About Kiln Control Activities by MD MAHABUB HASAN

“Overview of kiln operation, atmosphere control, temperature ranges, and industrial applications for sanitary and insulator ceramics, presented by Md Mahabub Hasan”

1. About Kiln Control Presentation, Date: 20-09-2025

Speaker Background
MD MAHABUB HASAN
Executive Engineer (Mechanical)
Bangladesh Chemical Industries Corporation (BCIC)

MS in Environmental Science
Master of Business Administration (MBA)
B.Sc. in Electrical & Electronic Engineering (EEE)
Diploma in Mechanical Engineering
Web: https://mahabubinfo.com
Business Site: https://www.mmbring.com
Email: [email protected]
Facebook: https://www.facebook.com/mahabub.abc.1
YouTube: https://www.youtube.com/@beautybd652
Contact: 01554-587190



Normally Kiln Gas flow 1:9 Apply for Sanitary & Insulator Kiln
Oxidation Gas Flow 1:10± তাপমাত্রা কম 1250
0
C
Reduction Gas Flow 1:9± তাপমাত্রা অনেক বেশী 1350
0
C
Neutral Gas Flow 1:8± তাপমাত্রা একটু কম 1300
0
C
Maximum Temperature Approximately 1350
0
C

Kiln Control Room

2. ?????? Kiln Atmosphere & Temperature Range for Insulators
Oxidation Atmosphere
?????? Temperature Range: 900 °C – 1280 °C
?????? Purpose: Complete combustion, stable glaze color, strong dielectric strength.
Reduction Atmosphere
?????? Temperature Range: 1200 °C – 1350 °C
?????? Purpose: Alters color/glaze, affects microstructure.
Neutral Atmosphere
?????? Temperature Range: 1000 °C – 1300 °C
?????? Purpose: Balanced (neither oxidation nor reduction).

Sanitary Kiln Car Capacity 46
Insulator Kiln Car Capacity 42

Sanitaryware Ceramic
Low-Fire Glazes Melting at Around 980-1120°C (1800-2050°F).
High-Fire Glazes Melting at 1260-1300°C (2300-2380°F).

Insulator Ceramic
Low-Fire Glazes Melting in Insulator 1100-1300°C.
High-Fire Glazes Melting in Insulator 1300-1400°C.

Sanitary Kiln 99-Meter-Long / 322 Feet Long
Preheating Long 18 Meter/60 Feet Long
Fire Long 32 Meter/105 Feet Long

3. Cooling Long 49 Meter/160 Feet Long

Sanitary Preheating Limit Level 40
0
C - 700
0
C
Fire Heating Level 700
0
C - 1270
0
C
Cooling Heating Level 1270
0
C - 60
0
C
Preheating Wall Thickness 0.85 Meter/2.75 Feet
Fire Wall Thickness 1.02 Meter/3.30 Feet
Cooling Wall Thickness 0.85 Meter/2.75 Feet

Ceramic Industry Raw Material
1. Feldspar / Stones
2. Clay BD / China / India
3. Kaolin / কাওলিে / Stone
4. Ball Clay White / Black
5. Bentonite
6. Chromium Oxide
7. Dolomite and Limestone
8. Glazes
9. Porcelain
10.Quartz / Stone
11. Alumina Oxide
12. Cobalt Oxide
13. Iron Oxide
14. Talc / টযািক / Stone
15. Magnesium

4. 16. Silica
17. Water
18. Fireclay
19. Iron Oxides
20. Cobalt (II) Oxide
21. Broken Sanitary

Types of Insulator
1. Pin Type Insulator

2. Suspension Type Insulator

5. 3. Shackle (Spool) Insulator

4. Line Post Insulator


5. Disk Type Insulator

6. Strain Type Insulator

6. 7. Types of Line Insulators


Uses / Application Areas of Insulators
1. Transmission & Distribution Lines

2. Substations

7. 3. Electrical Equipment

4. Domestic & Industrial Wiring

5. Special Applications High Voltage Labs

Uses / Application In
1. Lines & Towers → Pin, Suspension, Strain, Shackle.
2. Substations → Post insulators.
3. Equipment → Bushings, winding insulation.
4. Domestic & Industrial → Plastic, rubber, porcelain insulators.

