Their Composition.

3. INTRODUCTION Refractory Bricks are bricks that can withstand high temperature. A block of refractory ceramic material. Should not spall under rapid temperature change, and their strength should hold up well during rapid temperature changes. Dense firebricks are used in applications with extreme mechanical, chemical, or thermal stresses. In other, less harsh situations, more porous bricks are used.

4. DIFFERENT TYPES OF REFRACTORIES

5. DIFFERENT GRADES OF REFRACTORIES Low-duty (Max. Temp. 1750°F, 24-26% alumina) Medium duty(Max. Temp. 2700°F, 34-38% alumina) High Duty(Max. Temp. 2850°F, 36–40% alumina) Super Duty(Max. Temp. 2900°F, 40–44% alumina) High Super Duty(Max. Temp. 3000°F–3150°F, 40–44% alumina.)

6. PRODUCT SELECTION Fireclay Brick. High Alumina Brick. Insulating Fireclay Brick.

7. REASON FOR SELECTION Applications: Fire Clay Bricks – For lining Iron blast furnaces – Used in annealing, roasting and reheating furnaces; glass melting furnace and other frequently cooled furnace. – Used in flues, chimney linings, steel casting, pottery, cement and fertilizers industries. High Alumina Bricks – Used in very high temperature locations, such as, electric arc furnace roof. – Used in making thermal equipment of metallurgy, petroleum, chemical industry, construction materials, machinery etc. Insulating Bricks – Used in annealing furnaces, forging furnaces, electric arc furnaces and boilers.

8. WHY SELECT(MARKET) Fire clay refractory products are used by almost every industry, which has heat processing in the production process. Iron and steel, cement, petrochemicals, sugar, non-ferrous metal, glass and ceramic industries are some of the user industries. Iron and Steel industries account for 75% of the consumption of refractories. Thus, the demand for refractories is dependent on the growth of iron and steel industries in the country.

9. GENERAL SHAPE OF THE PRODUCTS Most bricks are pressed or extruded. Common shapes are straights, arches, wedges, keys, rotary kiln blocks (RKBs) and square-edge tiles. Figure: Common brick shapes

11. STANDARD SIZES OF PRODUCTS The standard refractory brick size is 9 x 4 ½ x2 ½ inches, also known as one brick equivalent (beq). The different sizes are given below- Straights—the standard straight is 9×4½×2½ inches or 9×4½×3 inches and available in larger sizes up to 18 inches long, 9 inches wide, and 4½ inches thick. Square edge tile —This term refers to “big” straights, which comprise 12×12 inches up to 24×12 inches with thickness ranging from 1½ to 3 inches. Soaps—A term used to describe a half brick in width such as 9×2¼×2½ inches or 9×2¼×3 inches. Splits—A term used to describe a the thickness of a brick thinner than 2½ inches, i.e., splits come in 1, 1¼, 1½, and 2 inch thicknesses.

12. Arch—This shape tapers in thickness along the width over its entire length and is used to make sprung or circular barrel arched roofs either 4½ inches or 6 inches in thickness. Wedge—This shape tapers in thickness along the entire length of the brick and is used to make sprung or circular barrel arches 9, 12 or 13 inches in thickness. Skew—A shape having a certain taper on one side or end to enable a sprung arch to be built. Four major types are available in both side and end skews that relate to the rise of the arch.

13. Specification for High Alumina Brick Al2O3 ≥ 82.5% Fe2O3 ≤ 2.0% SiO2 ≤ 11.5% Bulk density ≥ 2.7 gm/cc Apparent porosity ≤ 23%

14. Specification for High Silica Brick SiO2 ≥ 96% Fe2O3 ≤ 0.8% (Al2O3+R2O3) ≤ 0.5% True density ≤ 2.34 gm/cc Apparent porosity ≤ 22%

15. PROCESS LAYOUT Figure: Process flow chart.

16. RAW MATERIALS Bijoypur Clay. Black clays: bought from Ashulia. Red clay. Quartz. Granular grog. Feldspar. Bauxite. Saw dust.

17. COMPOSITION OF CLAYS Bijoypur clay – Al2O3 (28-30%) ; SiO2 (68-70%) ; FeO (Traces) Black clay – Al2O3 (26-28%) ; SiO2 (70-72%) ; Others. Red clay – Al2O3 (22-23%) ; SiO2 (75-78%) ; Others.

18. RAW MATERIALS PROCESSING  Steps Involved in Raw Material Processing → Crushing & Grinding → Pre-Treatment(optional) → Screening → Mixing

19. CRUSHING & GRINDING Raw materials are ground to obtain proper sizes of materials Common equipments are various types of crushers, pulverizers, hammer mills, ball mills, pan mills etc. JAW CRUSHER will be used as Cost effective Time efficient

20. Figure: Jaw Crusher

21. PRE-TREATMENT Molded firebricks or refractories shrink considerably during firing. To reduce this shrinkage, the raw materials are generally pre-treated i.e. fired/calcinated at higher temperature for considerable periods of time which bring about the complete mineral conversion and hence stabilizes the material. The Goal can be achieved by using GROG.

22. PRE-TREATMENT (CONTD.) The raw materials for insulating bricks need some additional pre-treatments. The highly plastic “Black Clay” (or, ‘Ashulia Clay’) is mixed with sawdust and water and kept under shade for about one month which enables it to mix in the highest compactness and with uniform distribution of the sawdust.

