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Habla Zig-Zag Kiln Design Features

The Habla Zig-Zag Kiln is unique with design features that set it apart from other zig-zag kilns. Key design features and differences include:

  • A long fire zone – enables almost complete combustion and fuel efficiency
  • A roof – brings significant economic and workforce benefits
  • No tall chimney – minimising fuel wastage
  • Scalable in both continuous or semi-continuous mode
  • Easy implementation of mechanisation

LONG FIRE ZONE

A unique heat transference mechanism within a long zig‐zag fire zone allows for the recovery of residual heat from burnt bricks to be moved ahead of the fire zone. This accelerates the pre-drying of ‘green bricks’ before full firing and enables faster fire progression, increases brick production and energy efficiency.

  • Enables a greater variety of fuels and clays to be used.
  • Allows for optimal combustion and maximum energy extraction from all fuel sources.

INDUCED DRAUGHT & AIR FLOW

The small fan within the kiln creates a unique, induced draught, enabling even heat distribution, maximum heat generation and maximum energy extraction from fuel sources.

FIRE CONTROL

The fire, controlled through use of unique HZZK internal kiln components, is pulled through stationary bricks placed in a zig-zag fashion. The kiln operator controls the fire.

  • Provides consistent quality bricks with even cure and brick shrinkage.
  • Enables less than 2% fired brick waste, or 98% ‘A’ Class yield.
  • Due to the excellent control of the fire and the low brick setting height, it is ideally suited to fire perforated bricks and thin walled hollow large clay blocks; this conserves top soil, minimises land degradation and reduces energy requirements for the production of bricks and clay products.

ROOF

  • Protects kiln workers from all weather so that working conditions are improved both day, night and in all seasons.
  • Allows for the brick making season to be extended into the monsoon season and the increase of annual brick production.
  • Overcomes the high ‘overlooked costs’ of drying out a wet kiln after every monsoon season. The roof protects the masonry and eliminates these high energy costs associated with annual kiln drying.
  • Annually, up to 300 tonnes of fuel can be wasted through floor and wall heat losses and the necessity to dry out the kiln which becomes a monsoonal “sponge” in the wet season. There are substantial costs incurred to dry out kilns every new brick season.
  • Minimises costly repairs required due to monsoonal damage.
  • Allows for water collection (drinking and sanitation).
  • Allows solar panels to be mounted on the roof supplying power for the fan and lighting.

WORKPLACE AND WORKER FRIENDLY

  • Comfortable, dry, safe and easier working conditions and work practices.
  • The lower brick settings, near ground level with no elevation required, decreases risk of falls and related workforce injuries.
  • Clean, non-polluted working environment.
  • Workers protected from all the elements by the roof.
  • Clean air quality, no billowing smoke or black carbon on site due to almost total fuel combustion.

NO TALL CHIMNEY

  • No tall chimney needed as draught is created through use of induced draught fan.
  • It is un-necessary because of low emissions
  • This decreases construction costs.
  • Decreases construction time.
  • Exhaust gases are minimised through near complete fuel combustion.
  • Minimal emissions are released via small chimney made of metal or brick extending just above the roof line.

SCALABLE OPERATING MODE

  • The smallest construction footprint (size), compared to other kilns with comparable outputs.
  • Options exist to operate in both a continuous or semi-continuous mode, allowing for smaller or larger outputs depending on operators requirements i.e. large scale (industrial) or small scale (village/rural setting).
  • The design, inclusive of all unique features, is the most suitable kiln replacement technology to minimise black carbon and provide clean air due to its almost complete fuel combustion.
  • It has flexibility in the source of power to drive the fan.
  • Can operate successfully without access to the electrical grid.
  • Diesel and solar can be used as a power source day and night.
  • Brick production requirements (output demand) determines the size/footprint of the kiln i.e. an increase or decrease in the number of kiln chambers.

PROGRESSIVE MECHANISATION IS EASILY ACCOMPLISHED

  • Kiln design can be adjusted to allow for forklift setting and removal of fired bricks.
  • Doors/wickets can also be altered in their size and sealing mechanisation, depending on kiln requirements including to allow for truck access.
  • Increase in mechanisation/machine automation systems reduces handling of bricks and reduces risk of associated damage.
  • Automatic fuel feeders can be incorporated into the kiln design, providing mechanised fuel distribution.