Alibaba construction ltd auto bricks in bangladesh

Auto bricks manufacturer and supplier in Bangladesh
Corporate Office:
House 25, Road 05, Sector 06
Uttara, Dhaka- 1230.
Phone No.+88-09-638673993, 01716-752370
Website: www.alibabaconstructionbd.com
E-mail: alibabaconstructionbd@gmail.com
Project Site:
Gazipur, Mymensingh, Magura, Narsingdi
Capacity: 100,000 pcs per day
ALIBABA CONSTRUCTION LTD
An automatic clay brick production project

Project Profile & Feasibility Report, Page: 1
The technology, now in practice, for production of bricks in Bangladesh is a primitive one which
is very much inefficient both in energy consumption and in production economies resulting high
unit costs, poor quality and environment non friendly.
This study describes a highly efficient kiln technology now in practice in China and the most
modern form of brick manufacturing with full automation. The proposed technology will
drastically reduce energy use and generate scale economies reducing production costs.
Moreover, this technology will reduce pollution by lowering CO2 emissions. The smallest size
plant can produce a net 60 million bricks of size 250 mm x 120mm x 75 mm all over the year.
The plant is capable of producing bricks of almost any size, shape and pigmentation (color) at
the plant with slight modifications in the molds. As a regular practice the supplier of the plant
and technology will supervise the technical matters of the project, oversee construction of the
project, commission the plant, supervise operation of the plant for about six months and train
local manpower of the plant in the technology and in quality control of the product.
One of the preferred supplier of the technology and machinery can be The China Light Industrial
Machinery Association, is the only national association in the industry of light machinery in
China and pioneers in Automatic Brick Plant Machinery Manufacturing in China. It is
internationally certified organization and Members of the association includes enterprises, public
institutions, universities, research institutes, local industry associations and some other trans-
regional and cross-sectorial organizations and societies which are involved in the manufacturing,
marketing, designing and testing of light machinery such as brick making and manufacturing
plants.
As per the government decision all conventional primitive chimney based plants will be
eliminated within 2014 and is to be replaced by the modern environment friendly technology.
The World Bank is already assisting Bangladesh to achieve the goal of replacing old brick plants
into modern technology based plants. Assuming this we can consider Bangladesh shall have to
set up many similar brick plants as the proposed to meet the market demand. This will widely
open the opportunity of this industry, Automatic Brick Plant.
In Bangladesh, brick is the predominant building material in urban areas. It has become a
significant building material even in the rural areas. High prices and/or scarcity of alternate
building material such as, stones, iron sheets, wood, bamboo, and straw are increasing the
demand for bricks at a very high rate. To meet the increasing demand, brickfields are
mushrooming all over the country with heavy concentrations at the outskirts of urban areas. With
increasing demand for bricks, more and more paddy fields are being converted to brickfields thus
putting tremendous pressure on the already scarce agricultural land of the country. The
haphazard growth of the brick industry is completely unsustainable. Table-1 lists the three brick
making technologies being used in Bangladesh along with the share of the market for each
technology. The description of these technologies is presented in the next section. The totals
shown in Table-1 for both kilns and bricks are approximate figures and are industry estimated,