23. SCREENING Sorting out desired sized materials from a wide size distribution. Screening of the materials being crushed is necessary so that the required product can be passed on to the brick making machinery and the coarser material returned to the crushers. Can Be Done By Screening Net Shaking Screen Machine

24. Figure: Vibrating screen

25. MIXING Composition of brick is adjusted by blending of different minerals, fluxing/binding agent. Blending is carried out not only by composition but also by size. The ratio between the course and the fine fractions are maintained to get the desired packing density. Control of ultimate porosity and strength can be possible. PUG MILLS

26. Figure: Pug mill (Puratek double shaft U mixer)

27. MOULDING  Hand Molding  Dry press process Uniaxial Pressing Machine  Semi-dry process  Slip casting etc.

28. Figure: Hydraulic press machine

29. DRYING To minimize shrinkage during firing. To reduce cracking and distortion. Can be done by, Natural Drying Forced Drying Flue gas from the Tunnel Kiln.

30. FIRING A number of kilns can be used Tunnel Kiln Beehive Oven Hoffmann Kiln Vertical shaft Kiln WHY TUNNEL KILN? Continuous Process High Production Rate More Economic Relatively Fast Process

31. MACHINING Especially for insulating firebricks, the evaporation of volatile matters cause deformation or dimensional changes of the brick. Other type bricks may also require finishing. For this reason, after firing the bricks are machined to close dimensions possible.

32. STORAGE Fired, machined products are stored in shelves in sheds according their type. The humidity level, temperature, air flow etc. inside the shed should be maintained to exact suitable conditions.

33. TRANSPORT Raw Materials Transport 5 Trucks Products Transport 5 Trucks

34. PROJECT IMPLEMENTATION Serial noActivityPeriod (months) 1a) Selection of Site. b) Provisional Registration. 2 2a)Availability of Finance. b)Construction of Building. c)Procurement of Machinery & Equipment. d)Availability of Electric Power, Gas & Water Supply,. 4 3a)Recruitment of Manpower. b)Trial runs. 2 Total implementation period8 Implementation Schedule

35. FINANCIAL ASPECTS(Total Capital) ParticularsArea(sq. m)Rate (Tk.)Value (Tk.) Land250010,0002,50,00,000 Built-up Area Office and Stores1005,0005,00,000 Workshed6002,0001,20,0000 Total2,67,00,000 A) Fixed Capital 1) Land and Building

36. DescriptionOriginQuantityRate (Tk.)Value(Tk.) a) Production Unit Vibrating Screen Pug Mill(Puratek Double shaft U mixer) Hydraulic Press Tunnel kiln(Gas fired) Moulds, Tools and other fixtures Office equipment/working tables etc 21112111 2,50,000 90,00,000 5,00,000 2,50,000 b) Testing Equipment CCS Testing Machine RUL Testing Machine Muffle Furnace Drying Oven Vibrating Sieve Misc. Lab. Items 1111111111 Total 2) Machinery and Equipment

37. WORKING CAPITAL 1)Personnel (per month) DesignationNos. Salary (Tk.) Total (Tk.) Administration and Supervisory Manager Supervisor Salesman Clerk Watchman 1212212122 20,000 12,000 7,000 6,000 4,000 20,000 24,000 7,000 12,000 8,000 Technical: Skilled and Semi or Unskilled Skilled workers Unskilled workers Technician 10 15 2 6,500 4,000 9,000 65,000 60,000 18,000 Total2,14,000

38. 2) Raw Materials ParticularsOriginQty.RateValue(Tk.) Bijoypur clay150 ton Black clay100 ton Red clay50 ton High alumina grog50 tonTk. 5/kg2,50,000 Bauxite700 kgTk. 300/kg2,10,000 Quartz, Feldspar, Saw dust Total1000000

39. 3) Utilities(per month) ParticularsValue (Tk.) Natural gas : 90,000 cu. ft @ Tk. 8 / cu ft 7,20,000 Power : 2500 unit @ Tk. 5 / unit 12,500 Water : 300 KL @ Tk. 30/ KL 9,000 Total7,41,500

40. 4) Other expenses ParticularsValue(Tk.) Postage, stationery, telephone, taxes5000 Consumables, repairs and maintenance15000 Transport charges10000 Advertisement and Publicity and sales expenses8000 Misc. expenditure5000 Insurance3000 Incidental cost5000 Total51000 Total working capital (3 months basis)20,06,500

41. TOTAL CAPITAL INVESTMENT ParticularsAmount (Tk.) Fixed capital2,67,00,000 Working capital20,06,500 Total2,87,06,500

42. FINANCIAL ASPECTS 1) Production cost (per year) DescriptionValue Total recurring cost80,26,000 Depreciation on Building Kiln Moulds Machinery and Equipment testing equipment and office equipment 6,00,000 Interest on capital investment at 8% 22,96,520 Total1,09,22,520

43. 2) Sales turnover ItemQty.RateValue Firebricks3,00,0003296,00,000 High Alumina bricks 2,00,000511,02,00,000 Insulating firebricks 1,50,0004364,50,000 Total2,62,50,000 3) Net profit (per year) Tk. 2,62,50,000− Tk. 1,09,22,520 = Tk. 1,53,27,480