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CGE - Kilns : gas,electric, high temperature

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CGE Hydralift
- Bogie Hearth Kiln

The CGE Hydralift Bogie Hearth Kiln has been developed for use in many applications, with significant success in areas such as roofing tiles and sanitaryware. Utilising a unique and patented 'hydralift' sealing system and advanced controls, this type of kiln produces exceptional yields and minimum firing cycles. Benefits include :-* The 'Hydralift system' combines both compression and labyrinth sealing to provide an excellent kiln to hearth seal. * High undercar temperatures are not experienced. * The seal reduces the need for pressure control allowing the kiln to operate under negative pressure without ingress of cold air into the kiln. * When the kiln is operating under negative pressure the cold face temperature of the kiln cars is lower, therefore extending wheel bearing life.

The whole kiln is mounted on hydraulic cylinders which permit the hood to be raised and lowered above the cars. There is no rubbing, only compression, which allows for long seal life. As the hood is lowered onto the cars , fibre blanket along the side of the kiln compresses on the edge of the refractories of the kiln cars. These, in turn are profiled in a labyrinth manner to ensure minimum losses to the environment.

CGE Double Deck Sanitaryware Kiln

The CGE Double Deck Kiln can be offered in Bogie Hearth or Moving Hood design. In either case each hearth has a sub deck and two ware support decks designed to minimise thermal mass and maintain adequate strength. Available kiln capacities include 125, 280, 400 and 600 pieces per firing. Benefits include :-* Fires both once fire and refire sanitaryware in only 11.5 hours from cold to cold. * Incorporates multi-zone control in upto 12 separate zones and is equipped with 'operator friendly' touch screen control. * Exceptional yields have been achieved in recent installations, including an average first fire yield of 85%. * CGE's unique and patented hydralift system combines both compression and labyrinth sealing to provide an excellent kiln to hearth seal, while the kiln to car and car to car sealing arrangement ensures minimum heat loss whilst maintaining outstanding temperature uniformity. * Kiln temperatures within 5 degrees C. * Minimal dunting owing to underdeck and overdeck product firing.

The choice of underdeck firing is based on the theory that the setting deck will act as a sink from which energy will be transferred to the ware. In this way, flame impingement on the ware, which creates higher temperature differentials, is avoided. CGE believe the use of underdeck firing eliminates the problem of dunting and this directly improves the overall process yield. Effective temperature control is a critical factor in providing fast, even firing and thus good quality products. CGE has developed a number of temperature control systems based on zone or individual burner control. The temperature of the kiln is controlled individually by modulating the burners in each zone. Each zone is controlled from its own thermocouple, which sends a signal to the system.

Solid Hearth Kiln The CGE Solid hearth kiln is a more traditional design, with the kiln and hearth static. This design is ideal for exceptionally large or heavy product. When firing small quantities of product, the CGE Solid Hearth Kiln is ideal and can be set from one side, or two doors can be provided so that the kiln can be loaded from both sides. For high output rates such as building bricks a Solid Hearth Kiln offers an economical production unit. Bricks can be set in packs and moved by forklift truck to the kiln. For this type of product the kiln can be top or side fired. The Solid Hearth Kiln has recently been used successfully to fire very large insulators and incorporates: * A low thermal mass lining which permits fast turnaround. * A rapid cooling system is provided as well as zone temperature control. * The combustion system utilises a number of CGE Universal Burners which fire horizontally under the load and vertically up the sidewalls.

The burner positions are alternated so all of the product is influenced and the resulting flow patterns produce excellent temperature uniformity at all timed during the firing. The kiln hearth is set into the ground so that the top surface is at floor level. This type of hearth is widely accepted as being very durable, has a good resistance to 'dirt trapping' and should result in minimal growth.

Gas Moving Hood Kiln The CGE Moving hood kiln has been developed for the firing of a wide variety of ceramics including bricks, tiles and refractories. The moving hood design is simple yet highly effective. The product to be fired is placed at pre-determined positions on one of two hearths situated at ground level. The hydraulically operated kiln lifts several inches and, guided on rails, positions itself over over the set hearth where the doors will close, allowing the automatic firing and cooling cycle to commence. While the kiln is firing the load, the other hearth can be cleared and reloaded. Benefits include :- * Individual burner control in upto 32 control zones providing excellent temperature uniformity. * CGE's own standard 'operator friendly' touch screen control system. * Burner and temperature control in the kiln ensures a controlled and even firing throughout the cycle, which substantially improves the success of the firing process and consequently reduces the cost to produce each good piece. * The flexibility of the moving hood configuration allows different firing cycles to be programmed for different products. * A far greater scope for product flexibility with a fast turnaround of approximately 15 minutes between firings. * The reduced downtime maximises both production and return on capital, while the incorporation of a low thermal mass lining contributes towards reducing the overall firing cycle. * As the product is set directly onto the fixed hearths, both handling and damage are minimised.