2010. As can be seen of the total 8.27 billion bricks produced in the country, approximately 6.28
billion of those have been produced in FCKs. The other two technologies are responsible for
24% of the bricks.
Table 1: Market Share of the Coal-Fired Kilns Being Used in Bangladesh
Percentage of
Annual Brick
Percent of Total
Kiln Type Number Production
Total Production
(ML)
FCK 3,138 76% 6,280 75.9%
BTK 797 19% 1,590 19.2%
Zigzag 198 5% 400 4.8%
Total 4,133 100% 8,270 100%
Current Structure of the Brick Industry
Brick making is yet to be classified as an industry in Bangladesh. Characteristically, though, it
can be described as a “footloose” industry. Production is seasonal, confined to the six to seven
dry months of the year; technology outdated; labor productivity low; capitalization non-existent,
mostly operating on equity capital; and management, informal. Small and medium enterprises
(SMEs) dominate the ownership pattern with little or no cooperative or large-scale operations.
An overriding characteristic of the majority of brick makers is the extreme difficulty that they
have with working capital; they are able to finance their activities only through informal
“banking” channels such as family, friends and moneylenders. In addition to high lending rates,
these channels are cumbersome, time consuming and, mostly, inadequate. A national standard
for building bricks exists, but most of the production does not meet these standards in one or
more of the specifications. The bricks produced in Bangladesh do not conform to any standards
even though a national standard exists. For instance, while the standard size of bricks in
Bangladesh is 240mmx 115 mm x 70mm, actual size varies from 225 to 250mm long, 115 to 125
mm wide 65 to 75 mm thick. Most of the bricks are still hand molded. Mechanical equipment
driven by ox or mechanical power are almost always used to mix the clay. Bricks are dried in
open air. BTK technology is mostly employed to fire the bricks. The bricks produced in
Bangladesh are visually sorted into three grades: first, second and third. About 20% id what is
popularly called “Zhama” bricks or refractory bricks. This type of production occurs because of
the nature of the kiln.
There are several barriers that have contributed to the current state of the brick making
“industry”
(BMI) and its inability to bring about changes:
Lack of supporting regulations to encourage more energy-efficient practices and
technologies. There has been little or no activity by the government to assist the brick
industry in developing a comprehensive program to make the industry less polluting and

more profitable. Brick makers have been left to develop the industry on their own which
they have failed to do. Some changes, however, have been initiated but these have come
not from the traditional brick makers but a few new entrants;
Lack of access to energy efficient technologies that can lower production costs.
Comprehensive technology diffusion programs that demonstrate the potential economic
benefits of energy-efficient technologies have yet to be carried out;
Lack of access to liquidity to finance modernization of plant and equipment; and
Lack of awareness of energy-environmental and scale production and management issues.
A majority of the Bangladesh Brick Manufacturing Owners Association (BBMOA) lack
understanding of the basic concepts of process technology, the relationship between
technology, techniques and output, modern management techniques and input-output
relationships.
Brick Manufacturing Technologies in Bangladesh
To understand the drawbacks and the benefit of the automatic brick/plant here are the brief of the
different types of technology are being used in Bangladesh.
1. FIXED CHIMNEY KILN (FCK)
The Chimney in a Fixed Chimney Kiln (FCK) as the
name suggests is fixed and is approximately 130 ft
high. This tall chimney creates a stronger draft thereby
improving the combustion process, and releases the flue
gas at a height 130 feet above the ground thus providing
faster and better dispersion.
The kiln has underground piping to divert the flue gas
from anywhere in the kiln to the fixed chimney. The
length of the kiln is same as that of the BTK but its
width is greater to accommodate the underground
piping. The FCK also has better insulation in the
sidewalls, which reduces heat loss to the surroundings.
The cost of constructing the chimney is Taka 1,500,000
(US$ 18,000), which is nearly 50% of the total cost of a FCK.
2. BULL’S TRENCH KILN (BTK)

