KR100758932B1 - Method for manufacturing clay brick using block clay - Google Patents

Abstract

A method for manufacturing a clay brick is provided to reduce drastically the production cost by using black clay with lower refractoriness and to improve the efficiency of far infrared rays emission from red soil. A method comprises the processes of: mixing black clay, sandy loam, polishing sand soil and red soil in a ratio of 50-60 wt%: 10-20 wt%: 20-30 wt%: 10-20 wt%; separating larger stones therefrom; primarily pulverizing the resultant in a crusher; aging the resultant so that the moisture contained therein is homogenously mixed; secondly pulverizing the resultant in a crusher; kneading the resultant while adding water; compression-molding the resultant into a rectangular panel in a vacuum compression molding machine; cutting the panel into a brick with a desired size and shape; drying the brick in hot air of 110-130 deg.C for 40-45 hours; firing the brick while passing through a furnace of 950-990 deg.C slowly for 23-25 hours; cooling the brick through a forced blowing cooler for 6-7 hours; and cooling the brick naturally in a room with a normal temperature.

Description

Method for manufacturing clay brick using black clay

1 is a process chart for explaining the manufacturing method of the present invention.

Figure 2a and 2b is a report showing the results of the chemical composition and fire resistance test for the normal clay and the black clay used in the present invention, commissioned by the Korea Building Materials Testing Laboratory.

The present invention relates to a method for producing clay brick using black clay capable of low-temperature firing, and more specifically, black clay (also referred to as "wood clay") whose fire resistance (SK) is lower than that of ocher or reclaimed clay is the main raw material. It can be used to make clay bricks, which can greatly reduce the production cost of the product through the reduction of fuel cost during firing. It also occupies a certain space in a diluted state with black clay, and the firing temperature is higher than that of black clay. The far-infrared radiation efficiency in clay (red) having a less calcined state is invented to be greatly improved.

The general method for producing ocher bricks is produced by mixing a certain amount of cement, sawdust, seaweed grass, etc. in loess (red soil) and the like at a predetermined ratio to form bricks and drying them at a temperature of about 50 ° C to 100 ° C.

However, ocher bricks manufactured in this way are not suitable for construction, due to the viscosity of the ocher itself, which is uneven in drying, weak in moisture, easily discolored (ocher → black), and weak in strength. Subject to the restrictions.

This is because the conventional ocher brick itself has effects such as far-infrared generation and odor removal humidity control function due to the components of the ocher itself, but is weak in humidity due to fluorine products, and the strength is lowered, so that there is a limit in use as a structural material. In the case of calcining and using it, as the firing temperature increases, the amount of far-infrared rays in ocher is significantly reduced.

Therefore, conventionally, in order to solve this problem, 60 to 70% of loess (red soil) and 40 to 30% of boreum clay (masato) are mixed and pulverized, and then adjusted to a moisture content of 19 ± 2%, which is molded by a vacuum injection molding machine. After molding the object, the molded object is dried for 40 to 50 hours at 50 ° C to 100 ° C, and put into a firing furnace, and then fired in an automatic baking furnace equipped with a program of preheating, firing and cooling. The firing was carried out at 1000 to 1060 ° C. for 10 to 15 hours, and loess bricks, which can be used as flooring materials as well as interior and exterior use of buildings, have been presented in Korean Patent Registration No. 10-0421698.

However, while the fire resistance (SK) of the loess (clay) and the reclaimed soil (masato) itself used in this method is as high as 12 (ie, 1100 ° C.) as shown in FIG. 2B, the firing of raw materials used to manufacture the loess bricks. Not only does it have a temperature of 1000∼1060 ℃ lower than the fire resistance, which is lower than the temperature, and there is a risk of uncalcination during firing, and the production cost itself is increased due to excessive consumption of fuel by maintaining the firing temperature itself at a high temperature of 1000∼1060 ℃. There is a problem such as rising.

In addition, the conventional clay brick has a problem that the generation of far-infrared rays generated in the yellow soil is reduced by using the loess (clay) having a very high firing temperature of 1000 ~ 1060 ℃ as the main raw material, there is also a problem that the effect due to the far infrared rays is reduced.

