GPH Project in Bangladesh - Turnkey Clay Brick Plant Solution from Design to Production
ECO CERAMICS is part of the Bangladesh GPH Group, which is the largest building material manufacturer in Bangladesh. It has the top three cement factories and the largest steel plant in Bangladesh, and the brick factory project currently under construction will also become Bangladeshi domestic The brick factory with the largest volume and the highest degree of industrialization.
The project adopts advanced secondary burning technology, the drying process adopts automatic upper and lower racks and tunnel-type single-layer drying system, and the burning process adopts two tunnel kilns with a section of 4.8 meters and an automatic pulverized coal combustion system. The entire brick-making production process has a high degree of automation and strong controllability, which can simultaneously meet the needs of producing ordinary bricks and high-end bricks. On March 31, 2019, Xi'an brictec Mining Machinery Project Department officially settled on the site, and the groundbreaking ceremony was held with Party A to formally take over the construction and management of the entire project.

The Importance of Process Design in the Early Stage of Clay Brick Project Planning
1. Process Design Perspective
Process design serves as the project's "blueprint," determining the overall layout and equipment selection. Key considerations include:
Raw material properties (plasticity index, mineral composition)
Product specifications (solid bricks, perforated bricks, etc.)
Capacity coordination (avoiding over/under-capacity issues)
Energy efficiency (integrated thermal system design)
2. Raw Material Processing
Raw material processing directly affects brick quality and equipment longevity:
Crushing size control: Double toothed roll crusher output ≤3mm (oversize reduces plasticity, fines increase energy use)
Aging & homogenization: ≥72 hours aging ensures moisture uniformity and forming stability
Impurity removal: Magnetic separators + screening for iron and stones
3. Aging & Forming
Aging process: Enclosed aging shed with >80% humidity promotes clay ion exchange
Extrusion forming: Vacuum extruder (vacuum ≥-0.092MPa) improves green body density
Die design: L/D ratio ≥4:1 minimizes spiral marks, chrome-plated lips reduce friction
4. Drying Technology
Drying is the most critical pre-sintering stage:
Multi-stage drying:
Preheating (40-60°C, 70% RH) to prevent cracking
Fast drying (80-120°C) for bound water removal
Airflow design: Vertical airflow to keep temperature difference <5°C in stacks
Waste heat recovery: Reuse tunnel kiln cooling zone heat for drying
5. Tunnel Kiln Firing Curve
The firing curve determines brick strength and fuel efficiency:
Preheating zone (200-600°C): Heating rate ≤50°C/hour to prevent explosions
Firing zone (900-1050°C): Hold for 2-4 hours under oxidizing atmosphere
Cooling zone: Slow cooling to <80°C (rapid cooling causes glass-phase cracking)

Failure Cases vs. Good Design:

Additional Notes:
Consequences of Poor Design:
Increased rework costs
Reduced equipment lifespan
Lower product qualification rate
Benefits of Good Design:
20-30% energy savings
≥15% production increase
40% lower maintenance costs

The Critical Role of Kiln Cars:
Load-Bearing Core:
Kiln cars must continuously carry tons of green bricks under combined mechanical and thermal stress. Poor-quality cars cause:
Frame deformation triggering "kiln jams" (>$10,000/day downtime)
Refractory spalling contaminating bricks (↑15% defect rate)
Sealing Vitality:
Ineffective sand sealing between cars and kiln walls leads to:
Heat loss (8-12% higher energy consumption)
Flue gas crossflow disrupting firing curves
Mobility Foundation:
Wheel systems must feature:
High-temp bearings (>400ºC)
Self-adjusting rail alignment (derailment prevention)
Brictec's Commitment
"We refuse to compromise kiln car quality for cost savings. Every refractory brick laid is a pledge to our client's productivity for the next decade."
- Brictec Process Director
Data Backing: Projects using Brictec kiln cars report <0.5% annual failure rate vs. industry average 3%.

Brictec's Philosophy in Tunnel Kiln Manufacturing
At Brictec, we consider tunnel kilns the "heart" of clay brick production. Every kiln we build embodies our clients' demands for product quality and energy efficiency. We insist on:
Stringent Refractory Standards: Kiln walls use high-load-bearing bricks (>60% Al2O3, refractoriness>1750ºC), while roofs adopt lightweight insulation composites for maximum thermal efficiency.
Millimeter Precision: Kiln straightness tolerance <3mm/10m, eliminating temperature deviation or product color variation caused by deformation.
Dynamic Validation: CFD simulation + physical kiln testing to optimize firing curve stability.

The Critical Role of Tunnel Kilns:
Quality Determinant:
Kiln temperature control directly affects bricks:
±5ºC variation causes>10MPa strength difference
Preheating-firing-cooling balance sets water absorption (optimal 6-10%)
Energy Center:
Consumes>70% of total energy. Brictec solutions achieve:
>65% waste heat recovery (industry avg. 40%)
<90m³ gas/10k standard bricks
Production Hub:
Kiln width and car speed coordination ensures:
Uninterrupted production (>95% capacity utilization)
<15min/car cycle time deviation

"Every refractory brick in our kilns carries a traceable 'ID', documenting material batches and firing parameters, making your high-temperature investment transparent and controllable."
- Brictec Kiln Division
Industry Comparison: Brictec kiln bricks last 8-10 years (industry avg. 5-7) with 40% lower annual maintenance costs.

● Company profile

Xi'an Brictec engineering Co., Ltd. (abbreviation: Xi'an Brictec) was founded in 2011. It employs senior Italian engineers to work with domestic experts, creating a strong technical team by combing the European and Chinese technologies. The company is devoted to provide clients multiple professional brick making solutions, including building structure bricks, decorative bricks,wall cladding bricks, paver and dry press bricks, etc.

