S.A. VSBK technology was established at Langkloof Bricks in 2011 - PowerPoint PPT Presentation

S.A. VSBK technology was established at Langkloof Bricks in 2011 through the SDC » climate change mitigation strategy, facilitated by Swisscontact. Technical support and technology transfer was provided by Development Alternatives, TARA, Minergy and Skat for the 6 shaft pilot VSBK constructed by Rowe Construction. » This 6 shaft VSBK derivative was completely redesigned and developed by Rowe Design & Consulting in association with Langkloof Bricks. The effort over the last 2-3 years has culminated in the latest RVSBK version of the technology and the construction of a further eighteen kilns at Langkloof Bricks. We are currently working with several project orders for approximately another fifty throughout South Africa. SOUTH AFRICA HUB

What makes RVSBK

» >200M³ concrete for the building » >40 Tons of steel reinforcing » Column and beam skeletal frame » 250,000 NFX stock bricks » 9 month construction program » Integration with the building

Autodesk 3D Inventor and Star CCM+ » computational fluid dynamics software are used to evaluate and enhance airflow design » FDS 2015 has enabled us to model the kiln in a true parametric environment and through Navisworks be able to integrate it into the factory environment. It can then be animated in such a way that there is no doubt as to the ease of operation and brick movement logistics.

» Parametric thinking introduces the shift in the mind-set between the search for a specific static and defined formal solution, and the design of the specific stages and factors used to achieve it. http://www.parametriccamp.com/ With FDS 2015 we have the best of both worlds with AutoCAD and Inventor.

» Individual raft foundation with combined pile design - Smaller foundation footprint reduces cost without compromising load bearing capability. This design provides a cost effective alternative to a combined foundation » Arch design change – Utilisation of technology to provide a durable heatproof casting for load bearing components. Reduces construction costs and time by alleviating support and shuttering lead times Cast flue design – Casting of a modular flue has » enabled the integration of an air induction system and provided a different approach to flue dynamics allowing ease of access for cleaning

» Flue duct system – Ducting is now connected below the working floor and a dual fans are connected to each shaft. This provides ultimate control over airflows for any combination of brick stacking or product » Short stroke hydraulics – The redesign has provided the ability to reduce the hydraulic system complexity and stroke length. The distribution system for the oil is housed in a duct run through the centre between the kilns. Together this has greatly reduced system cost » Integral plenum chamber and top working surface – Cast as a three part unit it provides an accurate means of green brick setting with working area purged with recirculated clean air. Loading times and construction is greatly reduced with an increase in brick setting accuracy

» RVSBK design - reduction of cost, time and materials compared to pilot kiln » Multi block customizable layout ease of access for loading / unloading » Decreased construction lead times with offsite component manufacturing » Modular approach- ability to enlarge facility to meet demand without shaft shutdown » Centralised hydraulic and crane supply system » Automatic fuel logging for CDM / ISO » Air recirculation system provides heat recovery and restricts emissions from the top of the shaft » Ease of access to reline the refractory shaft without affecting other shafts in proximity » Components can be easily replaced

» The RVSBK is the culmination of three years of design and testing it is globally available This is a truly industrial design capable of firing a » number of different clay brick products with greatly reduced fuel requirements

Energy efficiency and cost saving example from Langkloof Bricks Example used is the Pilot 6 shaft VSBK A VSBK averaging 3% fired losses can fire 120,000 more bricks per million than a clamp kiln typically averaging 15% nominal losses for the same quantity of bricks A VSBK is 12% more efficient regarding fired losses VSBK personnel only handle 97% sellable product not waste product VSBK produces 41.5% less CO 2 per brick VSBK is 41.5% more efficient as a firing system

Da Vinci Technology Top 100 Awards 2013

Contact: Jez Rowe Thank you Tel: 073 3699830 Fax: 086 5322186 Email: mail@rowepm.co.za