The present invention has been devised to solve such a conventional problem, using a clay brick having a fire resistance (SK) is lower than ocher or light soil (that is, 950-1000 ℃ with SK 1a) as the main raw material clay clay By lowering the firing temperature by manufacturing, it is possible to drastically reduce the production cost of the product through the reduction of fuel cost during firing, as well as occupying a certain space in a diluted state with black clay, and because the firing temperature is higher than that of black clay, The purpose of the present invention is to provide a method for producing clay bricks using black clay, which can greatly improve the far-infrared radiation efficiency in clay (red soil) having a stable state.

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The clay brick manufacturing method of the present invention for achieving the above object, 50-60% by weight of black clay and 10-20% by weight of light clay, 20-30% by weight of Masato and 10-20% by weight of clay (red soil) Putting in a mixer to mix; Separating out relatively large stones contained in the mixed raw materials; Putting into a grinder and pulverizing first and collecting only what passes through a 200 mesh sieve and transferring it to a aging chamber; Aging for a certain period so that the moisture contained in the raw material is mixed evenly; Putting into a pulverizer and pulverizing secondly, collecting and transferring only what passes through a sieve of 300 to 400 mesh; Kneading raw materials through a kneader while injecting water to have a water content of 16-19%; Putting the vacuum compression molding machine into compression molding into a rectangular plate body shape; Cutting the brick into a desired size through a cutter; Hot-air drying by injecting for 40-45 hours into a warm air dryer having a temperature of 110-130 ° C. suitable for a truck; Sintering slowly in a furnace having a temperature of 950-990 ° C. for 23-25 hours; Forced cooling by passing a forced blower equipped with a blower for 6-7 hours; Naturally cooling the room at room temperature until it cools down completely; Characterized in that it consists of a process of paving the finished clay brick.
Clay brick manufactured through the process as described above, by mixing 50-60% by weight of black clay, 10-20% by weight of clay, 20-30% by weight of Masato and 10-20% by weight of clay (red soil) to a certain size After pulverization, water is kneaded by injecting water into a raw material that has passed through a 300 to 400 mesh sieve, and then compression molding through a vacuum compression molding machine, followed by hot air drying, firing and cooling.

Hereinafter, exemplary embodiments of the present invention will be described in detail with reference to the accompanying drawings.

Figure 1 shows a process diagram for explaining the manufacturing method of the present invention, Figures 2a and 2b is a chemical composition and fire resistance test for the normal clay (red soil) and the black clay used in the present invention commissioned by the Korea Building Materials Testing Institute This is a report card showing the results of the test.

According to the clay brick produced by the manufacturing method of the present invention, by mixing 50-60% by weight of black clay, 10-20% by weight of light clay, 20-30% by weight of masato and 10-20% by weight of clay (red soil) Grinding, injecting water into the raw material passing through a sieve between 300 and 400 mesh, kneading, compression molding through a vacuum compression molding machine and then manufacturing through hot air drying, firing and cooling.

In the clay brick manufacturing method of the present invention, 50-60% by weight of black clay, 10-20% by weight of light clay, 20-30% by weight of masato and 10-20% by weight of clay (red soil) are added to a mixer and mixed. Process of doing;

Separating out relatively large stones contained in the mixed raw materials;

Putting into a grinder and pulverizing first and collecting only what passes through a 200 mesh sieve and transferring it to a aging chamber;
Aging for a certain period so that the moisture contained in the raw material is mixed evenly;
Putting into a pulverizer and pulverizing secondly, collecting and transferring only what passes through a sieve of 300 to 400 mesh;
Kneading raw materials through a kneader while injecting water to have a water content of 16-19%;

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Putting the vacuum compression molding machine into compression molding into a rectangular plate body shape;

Cutting the brick into a desired size and shape through a cutter;

Hot-air drying by injecting for 40-45 hours into a warm air dryer having a temperature of 110-130 ° C. suitable for a truck;

Sintering slowly in a furnace having a temperature of 950-990 ° C. for 23-25 hours;

A step of forcibly cooling the sample through a forced air cooler for 6-7 hours;

Naturally cooling the room at room temperature until it cools completely;

Characterized in that it consists of a process of paving the finished clay brick.

At this time, the temperature of the kiln is set to increase from the inlet to the outlet side, characterized in that set to gradually increase by a predetermined temperature step by step divided into 10 steps.

Referring to the operation and effect according to the manufacturing method of the present invention made of a process as follows.

