zig-zag company is the best Bhatta making company in India .zig zag company works across India. zig zag company specializing in construction bricks fields with the latest technologies like zig-zag technology and high draught technology. throughout our history, we were succeeded by providing a wide range of construction solutions to our clients and delivering a whole lot of quality work. we construct a unique platform of Bhatta in pan India.
Chimney Destruction within one day
Our company provides the facility of chimney destruction within one day by the experts. Somebody wants the destroy the existing brickfield, Our experts destroy within minimum time. We destroy the chimney without any Bomb. 80 Percent of bricks will be safe after the destruction of the chimney.
what is the need for the destruction of the chimney?
1.when we become zig-zag kilns, we have to increase the height of the chimney and also increase the diameter of the chimney hole. so we need to
2.the height of the zig-zag kiln allowance must be at least 140ft and the height of the chamber is 11ft.
3. Due to the chimney diameter being low, the chimney has to fall and rebuilt.
Types of a zig-zag kiln
1-NATURAL ZIG ZAG KILN
2-HIGH DRAUGHT KILN
3-HYBRID HOFFMANN KILN
what is the need to use zig-zag kiln technology
1-Zig zag kiln technology used to reduce air pollution and improved the quality of bricks.so we can use this technology.
2-reduce the quantity of coal so.we can use this technology.
High Draught Kiln technologies that are more energy efficient and cause lesser pollution.One such technology named fixed chimney Zig – Zag kiln .The Zig-Zag kiln or the High Draught kiln is similar firing technologies with essential variations in brick setting patterns where the kiln basic structure remains same. The principle followed in this family of high draught kiln types is to prolong the travel path of fire. This high thermal efficiency of the kiln reduces fuel consumption by 25%. The earliest type of this technology was termed as Zig-Zag kiln and high draught kiln developed in the early 1900s. Various reforms were also built which were relatively inexpensive variants adopted by small brick manufacturers. The design of this type of kiln ensures continuous operation of the kiln.
One of the more developed variant was The Habla Kiln. It was essentially an arch less zig-zag kiln patented in 1920 by British Engineer A. Habla. This had very wide and continuous open firing channels. Unlike zig-zag variants there were no permanently built dividing walls. Thus, the energy savings were higher. However the most important aspect of this kiln was that bricks could be loaded into the firing spaces through vehicular movement.
In Asian countries of India, Nepal, Bangladesh and Pakistan the High Draught or HD Kiln is the most popular technology of Zig-Zag firing. Their difference with European variation is the absence of any dividing walls. In the European variety of HD kilns, the length of the kiln gallery is increased by zigzagging the chambers and the fire follows a zig-zag path instead of a straight path followed in BTK. In the early 1900s, these types of kilns were widely used in developed countries particularly in Germany and Australia. In Europe, the interior cross-section of the kiln used to be small in original zig-zag kilns (7.5 ft wide x 7.5 ft high) and the kiln used to have 16-20 chambers each 20-25 ft long. Fan draught was provided and the kiln operated on high draught at a very fast rate of fire travel (50-100 ft per day).
The High Draught or HD Kiln in India also follows the Zig-Zag firing concept. The Indian variation has several similarities with the Habla kiln. The kiln consists of a rectangular gallery which is divided into 24 chambers by providing temporary partition walls with green bricks. The wall of each chamber runs along the width of the gallery except one end, wherein a space of 60 to 65 cm is left for communication to next chamber. Draught is created by an induced draught fan with a 20-35 HP motor for proper combustion of fuel. Depending on the design capacity of a kiln, a chamber can hold 7,500 to 15,000 bricks. Normally, two chambers are fired per day and an output of 15,000 to 30,000 bricks per day can be obtained. When brought to full firing, the kiln operates on a draught of 50 mm hg. High Draught kiln is a series of batch process kilns. Hoffmann kilns are the most common kiln used in production of bricks and some other ceramic products. Patented by German Friedrich Hoffmann for brick making in 1860, it was later used for lime-burning, and was known as the Hoffmann continuous kiln. The first Hoffmann kilns were in the form of a great circular ring chamber, with massive walls and a large chimney at the centre, to which underground radial flues converged from the inside walls of each of the twelve chambers. The barrel-arched chambers (like a railway tunnel) have several small feed holes in the roof arches through which fine coal could be fed into spaces made among the bricks to be fired.
The Hoffmann kiln is a series of batch process kilns. Hoffmann kilns are the most common kiln used in production of bricks and some other ceramic products. Patented by German Friedrich Hoffmann for brick making in 1858, it was later used for lime-burning, and was known as the Hoffmann continuous kiln.
