EPC Process Design Checklist for Clay Sintered Brick Plant 
(Professional Version)

I. Raw Material Evaluation & Process Suitability Analysis
1. Systematic Raw Material Testing
(1) Purpose: To determine the suitability of raw materials for sintered brick production and define process constraints.
(2) Mandatory test items:
· Chemical composition analysis (SiO₂, Al₂O₃, Fe₂O₃, CaO, MgO, SO₃, LOI, Organic matter);
· Particle size distribution (<0.1, 0.25, 0.5, 1.0, 2.0 mm);
· Liquid limit / plastic limit and plasticity index;
· Drying sensitivity coefficient (<0.6 is optimal);
· Sintering temperature range (Tstart–Tmax);
· Lime bursting / efflorescence tests;
· Optimal forming moisture content, permissible drying rate, deformation rate.
2. Sampling Principles
(1) Take one composite sample every 1–2 m depth during mining;
(2) Cover all geological strata using cross-section maps and GIS models;
(3) At least 10+ sample points are recommended for blending analysis.

II. Site Survey & Civil Engineering Design Basis
1. Topography and Geological Data
(1) 1:500 topographic map with boundary demarcation;
(2) Geological drilling (suggested ≥15 m depth), including bearing capacity and water table;
(3) Post-leveling site elevation for drainage and slope planning;
(4) Wind rose, annual extreme weather data (flood level, max wind speed, rainfall, etc.).
2. Environmental Impact Pre-Assessment
(1) Mapping of sensitive areas within 500 m (schools, residences, rivers);
(2) Plans for noise control, dust prevention, anti-seepage, and wastewater overflow containment.

III. Process Flow Design
1. Flow Diagram Structure
(1) Covers five major systems:
· Raw material processing → Aging & dosing → Forming → Drying → Firing system.
(2) Must indicate:
· Material flow paths,
· Key control points,
· Input of air/gas/water energy,
· Process parameter boundaries.
2. Output Process Parameters
(1) Annual capacity × effective working hours → single line output → determine number of lines;
(2) Daily material usage (wet/dry basis);
· Aging storage volume: usually for 3–5 days of production;
· Synchronization of drying and firing cycle (60–90 kiln cars);
· Sintering temperature: generally 920–1000 °C, calibrated by raw material;
· Flue gas O₂ content: design 16–18%, control ≤18%.

IV. Thermal Load Calculation & Thermal Engineering Design
1. Detailed Heat Load Calculations
(1) Latent heat of moisture evaporation (approx. 2250 kJ/kg);
(2) Sensible heat of raw material and green bricks;
(3) Reaction heat during sintering (dehydroxylation, calcium carbonate decomposition, etc.);
(4) Flue gas sensible heat (determined by exhaust temperature and volume);
(5) Internal combustion heat value and blending ratio (e.g. coal gangue, shale powder);
(6) Heat loss through kiln shell (typically 8–12% of total heat load);
(7) Design thermal efficiency: 55–60%, with 10% margin for winter/rainy season.
2. Fan Parameter Synchronization
(1) Gas exchange rate: 0.5–1 times/hour;
(2) Separate calculations for primary air, cooling air, combustion-supporting air, etc.;
(3) Recommended: Variable frequency fan control + in-kiln temperature/pressure PID feedback loop.

V. Tunnel Kiln Design Essentials
1. Structural Recommendations
(1) Standard cross-section: 6.9×2.1 m or 9.2×2.4 m;
(2) Effective length: 120–160 m;
(3) Longitudinal slope ≤ 2‰ for smooth car movement;
(4) Sintering zone includes 12–18 temperature-controlled subzones.
2. Refractory Configuration

VI. Natural Gas Burner System Design
1. Core Role: Natural gas burners are the “brain” of the tunnel kiln’s thermal system. Their control stability directly impacts product quality, energy consumption, and environmental compliance.
2. Key Technical Parameters:
(1) Thermal power design: 1.25–1.4 × max kiln heat load for redundancy;
(2) Turn-down ratio ≥ 1:10, enabling precise temperature control (ramp-up, holding, cooling);
(3) Low-NOx combustion technologies: FGR, staged combustion, low-NOx nozzles;
(4) Integrated control: PLC system linked to kiln temperature, O₂, CO sensors; supports DCS systems;
(5) Safety features: UV flame detector, dual solenoid valves, pressure stabilizer, flameout reset;
(6) Burner layout: staggered top + side opposing jets; avoid one-sided combustion;
(7) Maintenance-friendly: each burner equipped with blind flange and manual shut-off valve.

VII. Dryer System Design
1. Drying Duration: 24–32 hours, final moisture content ≤6%;
2. Hot Air Inlet Temperature: 120–150 °C;
3. Moisture Exhaust Temperature: 35–45 °C;
4. Relative Humidity:
(1) Inlet zone ≥90%
(2) Outlet zone ≤40%
5. Airflow Speed: 1.5–4.5 m/s (adjustable based on brick stack pattern);
6. Configuration:
(1) Variable frequency fans
(2) Electric temperature control valves
(3) Humidity sensors with auto-cleaning function.

VIII. Equipment Selection & Matching Parameters

(1) Note: All major equipment should include a performance guarantee clause covering:
· Daily production capacity;
· Energy consumption per 1000 bricks (kWh/1000 pcs);
· Brick green body flexural and compressive strength;
· Lifespan of key wear parts.

IX. Electrical & Automation System Design
1. Control System: PLC + SCADA;
2. Communication Protocols: PROFINET or EtherNet/IP;
3. Sensor Network: Online temperature / humidity / pressure / oxygen content;
4. Drives: ABB / Siemens VFDs;
5. MES System: Automatic reporting of production, energy, quality data;
6. Kiln Wiring: High-temperature-resistant mica-insulated cables, heat isolation bridges;
7. Dryer Sensors: Must be waterproof and equipped with automatic dust removal mechanisms.

X. Environmental Protection & Energy System
1. Emission Standards (recommended targets):
(1) Particulate matter ≤30 mg/m³
(2) SO₂ ≤100 mg/m³
(3) NOx ≤150 mg/m³ (≤80 mg/m³ in key control areas)
(4) Online CEMS monitoring system
2. Three-stage pollution control system: Baghouse filtration + desulfurization + SNCR denitrification
3. Energy-saving Measures:
(1) Waste heat from flue gas reused in dryer;
(2) Recirculation of cooling air;
(3) Energy target: ≤18–22 m³ of natural gas per ton of finished bricks (per 10,000 bricks).

XI. Utility Systems
1. Water Supply: ≥1.2 m³ per 1000 bricks; recycling ratio ≥90%;
2. Power Supply: Total installed capacity ≈ annual output (million bricks) × 1.3 kW;
3. Compressed Air: 0.6–0.8 MPa; oil content ≤0.1 ppm;
4. Steam Supply (optional): for drying or desulfurization; 0.4–0.8 MPa saturated steam.

XII. Construction & Delivery Management
EPC Project Milestone Plan (T0 = Contract Start Date):