Business Scope

(1) Design and engineering
Xi’an Brictec offers process design and engineering service for clients to have a fully automated modern bricks and tile factory, including chamber drying, tunnel drying, rapid drying and tunnel kiln and other process design and technical consultation, among which the dryer and kiln constructing and engineering is the utmost importance in our general contracting program. This part is the key to achieve production targets by using key technologies in the project.

(2) Machinery manufacturing and supply
Xi’an Brictec Machinery Equipment Manufacturing Co., Ltd. introduces the latest European brick machinery technology for smooth production domestically. In 2018, Xi’an Brictec built cooperation relationship with Shandong Mine Machinery Cosmec Materials Machinery Co, Ltd, jointly R &D and manufacturing automation equipment for brick making.
1.Cutting machine, setting machine, automatic unloading and packing machine and automatic packaging machine;
2.Ferry car, cone blower, stepping machine, pulling machine, kiln car and other kiln automation equipment;
3.Gas burning system (natural gas/liquefied petroleum gas / coal gas), liquid burning system (heavy oil/waste tire oil), solid fuel burning system (pulverized coal, petroleum coke, rice husk, palm kernel husk, coconut husk, cottonseed husk, etc.)

(3) Installation, maintenance and production guarantee service
Xi’an Brictec provides production, commissioning and maintenance services to brick making factories, helping clients to make bricks easily.

● Project reference from Xi’an Brictec

1.Shaoxing Lvzhan environmental protection technology Co., Ltd

Xi’an Brictec designed this Lvzhan project in 2023. The project has annual output of 300,000㎡ of sintered bricks and prefabricated brick wall by using local solid waste such as chemical contaminated soil, construction residue, printing and dyeing sludge as the main raw materials, etc. so as to make high quality sintered bricks making, and 60%-70% of electricity needed for production line is from the photovoltaic power generation on the factory roof. Xi’an Brictec provides whole package service from the preliminary planning and design of the project to the supply of core equipment in the later stage. Single layer tunnel dryer process is adopted with natural gas burning system for tunnel kiln (7 meters inner width). Xi’an Brictec has delivered a very satisfactory EPC project to our client, and also set a new benchmark for the solid waste recycle and utilization in the industry.

2.Najmadin project in Iraq

This project was jointly designed and implemented by Xi’an Brictec and China National Building Materials Co., Ltd. in 2023, with a daily output of 750 tons of sintered bricks. It is located in Sulaimani Province, Kurdish region of Iraq, and the raw material is shale. Xi’an Brictec has participated in project planning, design, construction and commissioning. Single layer tunnel dryer process is adopted, and Heavy oil/liquefied petroleum gas dual fuel serve as the fuel for dryer and tunnel kiln (9 meters cross-section) . In this project, Xi’an Brictec competes with European production line on the same platform and wins honor for the country. So far the project has been put into production, expecting to meet the production target in May 2024.

3.Antique Bricks Project for Yan'an Green Building Material Recycling Industrial Zone

The project was designed and implemented by Xi’an Brictec as a whole in 2022, mainly to produce antique bricks, facing bricks and paver, etc.. The raw material is high-quality shale and purple sand soil, and the fuel is natural gas. The entire production line combines two shaping methods (extruding and pressing), and uses chamber dryer for drying and tunnel kiln for burning, and integrates three shuttle kilns for antique bricks production. Xi’an Brictec was fully engaged and offer excellent package service in the project in the preliminary process design, dryer construction and core equipment supply and production commissioning. This automatic degree applied in this project is the highest domestically, also meets the advanced international level.

4.Guangdong Baolihua Electric Power Co. Ltd. brick making project with high content fly ash as raw material

Xi’an Brictec designed the whole project and led multiple raw material batching experiments, and finally got the result of 65% fly ash content being the perfect ratio to produce qualified sintered bricks. And because of this project, Xi’an Brictec has obtained the invention patent for making bricks with high content fly ash added.

5.ECO CERMICS project in Bangladesh
This is an EPC project by Xi’an Brictec. Single-layer tunnel drying process is adopted with two 4.8-meter tunnel kilns in use. Bongianni soft plastic extruder from Italy, roller and pulverized coal burner invented by Xi’an Brictec are also applied in this project. Invested by GPH, the 3rd largest cement enterprise in Bangladesh, the production line has the characteristics of highest automation and largest production scale. The factory roof is laid with solar photovoltaic, offering 60% power generation for production line.

6.Uzbekistan Project

The project is for the high-grade brick making production, ranking top three in Uzbekistan. It has two production lines and Xi’an Brictec is responsible for the whole set of cutting, loading & unloading automation system and the natural gas burning system. Client thinks highly of Xi’an Brictec and compliments it as the most reliable partner, offering the easier natural gas burning system with lower energy consumption than European burning system. With the assistance of Xi 'an Brictec, the client uses tire pyrolysis oil to make bricks in its Phase II project, producing high quality bricks under low cost.
Xi 'an Brictec will continue to make breakthrough in every aspects, continuously providing all various tailor-made brick making solutions for our valuable clients!

● Business region

Over 30 countries and regions including China, Russia, Kosovo, Kazakhstan, Uzbekistan, Tajikistan, Vietnam, Malaysia, Iraq, India, Bangladesh, South Africa, Zimbabwe, Peru, Colombia...
In addition, the company has local offices and after-sales service centers in countries such as Iraq, Kazakhstan, Bangladesh, Uzbekistan, Zimbabwe and other.
Adhering to company’s culture and spirit “ Struggle-oriented and customer-centered”, Xi’an Brictec is here to help you make bricks easily!