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Recently, a high efficient, environmental friendly and energy-saving rustic and polished glazed vitrified tile production line, supplied by HLT & DLT to Sichuan Kaifeng Ceramic Co., LTD., was successfully put in use under the cooperation between the both teams.

Kaifeng Ceramic is a high-tech modernized ceramic manufacturing company which is focusing on the research and development, production and marketing of high-end ceramic products with high quality to meet the needs of the customers and has won good recognition of the end-users. The successful operation of the production line provides a solid backup to Kaifeng Ceramic and has greatly enhanced its competitiveness in the tile market.

The line consists of two HLT YP4009 automatic hydraulic presses, a DLT DFC series "Energy Efficiency Benchmark" natural-gas-fueled roller kiln and a DHD-EM4 self –circulation 4-layer dryer as well as other auxiliary equipment. It is also equipped with the automatic man-machine interface and digitalized data management software. It has the advantages of high efficiency, environmental protection and energy-saving.

The line mainly produces 600*600*9.5mm rustic and polished glazed vitrified tiles, and is also able to produce 300*600mm, 400*800mm, 600*1200mm, 750*1500mm and 800*800mm ceramic tiles with medium and large thickness, with a designed output of 22,000m2/ day. On the first day of production, the line performed with a 98.3% first grade product rate. While the whole line is running smoothly, its gas consumption has kept the lowest record among the existing kilns in the factory.

YP4009 Hydraulic Tile Press is one of the bench-mark energy-saving models among HLT upgraded presses. With a maximum pressing force of 40000kN and up to 20 cycles/min in idle stroke, YP4009 has the following features:

1. The newly designed steel wire winded pre-load structure greatly reduces the stress concentration and maintains sufficient rigidity of the frame, having superior fatigue resistance and load stability.

2. The main cylinder adopts HLT external cylinder structure (HLT patented technology) which has been tested for many years. The work is stable and reliable, the failure rate is extremely low, and it is easy for maintenance.

3. The latest wide channel springless prefilling valve (HLT patented technology), increases the filling and discharging speed resulting in faster pressing cycle.

4. Multiplier together with position sensor detect real-time position of multiplying piston, making adjustment flexible and repetition accurate.

5. Speed and pressure boosting system, close-loop plunger control and pressure control system, servo ejection system, etc. together make an advanced hydraulic system that delivers high pressing speed and precise position control.

6.New HLT framework control program provides flexible operation and accurate performance repetition.

The kiln adopts Galaxy series exterior decoration panels and cold-rolled stainless-steel shaping technology. The appearance of kiln features nobleness, rigidity and user-friendliness, which is not only flexible and beautiful, but also showing the innovation level of the latest technology of DLT.

The SPR energy saving system, KHI updated insulation system for kiln, DHR heat recovery system and PPC super combustion system, which are equipped on the line in Kaifeng Ceramic, are exclusive technologies developed by DLT, able to reduce the unit natural gas consumption, save costs and improve the environment quality as well.

It not only guarantees the product pass rate and the stability of production, but also realizes zero discharge of waste air from the final cooling zone of kiln. Without using any kiln fume heat exchanger or using any waste fume, and without running the hot air generators, only the recycled hot air from the kiln can sufficiently meet the heat demand of the 4-layer dryer, the combustion air of the kiln burners and the heating source of the glaze line dryer.

Moreover, the latest updated driving control system can effectively maintain the safety running of the roller driving equipment, and guarantee the normal operation and stable quality of product, thus realizing the maximum energy saving result.

In addition, the self-circulation 4-layer dryer with good airtightness and high efficiency, can provide quality green tiles for the firing process quickly and efficiently.

At present, while the kiln output is not yet at its full capacity, the kiln gas consumption already keeps at less than 1.45Nm3 natural gas /m2 tile, which is far lower than expected by the customer, and has become a new benchmark of gas consumption among the same type of kilns in China. With the improvement of plant management and the increase of output, the kiln gas consumption is expected to be further reduced.

With the increasing strict requirements of energy-saving and cost-reducing in the industry, DLT, having a good sense of social responsibility, will spare no effort to invest more in research and development of energy-saving equipment in order to contribute to the healthy development of the industry.

HLT & DLT will continuously use advanced and latest technology to improve the product quality and maintain the stability of product to safeguard the smooth running of the production line in Kaifeng Ceramic by paying more attention to the implementation of the standards of international quality management system and focusing more on the technical innovation and brand updating.