The first high draught kiln were in the form of a great circular ring chamber, with massive walls and a large chimney at the centre, to which underground radial flues converged from the inside walls of each of the twelve chambers. The barrel-arched chambers (like a railway tunnel) have several small feed holes in the roof arches through which fine coal could be fed into spaces made among the bricks to be fired.
Around the outer wall or the kiln were the twelve openings for loading and unloading the individual firing chambers. These chambers were separated from each other by very large metal dampers that could be raised and lowered as the fire moved around the kiln from chamber to chamber.
Once the kiln is lit it is allowed to go out, and the sequence of operation is continuous. At regular intervals, the firing zone is moved forward and the corresponding changes made to the dampers between the chambers and into the chimney.
The chambers being loaded and unloaded move forward in sequence, and this way heat is extracted from the cooling bricks and also from the hot combustion gases. As the fire passes round the kiln, the chambers in front of the actual firing zone are gradually warmed and the chambers behind cool off slowly.
The zigzag firing concept was first used in the Buhrer Kiln, which was patented in 1868 by Jacob Buhrer of Switzerland. The Buhrer Kiln was similar to a Hoffmann Kiln in construction. The main innovation was the zigzag path of airflow. The zigzag path increased the distance traveled by air in the kiln and created turbulence. A fan was used to induce the necessary draught for the airflow.
The zigzag firing concept was later used in Habla Kilns, which were widely used in Germany between the first and second World Wars. They were also popular in Australia. In India, the Zigzag Kiln was first introduced by the Central Building Research Institute (CBRI) during the early 1970s, which was later replicated in Bangladesh and Nepal. These kilns were called Induced/High Draught Zigzag Kilns as they used a fan to create draught for airflow in the kiln.
In the past 40 years, many modifications have happened to the original design and several different variations of High Draught Zigzag Kilns can be found in the field. In recent years, some brick makers have modified the brick setting and practices and are successfully operating the kiln with the natural draught of the chimney without using a fan.
What are the main characteristics/features of Zigzag Kiln technology?
The main characteristics/ features of Zigzag Kiln technology are as given below.
Zig-zag brick Kiln is of rectangular shape. The bricks are fired in the space (called ‘trench’ or ‘dug’) between the rectangular central part of the kiln and the rectangular outer wall of the kiln.
The chimney can be located either at the centre of the kiln or on any side of the kiln.
It is a continuous moving-fire kiln in which the fire burns continuously and moves in a closed rectangular circuit through the bricks stacked in the trench.
The draught required for the flow of air in the kiln is created either by the chimney or by a fan.
In Zigzag Kilns, the bricks are stacked in a manner such that distinct chambers are formed in the brick setting. In alternate chambers, the openings for the flow of air through the brick sets are provided in such a way that it causes the zigzag flow of air in the kiln.
Usually, solid fuels such as coal, wood, sawdust, and agriculture residues are used in Zigzag Kilns.
The size (footprint) of the kiln is generally 65–100 feet (20–30 m) in width and 200–250 feet (60–75 m) in length.
Typical production capacity: 20,000–50,000 bricks per day.
Capital investment required: Rs 30 lakh to Rs 50 lakh (excluding the cost of land and working capital).
Area of land required: 4–6 acres (15,000–25,000 square metres) excluding the land required for excavation of clay.
Seasonal operation: the kiln operates during the dry season only.
What are various types of the zigzag brick setting being practised in Zigzag Kilns?
Single zigzag brick setting (one zigzag air flow stream)
In Zigzag Kilns, air flows in a zigzag path. There can be one, two, or three parallel zigzag airflow streams in a kiln. Accordingly, the airflow and the brick sets are called single, double, or triple zigzag airflow and single, double, or triple zigzag brick setting, respectively.
Depending upon the trench width and the draught available in the kiln, single, double, or triple zigzag brick setting is practised in the kiln. For the same trench width, the draught required for airflow in a single zigzag brick setting is higher than that required in the double and triple zigzag brick setting. Also, the draught requirement increases with increase in trench width. Nowadays, in some of the bigger kilns, the quadruple zigzag brick setting is also practised in which there are four parallel zigzag airflow streams.
What are the types of Zigzag kilns?
Zigzag kilns are of two types.
Natural Draught Zigzag Kiln (NDZK), in which the draught required for airflow in the kiln is created by the chimney.
high draught kiln technology increases the quality off bricks.
high draught kiln design is very different from zig-zag batata technology.
What are the differences between Natural Draught Zigzag Kilns and Induced Draught Zigzag Kilns?
high draught kiln
Draught for airflow
Chimney creates the draught required for the airflow.
The fan creates the draught required for the airflow.
Role of chimney
To create necessary draught as well as to expel the flue gases at a certain height as required under environmental rules.
Mainly to expel the flue gases at a certain height as required under environmental rules.
Taller chimney (130–150 feet high); the height of the chimney is usually determined by draught requirement.