The Bull‟s Trench Kiln (BTK) is essentially an elliptical
shaped dug out area in an open field. The kiln is about
250 ft long and 57 ft wide and has two 32 ft high
moveable chimneys. The bottom and the sidewalls of the
kiln are lined with bricks with the top left open. Sun dried
bricks are stacked in the kiln in an orderly fashion
leaving enough room for fuel stoking and air circulation.
After arranging the bricks in the kiln, the top of the kiln is
covered with fired bricks and pebbles. The bricks are
fired from the top and the fire moves forward towards the
chimney. The air entrance opening (air hole) and the
chimney are located at the two ends in such a way that
combustion air is preheated by taking heat from the fired
bricks, and the green bricks to be fired are preheated by the flue gas on its way out of the
chimney. The bricks are fired all around the kiln, which means that the chimney and the air hole
must be progressively moved forward, until all bricks in the trench are fired.
The chimneys are made of iron sheets and during a typical season of five months these need to
be replaced two to three times because the corrosive flue gases eat away the chimneys very fast.
Rain and floodwater destroy the kiln every year because of which BTKs need to be constructed
almost from scratch every year.
3 HEBLA OR ZIGZAG KILN
The Hebla or Zigzag Kiln is rectangular in
shape and measures 250 ft by 80 ft. It has a 55
ft high fixed chimney located on one side of the
kiln. At the bottom of the chimney there is a
blower, which draws the flue gas from the kiln
and discharges it to the atmosphere. The kiln is
divided into 44 to 52 chambers, which are
separated from each other in such a way that
the hot gases move in a zigzag path through the
kiln. The Zigzag Kiln is reported to be 10-15%
more fuel-efficient than the FCK. This Kiln is
expensive to construct and costs approximately the same as a FCK. There are about 30 such kilns
in operation mainly in the Comilla region. Present FCK owners are keen to convert to the Zigzag
technology if the Department approves it as an acceptable technology. The construction
technology is not easily available and expertise has to be procured from the neighboring states of
India.

Our Auto Brick Plant
4. HYBRID HOFFMAN KILN
The proposed plant will use the most modern
and highly efficient kiln technology now in
practice in China and many other countries of
the developed world using brick
manufacturing with full automation. The
proposed technology will drastically reduce
energy use and generate scale economies
reducing production costs.
Moreover, this technology will reduce
pollution by lowering CO2 emissions. The
study is based on actual experience in China with necessary modifications for adaptation in
Bangladesh. The plant will produce 60 million bricks of size 240 mm x 115 mm x 53 mm
annually. Annual working days have been assumed to be of 300 day, each day in 2 shifts of 8
hours. Bricks of any size, shape and pigmentation can be produced at the plant with minor
modifications. All bricks will be of uniform quality and will meet international standards for
strength, quality and appearance. In addition to kiln efficiency, a technique commonly used in
China to make bricks is to inject fuel into the green bricks. This technique enables better thermal
bonding and reduces fuel usage, and hence CO2 and other emissions. The supplier of the plant
and technology of China will supervise technical matters of the project, oversee construction of
the plant, commission the plant, supervise operation of the plant for about six months and train
local manpower of the plant in the technology and in quality control of the product.
The supplier of the technology and machinery of China will be the technical supervisor to the
project and will oversee the construction of the project, commission the plant, supervise its
operation for about six months and provide training in the technology.
A team consisting of professors from the Bangladesh University of Engineering and Technology,
members of the Bangladesh Brick Manufacturers and Owners Association and the technology
promoters visited China in February 2005 to study the technology and to make site visits to
operating brick fields in China. The consensus of opinion was that this technology was highly
suitable and could readily be adapted in Bangladesh. Bricks brought back from China were
tested at BUET and found to be of superior quality than those currently being produced in
Bangladesh from higher quality clay.

THE MAIN FEATURES OF THE PLANT ARE AS FOLLOWS
Housing is the one of the essential need of the human being. With the increase of population as
well as economic development of the country, the requirement of brick is increasing day by day.
The demand for environment friendly quality bricks is higher than manually produced brick. The
proposed project has been designed for production of fully automatic environment friendly clay
bricks manufacturing unit. In this project, the plant is made up of the brick molding workshop,
drying chamber, tunnel kiln, the power supplying equipment and other assisting equipment, etc.
The different processing is below:
A. The material processing period: the processing treatment and aging of the Clay
B. The molding period: green brick making
C. The drying period: the green brick drying
D. The finishing firing period: brick finishing firing
In this project, the power and the assisting equipment include, material stacking site, finished
brick palletizing site, electricity distribution station, water pump room, laboratory, office,
storage, and dormitory for different shifts workers, etc.
Production Process Flow Diagram:
Clay Brick Producing Technical Process Description:
Most brick workshop has some or all of the following:
i. A kiln, for firing, or 'burning' the bricks.