First, the clay brick manufactured by the manufacturing method of the present invention is mainly composed of black clay (wood clay) whose fire resistance (SK) is relatively lower than ocher, as shown in the transcripts shown in FIGS. 2A and 2B. The main technical composition is to allow Masato and loess to be mixed at a certain rate to significantly reduce the fuel cost and the production cost of the product during firing.

In other words, instead of reducing the amount of clay and clay (red) to 10-20% by weight compared to 100% by weight, 50-60% by weight of black clay, also known as wood clay, is used, in which trees are turned into soil by crustal changes. Masato is mixed by mixing 20-30% by weight in a mixer, and then crushed to have even texture and shrinkage, and then kneading through a kneader while injecting an appropriate amount of water into a raw material that passes through a sieve between 300 and 400 mesh. After compression molding through a vacuum compression molding machine having a predetermined shape, and then hot-air dried in a hot air dryer for a predetermined time, and then passed through a firing furnace having a predetermined temperature for a predetermined time, and then calcined, followed by primary cooling through forced air, and then at room temperature. The main technical component is the manufacture of clay bricks with complete cooling in the room.

Referring to the manufacturing process of the clay brick having such a composition in more detail as follows.

First, the manufacturing method of the present invention, as shown in Figure 1, largely the raw material input and mixing process, the separation process, the first grinding process, the aging process, the second grinding process, kneading process, forming and cutting process, warm air It consists of a drying process, a firing process, cooling by forced blowing, natural cooling at room temperature and a packaging process.

At this time, in the mixing process of the raw materials, as described above, the black clay and the reclaimed clay, the masato and the clay (red clay) raw materials were put into the hopper, respectively, and they were 50-60 wt%, 10-20 wt%, and 20-30 wt%, respectively. % And 10-20% by weight of the automatic feed to the mixer to be mixed.

In other words, 50-60% by weight of black clay, 10-20% by weight of clay, 20-30% by weight of masato and 10-20% by weight of clay (red soil) are added to the mixer and mixed.

At this time, in order to lower the firing temperature, the clay having a fire resistance (SK; 1a) of 1a lower than the clay (red soil) having a fire resistance (SK) of 15 may be introduced at a ratio of 50-60% by weight relative to the total 100% by weight. If the black clay is less than 50% by weight compared to 100% by weight, the amount of clay (red soil) with high refractory strength must be increased. Therefore, the firing temperature must be increased, leading to an increase in fuel costs and production costs. In addition, if the firing temperature is increased, foaming occurs during firing, and thus a desired brick shape cannot be obtained. On the contrary, if the black clay is put in an amount of 60 wt% or more relative to 100 wt%, the firing temperature can be lowered. While the cost can be reduced, there is a problem that cracks occur during firing due to lower overall viscosity.

In addition, the boring soil and masato used to maintain the shape of the brick during drying and firing are added at a ratio of 10-20% by weight and 20-30% by weight, respectively, relative to the total 100% by weight. If the ratio is less than 10% by weight and 20% by weight with respect to 100% by weight, cracks are generated during drying and firing, as well as shrinkage occurs during firing. In the case of excessively added to the ratio of 20% by weight and 30% by weight of the clay and masato, respectively, there is a problem that the shrinkage during the firing is less obtained to obtain a clay brick of the desired shape and size, as well as in such an excessive ratio state. In order to obtain the shrinkage of the desired shape can not only increase the firing temperature, there is a problem that leads to fuel costs and production costs increase.

On the other hand, due to the mixing of 50-60% by weight, 10-20% by weight and 20-30% by weight of black clay, Bomyeong soil and Masato, respectively, that is relatively less than 10% by weight compared to the conventional 100% by weight %) If less than 10% by weight of the clay (red soil) is added to the total 100% by weight, the desired orange color does not come out during firing, and the viscosity is low, so a lot of cracks occur during drying and firing, as well as a cracked shape If excessively added at a ratio of more than 20% by weight to 100% by weight, too dark orange color appears during firing and high viscosity, resulting in warpage during drying and firing, as well as in some shapes There is a problem.