Height of the chimney is relatively lower (80–90 feet); height is usually determined by environment rules.
Kiln operates at lower draught (6–8 mm water column).
Kiln operates at higher draught (30–50 mm water column).
Usually, double or triple zigzag brick settings are practised.
Usually, a single zigzag brick setting is practised.
Relatively loose brick setting (no. of bricks per unit volume is lower).
Relatively denser brick setting (no. of bricks per unit volume is higher).
Not required in the operation of the kiln.
Required in the operation of the kiln (to power fan).
What is the typical performance of Zig zag brick Kiln technology?
The performance of Zigzag Kiln technology in terms of energy consumption, product quality, and pollutant emission is given below.
Specific energy consumption (SEC) of Zigzag kiln technology: 0.95–1.15 MJ/kg of fired bricks.
Usually, over 80% of the bricks produced in a Zigzag kiln are of Class-1 quality. The remaining are either over-burnt, under-burnt or breakages.
The emission of particulate matter (PM) in the flue gases is in the range of 30 to 250 mg/Nm3 or about 0.23 g/kg of fired bricks.
What are the main advantages of Zig zag brick Kiln technology?
Zigzag Kilns have several advantages over the traditional FCBTKs:
About 20%–25% savings in fuel consumption.
Better product quality – over 90% of bricks are of Class-1 quality.
Substantial reduction in carbon dioxide (CO2) and PM emissions.
zig zag Bhatta price
zig zag Bhatta price depends on your city. In India, the price of the material is different for each city. If you want to make zig-zag kiln then the below material will be required.
zig zag Bhatta price depends on your location.
zig zag Bhatta design
zig zag Bhatta & high draft Bhatta
High Draught Kiln technologies that are more energy-efficient and cause lesser pollution.One such technology named fixed chimney Zig – Zag kiln. The Zig-Zag kiln or the High Draught kiln is similar to firing technologies with essential variations in brick setting patterns where the kiln basic structure remains the same. The principle followed in this family of high draught kiln types is to prolong the travel path of the fire. This high thermal efficiency of the kiln reduces fuel consumption by 25%. The earliest type of this technology was termed as Zig-Zag kiln and high draught kiln developed in the early 1900s. Various reforms were also built which were relatively inexpensive variants adopted by small brick manufacturers. The design of this type of kiln ensures continuous operation of the kiln. One of the more developed variants was The Habla Kiln. It was essentially an arch less zig-zag kiln patented in 1920 by British Engineer A. Habla. This had very wide and continuous open firing channels. Unlike zig-zag variants, there were no permanently built dividing walls. Thus, the energy savings were higher. However, the most important aspect of this kiln was that bricks could be loaded into the firing spaces through vehicular movement. high draught Bhatta is very using full technology in the fields of bricks kiln.
zig zag Bhatta video
watch more the 30 zig-zag Bhatta video on our youtube channel.
Click below link and watch the zig-zag Bhatta & high draft Bhatta video
Zig-zag chimney Bhatta offers a 20-25% reduction in Specific Energy Consumption (SEC) and up to 75% reduction in SPM emissions over Sada Bhatta FC-BTK. A higher percentage of Class I bricks are produced as compared to FC-BTK (80-85% Class I bricks as compared to 55-60% in FC-BTK).
There is an option for easy retrofit of FC-BTK to natural draught Zig-zag kiln. Savings from reduced fuel consumption and an increase in revenue due to a higher percentage of Class I bricks.
zig zag Bhatta chimney is very used full technology in the fields of bricks kiln. its reduce the coal consumption and also increase the percentage of first-class bricks. zig zag brick kiln & high draught bricks kiln technology are very different from each other.zig zag Bhatta technology air passed through the chimney and high draught technology air passed through the high draft id fan. High draft bricks are easily passed air by fan.
zig zag Bhatta technology
in which technology we need a clay mixer machine, high draft fan and coal mixer machine.
we are providing an inclusive series of Simple Bricks Clay Mixing Machine. Our range is extensively employed by our customers owing to high strength and longer life service. we are supplying the clay mixing machine all over india.we are manufacture clay mixer machine zig-zag kiln and high draft id fan and high draught kiln id fan, coal mixture machine.
We are a supplier of Clay Mixer Machine Tractor Driven, Hydra Blower and Coal Crusher. The clay mixing machine is with the dual capacity 40000 bricks and 60000 bricks, the bricks kiln owner must be held JCB machine. It can control gearbox also. 8 MM AND 4 mm plate used for its cover and a very superior production This machine is a maintenance-free, probably rare chance to breakdown the only screw can be replaced after about two seasons Double wheel and four truck tyre can be used in this and mostly used tyre is capable to run this Weight of this machine about 2200 kg And tyre set depend on the customer choose because tyre cost not included in this.