ii. Drying yard or shed, for drying bricks before firing.
iii. A building or buildings for manufacturing the bricks.
iv. A quarry for clay.
v. A pug mill or clay preparation plant
In typical modern brick workshop, clay is taken from the quarry, and then carried by conveyor
belt or truck/lorry to the main factory, although it may be stockpiled outside before entering the
machinery. When the clay enters the preparation plant (Clay Prep) it is crushed, and mixed with
water and other additives which may include breeze, a very fine anthracite that aids firing. This
process, which is also known as pug milling, improves the consistency, firing qualities, texture,
and color of the brick.
From here, the processed clay can be extruded into a continuous strip and cut with wires, or put
into moulds or presses (also referred to as forming) to form the clay into its final shape. After the
forming or cutting, the bricks must be dried, either in the open air, in drying sheds, or in special
drying kilns. When the bricks have been dried, they must then be fired or 'burnt' in a kiln, to give
them their final hardness and appearance.
Brick making process, with clay as raw material
Clay Brick Producing Equipment
1. Box feeder
A box feeder is designed for storage, dosage and preliminary breaking up of materials used in
clay brick production. Their basic functionality is to dose and transport raw material for further
production stages.
Model Capacity
(m3
/h)
Conveyor belt Conveyor
width (mm）
Conveyor
speed (m/s）
Power (kw）
GD650 9-35 Rubber 650 6 5.5
GD800 15-40 Rubber 880 5.3 5.5
GD1000 25-90 Rubber 1000 6 7.5

Plate feeder
Plate feeder is used to convey diferent kinds of particulate, lumpy materials in horizontal or
inclined direction in building material, metallurgical, coal and chemical industries, and it's
suitable for feeding lumpy lime stone, gypsum or clay from the bottom of feed bin to the inlet of
crusher continuously and evenly.
Model Capacity
(m3
/h)
Conveyor belt Conveyor
width (mm）
Conveyor
speed (m/s）
Power (kw）
GL800 20-35 Chain board 680 7 7.5
GL1000 25-40 Chain board 880 7 7.5
GL1200 30-50 Chain board 1080 7 7.5
2. Rubber belt conveyer
Belt conveyor is used in the transmission of sections like Clay Preparation, Molding, Loading &
Unloading, etc.

Rubber belt
conveyor width
(mm)
Conveyor length(meter)/Powder (kw)
Conveying
speed
(meter/second)
Capacity
(MT/hou
r)
500 ≤12/3
12-20/4-
5.5
20-30/5.5-7.5 1.3-1.6 78-191
650 ≤12/4 12-20/5.5 20-30/7.5-11 1.3-1.6 131-323
800 ≤6/4 6-15/5.5 15-30/7.5-15 1.3-1.6 278-546
1000 ≤10/5.5
10-20/7.5-
11
20-40/11-22 1.3-2.0 435-853
1200 ≤10/7.5 10-20/11 20-40/15-30 1.3-2.0 655-1284
3. Double roller crusher
Double roller crusher is mainly used for the crushing of medium or lower-hardness mines and
rocks with medium or lower rigidity in the cement, metallurgy, chemical industry, electric
power, coal and other industry. The crushing materials include limestone, slag, coke and coal.
Item SGP500 SGP600 SGP800
Manufacturing capacity,
m3
/h
13-18 17-23 23-26
Roller specifications, mm 500×500 600×500 800×500
Rollers interval, mm 3-5 3-5 3-5

