zig zag bhatta (kiln) offer 15-20% reduction in Specific Energy Consumption and upto 80% reduction in SPM emissions over FC-BTK.
A higher percentage of Class first bricks are produced as compared to FC-BTK (80-85% Class first bricks as compared to 55-60% in FC-BTK).
There is an option for easy Convert of FC-BTK to natural draught Zig-zag kiln and Savings from reduced fuel consumption and increase in revenue due to higher percentage of Class I bricks.
Capital cost of retrofitting of existing FC-BTKs ranges from INR 10-25 lakhs and pays back in 3 months-2 years.
The payback period for new construction of Zig-zag kiln is 2-3 years. Zig-zag kiln required skilled manpower for its operation.
However, the same workforce working in FC-BTK can be easily trained for operating Zig-zag kilns.
four persons are required for firing at a 6 hour shift.Natural Draught Zigzag firing kiln is a moving fire kiln in which the fire moves in a closed rectangular circuit.
It has many similarities with FCBTK technology; the main difference being the zigzag air flow path.
The bricks are stacked in such a manner to guide the air flow in a zigzag path.
Zig zag bhatta flow increases the air flow path length and turbulence in the air, thereby resulting in improved combustion & heat transfer rate and uniform temperature across the kiln cross section.
the long firing zone and fuel feeding practice improves the combustion efficiency of the kiln.
The main innovation in natural draught zigzag kiln is that while traditionally zigzag firing was done with the assistance of fan draught, in this ki
ln the zig zag bhatta operation is achieved through the chimney draught.
benefits of zig-zag Bhatta
1- zig-zag kiln and high draught Bhatta reduces 20-25% Specific Energy Consumption.
2-zig zag kiln & high draught kiln reduction up to 75% in SPM emissions over FC-BTK.
3-Increase the percentage of the class 1st bricks.
4-zig zag kiln & high draught kiln produces 85-90%, first-class bricks.
History of Zigzag Bhatta
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)
Double zigzag brick setting (two parallel zigzag airflow streams)
Triple zigzag brick setting (three parallel zigzag airflow streams)
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.
- Induced or High Draught Zigzag Kiln (IDZK), in which a fan is used to create the draught for airflow in the kiln.
- 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?
|Zigzag Kiln||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 Bhatta in Bihar
Our company has made a lot of zig-zag kilns in Bihar. Contact us if you want to make Zig Zig Bhatta in Bihar.
If you want to see the Zig Zig Chimney Allowances, then visit the YouTube channel of the company.
Click on links:-
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.