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News CenterFollowing the successful launch of DLT wide-body roller kiln in Line 3 for the production of “zero point zero percent” water absorption GVT (glazed vitrified tile) in February, 2020, recently in March end at Monalisa Group (Guangxi) Production Base, another DLT kiln which is installed in the neighbouring Line 4 started mass production successfully, showing good performance and having met the stringent requirements of the well-known tile manufacturing giant.
Since its being put in use, the kiln for Line 3 has shown a record of 95% and above first grade pass rate until now. Its overall gas consumption including that of the kiln, 4-layer dryer, pre-kiln dryer and glaze line dryer, has been keeping at a level lower than 1.62Nm3 natural gas/m2 tile without any backup from a chimney fume type heat exchanger for supplying recycled hot air to the 4-layer dryer（Note：In China, the formula of tile body and calorific value of natural gas are different from that in some countries like India or Middle East, and therefore the kiln gas consumption in China is usually higher than in other countries) . It is further another successful sample of DLT wide-body, large output and energy-saving kiln following the one which is currently running in Monalisa (Qingyuan) Production Base. Its excellent performance marks a new milestone in the research and development of energy-saving kilns in the ceramic industry of China, showing that DLT kiln technology has stepped into an era of intelligent manufacture 4.0+.
As a leading manufacturer of ceramic tile for high-end markets both home and aboard, Monalisa Group has put great efforts in the technical promotion and upgradation for the Chinese ceramic industry all the time since its founding. The successful startup of the intelligent manufacture 4.0+ energy-saving kilns in Monalisa (Guangxi) plant provides a good reference for all the other ceramic production areas in China.
The wide-body natural gas type roller kiln (W3100/L380.1M) and "EM" series 4-layer self-circulation dryer is a conjunction of high-end firing equipment with the mode of modernized and digitalized intelligent manufacture 4.0+. Overcoming the area limitation, the production line has utilized efficient remote control and big data cloud technology to change qualitative description and experiential management into intelligentized data-based management. The automation, informization and intelligentization level of the production line has reached the industry's most advanced level.
Decorated with the latest DLT 4th generation fully-covered industrial design which is conforming to CE standards, the exterior appearance of the kiln for Line 3 not only looks beautiful but also reflects the scientific configuration of design. Supported by a number of DLT patented technologies with independent intellectual property, the line boasts high automation and stable finished product pass rate. At present, it mainly produces 800*800*10.5mm "zero point zero percent" water absorption GVT with a designed output of
25,000m2/ day.
The kiln for Line 3 features a fully-covered streamline structure and high quality nano grade thermal insulation material, in addition to the advanced heat retaining burners, SPR energy saving system, DMA movement control system and KHI updated Insulation system. Besides the above, the kiln is particularly equipped with DLT’s patented technology - DHR heat recovery system (Patent No.: ZL2016010992314.3) for recycling waste hot air from the indirect & direct cooling zones of kiln and supplying it to the 4-layer dryer, pre-kiln dryer and glaze line dryer, and therefore no need to start the burners of these dryers in their normal running, thus achieving zero emission of waste heat from the kiln.
The multi-layer self-circulation dryer has the advantages of good air-tightness, excellent drying efficiency, zero breakage and space-saving. It also shows stable performance and good adaptability to low strength tile formula, fast and efficiently providing qualified tiles for the firing process. Its work efficiency in the utilization of waste heat of kiln is excellent and unbeatable as compared with other similar equipment in the present market.
Equipped with DLT’s unique digitalized PPC proportional control system for combustion air and OCE optimal combustion eco system, the gas consumption of kiln is greatly reduced, once again updating the lowest record of kiln overall gas consumption among the natural gas type large output roller kilns for "zero point zero percent" water absorption GVT production in the whole industry.
This exclusive technology has been maturely applied to many of DLT’s overseas projects. While as the first time being used in China at Monalisa (Qingyuan) plant, it made a record lowest kiln overall gas consumption (including that of the 5-layer dryer, pre-kiln dryer and glaze line dryer) between 1.55 and 1.6 Nm3 natural gas/m2 tile, and later became a new benchmark followed by many of the manufacturers of energy-saving kilns in the industry.
The 4.0+ energy-saving kiln is a notable result of DLT team’s over 20 years’ exploration in the global market and experience accumulated from more than 800 sets of natural gas roller kilns. By possessing the core technology and grasping the current trend of the industry, DLT’s R&D engineers have particularly studied the actual condition in the customer’s factories so as to develop the most efficient and optimal drying and firing systems to match the production condition. The performance of DLT dryers and kilns has gained good recognition of the management team of Monalisa Group.
Obviously, the successful running of Line 3 and Line 4 in Monalisa (Guangxi) Production Base will provide a solid support to Monalisa Group in its brand upgrading and market competitiveness.
As a major strategic partner of HLT & DLT, Monalisa Group has shown their admiration and recognition of the efforts which DLT work team has put in the development of the intelligent 4.0+ energy saving kilns. Responding to the customers’ expectation, DLT will further proceed in the exploration in order to provide more and more energy-saving and eco-friendly drying and firing equipment for the customers all over the world.