Power, KW 7.5/10 10/13 18.5/22
4. Double shaft mixer
Double Shaft Mixer efficiently mix dry to very wet materials, or blend liquids and sludges with
dry solids. Materials can range from wet and sticky clays, sludges, or filter cakes to silty, sandy
soils and other abrasives. These machines can be used as pugmills for mixing liquids or sludges
with dry solids, especially when a greater tub volume is required for longer retention times. Most
often, they are used for the intensive blending of two dissimilar wet or dry materials.
Item SJ2m SJ2.5m SJ3m
Mixing length, mm 2000 2500 3000
Power, KW 22 22-30 30-37
6. Brick extruder
For extruded bricks the clay is mixed with 10-15% water (stiff extrusion) or 20-25% water (soft
extrusion). This is forced through a die to create a long cable of material of the proper width and
depth. This is then cut into bricks of the desired length by a wall of wires. Most structural bricks
are made by this method, as it produces hard, dense bricks, and suitable dies can produce holes
or other perforations. The introduction of holes reduces the volume of clay needed, and hence the
cost. Hollow bricks are lighter and easier to handle, and have thermal properties different from
solid bricks. The cut bricks are hardened by drying for 20 to 40 hours at 50 to 150 °C before
being fired. The heat for drying is often waste heat from the kiln.
Vacuum extruder, double stage, hard plastic
Vacuum extruder of hard plastic are mainly used to produce bricks with low plastic materials as
raw materials, such as coal gangue, fly ash, shale, sandy soil of poor quality, etc., and produced
bricks strength can reach 3.5-4 KG/cm2
.

Model Capacity,
pcs/hour
Moisture
content
Vacuum
degree (Mpa)
Extrusion
pressure (Mpa)
Power
(KW)
JZK90Y-4.0 20000-25000 11-14% ≦-0.092 4.0 132+315
JZK75Y-4.0 15000-20000 11-14% ≦-0.092 4.0 110+250
JZK60Y-4.0 11000-13000 11-14% ≦-0.092 4.0 90+160
Vacuum extruder, double stage, Split type
Model Capacity,
pcs/hour
Moisture
content
Vacuum
degree
(Mpa)
Extrusion
pressure (Mpa)
Power (KW)
JKY60/60- 16000-22000 15%-18% ≦-0.092 4.0 200+90+22

4.0
JKY55/55-
4.0
14000-19000 15%-18% ≦-0.092 4.0 200+75+22
JKY50/50-
4.0
12000-16000 15%-18% ≦-0.092 4.0 160+75+22
JKB55/55-
3.0
12000-16000 17%-19% ≦-0.092 3.0 160+55
JKB50/50-
3.0
10000-15000 17%-19% ≦-0.092 3.0 132+55
JKB45/45-
3.0
8000-12000 17%-19% ≦-0.092 3.0 110+45
Vacuum extruder, double stage, Integral type
Model Capacity,
pcs/hour
Moisture
content
Vacuum
degree (Mpa)
Extrusion
pressure (Mpa)
Power
(KW)
JZKE50-3.0 12000-16000 17%-19% ≦-0.092 3.0 160+7.5
JZKE45-3.0 10000-15000 17%-19% ≦-0.092 3.0 132+5.5
JZKE40-3.0 8000-12000 17%-19% ≦-0.092 3.0 110+5.5
JK35-2.0 6000-8000 18%-22% ≦-0.092 2.0 75
JK30-2.0 5000-7000 18%-22% ≦-0.092 2.0 45