In addition, although the clay occupies a certain space in the diluted state with the black clay, the retaining clay and the masato, and the firing temperature is higher than that of the black clay, the clay (red) has a less firing state, although the ratio of the conventional clay ( Even though the dilution is less than that of red soil, the far-infrared emissivity is high, and the far-infrared emissivity generated in the clay brick of the present invention has almost the same emissivity as that of brick using yellow soil (red soil) as the main raw material.

At this time, since the masato has a higher shrinkage rate and a lower particle size ratio (also referred to as a "residual rate"), the masato is added at a higher ratio than that of the retained soil. When the particle size increases, shrinkage decreases, and fire resistance increases, not only the brick of the desired size can be obtained but also the firing temperature needs to be increased, thereby increasing fuel cost and production cost.

In view of the above problems when the mixing ratio of each raw material is too small or excessive, 55% by weight of black clay, 12.5% by weight of clay, 22.5% by weight of masato and clay ( Red soil) to be mixed at a ratio of 10% by weight to use as a raw material for the manufacture of clay brick can be presented as the most preferred embodiment of the present invention.

On the other hand, in the separation process has a mixing ratio as described above is mixed in the mixer is discharged to separate the foreign matter including the relatively large stones contained in the raw material which is discharged and carried on the conveyor belt.

In addition, in the primary crushing process, the separation is performed through the separator, as described above, and then, the raw material is introduced into the raw material grinder, which is transferred through the conveyor belt, to be firstly crushed. It will be moved to a certain place and matured.
In this case, the reason for selecting only the raw materials passing through the 200 mesh sieve after the first grinding in the primary grinding process to transfer to the aging chamber is to smoothly crush the raw materials to the desired smaller size during the second grinding process to be described later 300 to This is to use only the raw material which has passed through any one of the sieves between 400 meshes for the manufacture of bricks.If the raw material having the size of the raw material is 200 mesh or more after the first grinding process, the desired particles after the second grinding process Not only do not obtain raw materials with sizes smaller than 300-400 mesh, but also high maintenance costs due to high wear rate of the secondary mill.

The reason for aging the raw material mixed with the black clay, the bodhisattva, masato, and clay (red soil) in the above ratio is to perform the mixing of the entire moisture of the raw materials mixed with the soils having different moisture evenly. Aging time may be different from each other depending on the amount of moisture contained in the soil, but it is preferable to load in a well-ventilated place for about 3-4 days to ensure sufficient mutual flow of moisture for each soil.
In other words, clay (red soil) has a lot of moisture, and Bomyeong soil and Masato have relatively low moisture content, so the water content of different raw materials is different, so that the water diffusion between the materials through the process of mixing, grinding and aging Moisture flow) so that the total moisture content of the mixed raw materials can be evenly maintained.
In addition, the aging process is to perform a 3-4 days to evenly distribute the moisture through the water flow of the mixed raw materials by mixing, grinding and aging the raw materials with different moisture, to facilitate molding, If it is aged less than 3 days, it is not evenly distributed in the raw materials mixed with moisture, so that the clay and the relatively low level of Masato and Boyung Clay are not mixed properly when forming the dough. In case of aging for more than 4 days, the surface of raw material dries, and dry soil is exposed to the surface of the product when cracking and cracking occurs on the surface of the product. Becomes appropriate.

As such, raw materials for clay brick production after ripening for a certain period of time (that is, about 3-4 days) are transferred to a second grinder through a conveyor belt, and then crushed in a second step, and then passed through a sieve of the final 300-400 mesh. Only raw materials are continuously transferred to the kneader through the conveyor belt.

At this time, the reason for using only to pass through the sieve of 300-400 mesh after the second crushing of the raw material for clay brick manufacturing is to ensure that the texture is good and the shrinkage ratio has a desired degree when the manufacture of the clay brick, If only the particles having a smaller particle size than 300-400 mesh are used, the shrinkage is high, and the brick of the desired size is not produced. Also, plasticity is generated, and raw materials including those having a larger particle size than the 300-400 mesh are used. When the brick is manufactured, there is a problem that the clay brick is rough due to some large particles, the texture is reduced.