8. Based on Voltage Level
1. Low-voltage Insulators – Used below 1 kV.
2. Medium-voltage Insulators – Up to 33 kV.
3. High-voltage Insulators – 33 kV to 220 kV.
4. Extra High Voltage (EHV) Insulators – Above 220 kV.



Selector Switch, Indicator / Lamp, Push Button Switch, Firing Zone, Recorder, Alarm Stop Button,
Alarm Test Button, Alarm Reset Button, Air Pressure Controller, Gas Pressure Controller, Kiln Car
Capacity Sanitaryware 46, Kiln Car Capacity Insulator 42, Thermocouple,
Manual - Human-Machine Interface (HMI)

9. Sanitary Kiln Car Capacity 46
& Show Temperature Wave

10. Insulator Kiln Car Capacity 42
& Show Temperature Wave

11. Thermocouple

12. Selector Switch
Lamp / Alarm Indicator

13. Gas Pressure Controller & Indicator
Gas Pressure Controller of Sanitary Kiln

Gas Pressure Controller of Sanitary Kiln

14. Draught on Mod / Carbon Emissions Controller
Gas Pressure Controller of Insulator

15. Digital Indicator
Selector Switch

16. Digital Indicator
Selector Switch

17. Digital Indicator of Insulator
Selector Switch

18. Digital Indicator of Insulator
Selector Switch

19. Gas Indicator & Controller of Insulator

20. Gas Indicator & Controller of Insulator

21. Digital Indicator of Insulator

22. Gas Pressure Controller
A = Auto Mode
M = Manual Mode
Y= Yes Mode
X = Exit Mode
X = Stop Mode or Off Mode → halts operation.
m² = square meter (area).
Kp/m² = The Kilogram force per square meter (kp/m²)
Pound per square inch (psi)

23. Regulator of Gas & Air Ratio

24. Selector Switch
Car Pushing Indicator
Indicator
Push Button Switch
Industrial Control Panel / Board, Sanitary Kiln

25. Industrial Control Panel / Board, Insulator Kiln

26. Industrial Control Panel / Board, Insulator Kiln

27. Industrial Control Panel / Board, Insulator Kiln

28. Industrial Control Panel / Board, Sanitary Kiln

29. Industrial Control Panel / Board, Sanitary Kiln

30. Air Passing Pipe
Heat Transfer Pipe
Electrical Cable

31. Air Passing Pipe Gas Passing Pipe
Burner Point Observation Hole Control Valve

36. Selector Switch Pusher Push Switch On / Off Indicator Back / Forward

37. Pressure Gauge Regulator
Oil Input Point
Regulator Coil
Motor Oil Passing Pipe Oil Tank

38. Pressure Gauge

39. Gas Measuring Meter

40. Gas Passing Control Valve On / Off

41. Dryer Temperature Gauge

42. Green Body

44. Green Body

45. Green Body

46. Green Body

47. Heat Transfer System

48. Differential Pressure Transmitter (DPT) of Insulator
Sensor & Diaphragm
Transmitter

49. Inside Impeller
Air Passing Pipe of Insulator

50. Motor Identification Number of Insulator

51. Kiln Up Side of Insulator

52. Kiln Inside of Sanitary Kiln

53. Refractory Bricks

54. Refractory Bricks

55. Semi Finish Products

56. Semi Finish Products

57. Semi Finish Products

58. Mold

59. Semi Finish Products

60. Mold & Semi Finish Products

61. Mold

62. Reusable / Recycling Rock

63. Semi Finish Products

64. Mold & Semi Finish Products

65. Cylinder Mold

66. Sanitary Broken Body

67. Mold & Semi Finish Products

68. Mold & Semi Finish Products

69. Mold & Semi Finish Products

70. Semi Finish Products

71. Heat Chamber

72. Heat Chamber

73. Glazed Station

74. Glazed Station

75. Glazed Station

76. Green Body

77. Ball Mill Machine
Green Body
Ball Mill Machine

78. Crusher Process



Refractory Bricks

Refractory Bricks

79. Raw Materials of Refractory Bricks


Mixing Rock of Refractory Bricks

Raw Materials of Refractory Bricks


Mixing Rock

80. Insulator Mold


Recycling Wastage of Sanitaryware

Insulator Mold

Reusable / Recycling Wastage

81. Wastage of Insulator


Wastage of Insulator




Wastage of Insulator

Wastage of Insulator