Pallet Hearth Kiln The CGE Pallet Hearth Kiln is an exclusive CGE design. Its main benefit is its flexibility, while providing the added advantage of eliminating the need to handle the ware more than once between the production area and the kiln. Using normal setting methods, the ware is set straight onto the hearth at the production area. Once full, the hearth itself is then transported using either a hand operated pallet truck or a fork lift truck and lowered directly into the kiln. This gives much greater flexibility in factory layout as there are no requirement for car tracks.

The sealing method for this kiln is based on the same principle as for the Hydralift Bogie Hearth Kiln. However, instead of lowering the kiln onto the hearth, the hearth is lowered onto a seal inside the kiln, providing an excellent gas tight seal. Where the kiln holds more than one hearth, the interlocking pallet design ensures the same gas tight hearth to hearth sealing.

These kilns have been found to be suitable for firing all types of ware, and have been particularly successful in the manufacture of small components such as technical ceramics, which can be easily damaged through excess handling.

Fast Track Kiln The CGE Fast Track kiln has been developed for the fast firing of tableware, bricks, sanitaryware, refractories and industrial ceramics. This highly innovative design provides a cost effective solution to continuous firing up to temperatures as high as 1500 Centigrade. Benefits include: * Excellent temperature uniformity is achieved across the section of the Fast Track Kiln owing to its envelope of heat input. * A very accurate temperature profile can be achieved down the length of the kiln and multiple zones can create the ideal firing conditions. * Control of the kiln is directed from a single panel mounted on the unit. * Electrical input to the kiln is distributed over the roof, side walls and hearth, with a digital temperature controller incorporated in the control panel for each of the zones. * The kiln can be accommodated into most in-line systems and, should production capacity increase, extra modules can be added to extend the kiln's length. * The unique design of the kiln means that a complete seal is created in the hearth, enabling kiln pressure to be completely stable. * This type of kiln can be electric or gas fired and has all the advantages of competing designs such as roller hearth kiln and many unique features where rapid firing of multi products is required. * The Fast Track, by comparison with the roller hearth kiln, has a far greater setting width and a very high load bearing capacity for product. *
The kiln also eliminates any relative movement between the product and the hearth. * A rapid cooling system which minimises product cooling time and rapid change of operating conditions / cycle times to suit any product requirements. The ratio of refractories to ware is low thus allowing more product to be fired with the same amount of energy in the kiln. * Low capital cost implications as there are no requirements for kiln cars, car transfer and car return systems. * Very flexible. * Low thermal mass means the heat up and cool down times are rapid and therefore the kiln can be shut down economically at the end of shifts / day weekend etc. * Conveyor speed and process temperature are variable which allows for very rapid product changeover.

High Temperature Kiln The CGE High Temperature Kiln is designed for firing technical ceramics such as Silicas and Aluminas. Capable of producing oxidising atmospheres at temperatures of upto 1760 Centigrade, these kilns utilise traditional construction techniques combined with advanced control systems. Benefits include :- * CGE's unique combination of thermocouple and optocouple which provides extended life and excellent control. * Insulated lining providing low coldface temperatures, greatly reducing energy losses. * CGE Self Recuperative Burners, positioned at low level to fire horizontally up and down the kilns length. This burner was specifically developed to save energy and promote rapid firing capabilities.

The kiln pressure is controlled by varying the suction through the Self Recuperative Burners thereby evacuating more or less exhaust products as necessary. A panel mounted pressure indicating controller provides a signal to the educator system which maintains the kiln pressure within the pre-determined limits.

Electric Moving Hood Kiln The automated CGE Moving Hood Kiln has a vertically operating door at each end of the kiln, and has two hearths situated such that the kiln can move from one hearth to the other on rails. The pieces to be fired are placed on the available hearth. The kiln extends its wheels lifting clear of the hearth; the doors open and the kiln will then traverse to the set hearth where the doors will close. The kiln then lowers itself onto its seals and the firing sequence starts. The operation will generally be controlled by an operator, but there is the added facility to make automatic transfer and restart sequences. The kiln is sealed by lowering onto a refractory base and all kiln movements are powered hydraulically.The hearth construction is of low thermal mass design and comprises a perimeter of refractory bricks complete with element support and is then filled with ceramic fibre blanket. The kiln is very effectively sealed by lowering the kiln hydraulically and compressing the fibre seal on the underside of the kiln onto the refractory perimeter of the hearth. This perimeter has a casilated cross section to form a labyrinth seal. CGE have considered the problems associated with high temperature elements and the relative high maintenance costs incurred. With this in mind, CGE supply high quality elements which provide the following benefits: - * Improved form stability (no bunching or creeping). * Less need for element support. * Longer element life.
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