In the kneading step, the water content of the raw material introduced into the kneader is measured, and if the total water content of the raw material is less than 16-19%, water is injected as much as the corresponding water, and the dough is continued to carry out the total water content of the raw material. By maintaining this 16-19%, the dough is made in a form in which sufficient viscosity is maintained in the raw material itself.
The raw material kneaded through the kneading machine is put into a vacuum compression molding machine having a predetermined mold, is compression molded into a square plate shape, and then passed through a cutter to be cut into bricks to a desired size and shape.
At this time, the raw material is put into a vacuum compression molding machine at the same time as the dough is pressed to form a square plate shape so that the molding to facilitate the molding so that the moisture content of the entire raw material is 16-19% when kneading evenly If the water content of the raw material is less than 16%, excessive pressure is generated in the molding machine during the molding process, and the frictional heat is generated so that a bad product is cracked on the surface of the product. Moisture content of raw materials when forming dough, because molding force of molding machine is lowered during product movement and crushing during balance loading, and cracks occur during drying due to high moisture during drying process. If the total moisture content of the raw material is less than 16-19%, Jumyeo by the injection there is continuously carried out the dough to ensure that the total water-moisture content of the raw maintain 16-19% of about 17.5% was the most desirable Experimental.

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Thereafter, the bricks are loaded on a bogie, and then placed in a warm air dryer having a temperature of 110-130 ° C., warm-dried for 40-45 hours, and then introduced into a kiln, and slowly moved for 23-25 hours to be fired. .
As mentioned above, when the temperature in the hot air dryer is 110 ° C. or lower when the brick is hot rolled to the bogie, drying takes a lot of time and undried products are generated, and cracks are generated due to undried products upon firing, leading to the production of defective products. If the temperature in the warm air dryer is higher than 130 ℃, drying is well done, but a lot of drying cracks occur due to rapid heat, leading to poor productivity due to poor drying. Also, if the warm air drying time is less than 40 hours, problems due to undrying occur. In case of more than 45 hours, a problem due to overdrying occurs, so it is most preferable to dry for about 43 hours in a warm air dryer at 120 ° C.

At this time, the kiln has a temperature of 950-990 ℃, the temperature of the kiln is designed so that the inlet side is as low as 950 ℃ and the final outlet side is as high as 990 ℃, the multi-step (for example 10 steps) from the inlet to the outlet side It is set to gradually increase by a certain temperature step by step.

In other words, when firing bricks heated to a high temperature from the beginning in firing the warm air dried brick, there is a possibility that cracks may occur due to internal and external temperature difference and humidity evaporation difference, so that the heating is started at a low temperature of 950 ° C. It is divided into 10 stages over 23-25 hours and gradually moves to the burner side having a higher temperature, and the exit side is heated to a final 990 ° C and fired.

In the above, when firing the warm air-dried brick, if firing starts at an initial temperature of 950 ° C. or lower and gradually increases the temperature, there is a possibility that cracks occur due to a large temperature difference between each step, and the final firing temperature is 990 ° C. or higher. If it exceeds, there is a problem that the hardness of the clay brick is increased due to over-calcination.

In addition, when the firing time is lowered to less than 23-25 hours, there is a risk that uncalcination occurs, and if the firing time is increased above that time, there is a problem that excessive firing occurs. There is also a problem in that the temperature difference of each step must be adjusted, including the temperature of.

As described above, in the kiln having a temperature of 950-990 ° C., the brick is slowly moved for 23-25 hours, and the completed brick is provided with several blowers and gradually passes through the cooling chamber formed in series with the kiln for 6-7 hours. The cooling is performed by an air cooling method by forced air blowing. When the bricks discharged from a predetermined state through the forced air cooling are cooled for 6-7 hours, the remaining temperature of the bricks is about 150 ° C.
In the process of passing the brick brick product fired at a high temperature in the cooling chamber rapidly for 6 hours or less, the strength of the product decreases due to the rapid decrease in the temperature of the product and cracks occur due to rapid cooling. Many defects of the product are generated, and if it passes slowly for more than 7 hours, the quality of the product is good, but the productivity is lowered and the production time takes a lot of disadvantages. It is most preferable to perform forced blow cooling within 6 hours or more.

In this way, the forced air cooling room is passed through the bricks to the room to maintain the room temperature is made of natural cooling in the air and then transferred to the yard through the pavement.

On the other hand, Figures 2a and 2b is a report showing the results of the chemical composition and the fire resistance test for the normal clay and the black clay used in the present invention, commissioned by the Korea Building Materials Testing Institute, as shown in this report, general clay showing 12 It can be seen that the clay is 1a lower than the fire resistance (SK) of.

