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TCK designs, manufactures and installs both single-layer and
double-channel roller kilns suitable for the ceramic
industry. TCK kilns are the best ones available in the
market in terms of technology, quality and quantity of
production, as well as low energy consumption and low CO2
emissions. |
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These kilns have been designed using the same technological
concepts of the larger TAGDAN kilns for tile production but
with a special focus on the quality and quantity features of
the pieces that they will process. TCK perfectly knows that
Customers expect these kilns’ performance to match the
specific characteristics of their products. |
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Tunnel kilns are suitable for firing drawn items such as
roof tiles or bricks. They are fully equipped with transfer
units, parking system and, on request, fully automated
loading and unloading systems. |
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Kilns for carrying out tempering, stress relieving and many
other thermal treatments on metallic items both in neutral
environments and under Endogas atmosphere. |
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Roller kilns: TAGDAN
TAGDAN
is a high performance roller kiln for ceramic products. It is
available in a single-layer and a double-channel version.
TAGDAN offers the following great advantages:
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Very high quality production in terms of work size,
flatness, absorption, colour, prevention of defects such as
“black core”, burrs, cuts, etc..
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Low fuel and electrical energy consumption
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Lower CO2 emissions into the atmosphere
This results into huge economic advantages that turn TAGDAN into
an undisputedly cost-effective kiln.
SHORT TECHNICAL DESCRIPTION:
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TCK PATENT
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12 burners per high speed module, with stoichiometric
combustion;
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Specially designed combustion chambers to optimize hot air
flows;
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Double arch cross-section to suitably manage hot air flows
and avoid the “wall effect”
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A different longitudinal section in the pre-heating area to
improve heat exchange and reduce “black core” flaws (TCK
patent)
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Very low methane gas and electricity consumption (see the
table below);
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Smaller amount of fumes sent to the stack along with lower
temperatures;
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Temperatures are kept uniform inside the firing chamber to
avoid any defects relating to firing such as flatness, work
size, colour and black core;
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Very efficient insulation to reduce heat losses;
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0 – 0.1 bar pressure in the firing area to prevent
pollutants from being released into the working environment
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PLC-assisted control board to manage the thermal machine and
production, complete with alarm, consumption and production
statistics.
Production quality
The TCK-patented technologically advanced concepts have been
applied to this kiln, keeping the firing process under the
maximum control according to pre-set adjustments, to achieve top
quality production.
In fact, greater control means greater efficiency and
effectiveness.
Energy saving and a lower environmental impact
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An innovative and well-tested combustion system with 12
burners per module guarantees noticeable fuel saving,
generally 25% less than standard systems.
Moreover, by reducing the amount of fumes sent to the
stack and their temperatures, the legislation in force
regarding emissions can be fully complied with. This is
a great advance that allows us to increase environmental
protection.
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Type of product |
Temperature |
Consumption |
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Technical porcelain stoneware |
1220° C |
420 Nm3/hour |
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Glazed porcelain stoneware |
1205° C |
390 Nm3/hour |
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Single-firing |
1185° C |
360 Nm3/hour |
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Body tile |
1120° C |
320 Nm3/hour |
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Vitrified |
1050° C |
270 Nm3/hour |
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Porous single-firing |
1130° C |
410 Nm3/hour |
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Emissions
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A substantially lower consumption implies a reduction in
emissions, both in terms of volumes and temperatures.
Such a result is also achieved through the innovative
geometry of the kiln's inner sections (TCK patent),
which generates flows’ dynamics that are highly
beneficial to production, by reducing both the amount of
fumes sent to the stack by generally 20%, and their
temperature.