7. Cutter, automatic
8. Automatic unfired brick stacking machine

Automatic Unfired Brick Stacking Machine are used to pick up the grouped billet automatically
(wet billet or dry billet) and put down them to the assigned position of the kiln car, and Suitable
for both once brick setting system and twice brick setting system. There are many ways to
putting down the billet ,such as putting down billet in face up or putting down billet in side face.
The type of brick stacking machine can be designed according to user’s demand.
Type Production Capacity (Pieces/Hour) Weight (Kg) Dimension (mm)
ZMP460×2 4600 13500 8000×5980×7570
ZMP690×3 7400 14000 11500×6010×6610
ZMP460×2×
2
8615 16500 12440×6010×6610
ZMP923×4 8615 16500 12440×6010×6610
ZMP731×3×
2
11270 9000 11850×3782×5000
ZMP3×2A 12960 16264 17390×6680×6453
10. Hoffman kiln
The Hoffmann kiln is a series of batch process kilns. Hoffmann kilns are the most common kiln
used in production of bricks and some other ceramic products. Patented by German Friedrich
Hoffmann for brickmaking in 1858, it was later used for lime-burning, and was known as the
Hoffmann continuous kiln.
A Hoffmann kiln consists of a main fire passage surrounded on each side by several small
rooms. Each room contains a pallet of bricks. In the main fire passage there is a fire wagon, that
holds a fire that burns continuously. Each room is fired for a specific time, until the bricks are
vitrified properly, and thereafter the fire wagon is rolled to the next room to be fired.
Each room is connected to the next room by a passageway carrying hot gases from the fire. In
this way, the hottest gases are directed into the room that is currently being fired. Then the gases
pass into the adjacent room that is scheduled to be fired next. There the gases preheat the brick.
As the gases pass through the kiln circuit, they gradually cool as they transfer heat to the brick as
it is preheated and dried. This is essentially a counter-current heat exchanger, which makes for a
very efficient use of heat and fuel. This efficiency is a principal advantage of the Hoffmann kiln,
and is one of the reasons for its original development and continued use throughout history. In
addition to the inner opening to the fire passage, each room also has an outside door, through
which recently-fired brick is removed, and replaced with wet brick to be dried and then fired in
the next firing cycle.
In a classic Hoffmann kiln, the fire may burn continuously for years, even decades. Any fuel
may be used in a Hoffmann kilns, including gasoline, natural gas, heavy petroleum and wood
fuel. The dimensions of a typical Hoffmann kiln are completely variable, but in average about 4
m (height) x 15 m (width) x 150 m (length).

11. Tunnel kiln
In modern brickworks, clay bricks are usually fired in a continuously fired tunnel kiln, in which
the bricks move slowly through the kiln on conveyors, rails, or kiln cars to achieve consistency
for all bricks.
Tunnel kiln is a long structure in which only the central portion is directly heated. From the cool
entrance, ware is slowly transported through the kiln, and its temperature is increased steadily as
it approaches the central, hottest part of the kiln. From there, its transportation continues and the
temperature is reduced until it exits the kiln at near room temperature.
The tunnel kiln is composed of of furnace body, traction system, rail, kiln-car, and firing system,
hot air ventilation system, control system, etc. The design and manufacture of the tunnel kiln
could be negotiated based on customers' request, including chamber dimension, working
Temperature, controlling method and number, traction way and speed as well as heating power.
Basically, a brick kiln consists of two main parts. One is drying chamber. The other is tunnel
kiln. There is no special burning system for drying chamber. The extra heat used in tunnel kiln
will be feedback to drying chamber through a pipe system.
The project will use the Hoffman Kiln for firing bricks.

Auto Bricks Sample
3 holes auto bricks

10 Holes Auto bricks
We supply auto bricks all over Bangladesh, ncluding Dhaka, Mymensingh, Magura, Narsingdi
and Gzipur. If you require auto bricks for your construction sites, please contact us.
Corporate Office:
House 25, Road 05, Sector 06
Uttara, Dhaka- 1230.
Phone No.+88-09-638673993, 01716-752370
Website: www.alibabaconstructionbd.com
E-mail: alibabaconstructionbd@gmail.com
Project Site:
Capacity: 100,000 pcs per day
Alibaba Construction ltd is one of the leading auto bricks manufacturer and supplier in
Bangladesh.
Dhaka Auto bricks is the brand name of Alibaba Construction for Auto Bricks.
We supply Auto Bricks in Dhaka.

Alibaba construction ltd auto bricks in bangladesh

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