In addition, the clay brick of the present invention having the above characteristics of the product was tested according to the test method of the Korean Industrial Standard KSL 4201, and the following results were obtained.

<Test Example>

* KLS 4201 Clay Brick Product Quality Regulations

Type 1 2 types 3 types Absorption rate (%) below 10 13 or less 15 or less Compressive strength (N / ㎡) 20.59 or later 15.69 or higher 10.78 or more

* Comparison of absorption rate (%) and compressive strength (N / mm2) according to the mixing ratio of black clay used as the main raw material in the present invention (where the firing temperature is 990 ° C)

Black Clay 45% 50% black clay 55% black clay 60% black clay 65% black clay Absorption rate (%) 11-15 9-10 7-9 6-8 5.5-8 Compressive strength (N / ㎡) 12.50-18.72 21.90-32.52 25.20-42.75 28.50-45.65 18.65-33.50

As a result of testing the absorption rate (%) and compressive strength (N / mm2) of black clay mixture ratio of the clay brick of the present invention tested according to the product quality characteristics of KSL 4201 clay brick, the Korean industrial standard, the firing temperature was The present invention uses black clay with a low firing temperature of 950-990 ° C. as a main raw material (50-60% by weight) compared to conventional clay bricks using high loess (red soil) at 1000-1060 ° C. as a main raw material (60-70% by weight). Absorption rate (%) of clay bricks is the same as the first class product (10% or less) of KLS 4201 (9-10% for 50% black clay) or surpasses (6-8 for 60% black clay). The compressive strength (N / mm 2) also exceeds the requirements of Class 1 products (more than 20.59) (for example, 50% black clay 21.90-32.52 (N / mm2), 28.50-45.65 black clay 60%). (N / mm2) indicates that the interior and exterior materials of buildings can be used as flooring materials.

Although the above-described embodiments have been described with respect to the most preferred embodiments of the present invention, it is not limited to the above embodiments, and it will be apparent to those skilled in the art that various modifications can be made without departing from the technical spirit of the present invention.

As described above, according to the method of manufacturing clay brick using the black clay of the present invention and the clay brick, the temperature of the kiln is produced by producing clay brick using black clay having a refractory degree (SK) lower than that of yellow clay or reclaimed clay as a main raw material. It can lower the production cost of the product by reducing the fuel cost during firing, and also occupies a certain space in a diluted state with black clay, and has a less calcined state because the firing temperature is higher than that of black clay. Far-infrared radiation efficiency in clay (red soil) is a very useful invention, such as can be greatly improved.

Claims (6)

Adding black clay, complementary clay, masato and clay (red clay) to a mixer at a ratio of 50-60% by weight: 10-20% by weight: 20-30% by weight: 10-20% by weight; Separating out relatively large stones contained in the mixed raw materials; Putting in a grinder and pulverizing first; Aging the water contained in the raw material to be mixed evenly; Injecting into a grinder and pulverizing secondly; Kneading with injecting water; Putting the vacuum compression molding machine into compression molding into a rectangular plate body shape; Cutting the brick into a desired size and shape through a cutter; Hot-air drying by injecting for 40-45 hours into a warm air dryer having a temperature of 110-130 ° C. suitable for a truck; Sintering and slowly passing the inside of the furnace having a temperature of 950-990 ° C. over 23-25 hours; A step of forcibly cooling the sample through a forced air cooler for 6-7 hours; Process for natural cooling in the room at room temperature; clay clay manufacturing method using black clay, characterized in that consisting of. The method according to claim 1, In the first and second grinding step, only the raw material passing through the sieve of 200 mesh and 300-400 mesh, respectively, discharged to the maturation chamber and kneader side clay clay manufacturing method using the clay. The method according to claim 1, The aging process is a method of manufacturing clay brick using black clay, characterized in that carried out for 3-4 days. The method according to claim 1, The amount of water injected in the kneading step is a method of producing clay bricks using black clay, characterized in that the moisture content of the kneaded raw material can maintain 16-19%. The method according to claim 1, The temperature of the kiln is designed so that the inlet side is as low as 950 ℃ and the final outlet side is as high as 990 ℃, divided into 10 stages from the inlet to the outlet side to set the black clay, characterized in that gradually set by step by step temperature Method of manufacturing clay bricks used. delete

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