These reductions lead to a number of advantages. The
first one is at environmental level (by reducing the
volumes of fumes, the amount of CO2 and CO
released into the atmosphere is also lowered). Of
course, another advantage is that wear and tear on the
filters diminishes. It is apparent that filters will
benefit from the simultaneous reduction in the amount of
fumes and their temperatures since the need for
maintenance and the likelihood that too high
temperatures could damage or even break the filters’
sleeves will decrease. An indirect positive consequence
is that onerous production stoppages and/or slowdowns
will be avoided. |
Compared to a standard kiln, a TagDan kiln releases …
within one year of production...
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Insulation
The kiln’s insulation - both in terms of structure and
cutting-edge and environmentally-friendly materials – has been
carefully designed to reduce the temperature difference as much
as possible (up to 10°C) between the outer wall of the kiln and
the work environment.
Heat distribution
The smaller distance between the burners, from an average of
1,100 mm to 700 mm approx., allows to keep temperatures inside
the kiln more uniform, and to achieve immediate advantages in
terms of flatness, work size and uniform product porosity all
over the kiln’s cross-section. By increasing the number of
burners and consequently reducing their power, the thermal
impact on the refractory materials of the inner walls will be
lower, thus making their life longer.
Double-channel TAGDAN
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Third Firing and Special Trims Kilns : K3F
Our
kiln for third-firing applications and special trims has been developed
from the TAG DAN kiln, as the former maintains all the innovative
characteristics that have turned the latter into a technologically
advanced kiln in terms of materials and building concepts, such as:
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12 burners per module.
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Specially-designed silicon carbide combustion chambers for a more
uniform “fan-like” heat distribution.
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Cutting-edge insulated materials suitable to minimize the machine’s
heat losses and to reduce its environmental impact.
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Computerized control of all air/gas pressures and of any adjustment
required by the customer’s specific project.
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Possibility to choose between a fixed or modulated air solution for
each firing curve. This can be done for each gas ramp, and the whole
system is managed by a software installed in the kiln.
All
these characteristics ensure a homogeneous production in terms of colour
and/or any special effects.
Of
course, K3F kiln offers very low fuel and electricity consumption as
well as a low amount of fumes to the stack. These features are also
found in TAG DAN of which the K3F kiln is a further development.
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Tunnel kilns
: TKC
All the advantages of flexibility in a tunnel kiln.
This
kiln has been conceived and built especially for firing drawn items on
transfer systems, including bricks, terracotta floor tiles or roof
tiles.
TKC
has been designed to achieve the maximum structural flexibility right
from the assembly phase. Its modular structure makes construction,
transport and assembly easier, faster and cheaper while facilitating
disassembly and placement to another site at a later time. It is also
possible to add new modules to increase its production capacity and to
better adjust to the type of product to be fired.
In
just one sentence: the flexibility of a roller kiln with the sturdiness
and great potential of a tunnel kiln.
COMBUSTION SYSTEM:
TKC's
combustion system is equipped with high speed burners and specially
designed combustion chambers. Moreover, careful studies have been
carried out to direct the fumes in the most suitable manner - according
to the type of transfer system and supports - to achieve controlled
flows with homogeneous temperatures inside the firing chamber.
These
highly performing characteristics provide the kiln with excellent firing
quality in a shorter time compared to the average time required by
traditional tunnel kilns. By notably reducing combustion consumption and
the amount of fumes to the stack, the requirements laid down by the
Kyoto treaty regarding CO2 and CO emissions can also be
complied with.
Besides the kiln, TCK also manufactures the whole transfer system
including the set of chains and the transfer units which are made up of
brand-new refractory materials and designed to suit each type of
product. As a result, they are highly performing and resistant both to
physical work and thermal shocks.
Both
the material transfer and the kiln’s firing curves are controlled by
PLCs which allow the operator to fully automate the process, to adapt it
to new needs at any time and to check the work already done by
consulting the statistics which are automatically generated by the
software during the machine’s operation.
Last but not least, the firing system (using the term “kiln” would
certainly be a limited way to define it) can be equipped with completely
automated loading and unloading machines suitable for any type of
product, from bricks to roof tiles of any shape and/or size.
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