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Tunnel kilns are continuous type kilns which are used for firing of various ceramic products.There are 5 number of tunnel kilns. Three tunnel kilns are used for production of ceramic products and use Rubber Processed Oil (RPO) and Light Diesel Oil (LDO). Other two tunnel kilns use pet coke and are used for manufacturing of products such as high alumina refractory bricks. The capacity of tunnel kilns is about 7.5 tonne per day for ceramic products andfor refractory products; the production is about 20 tpd.
A typical tunnel kiln has three different zones, namely, preheating, firing and cooling zones.The kiln has two ends viz. loading end and unloading end. The green wares are stacked on trolleys, and moved on rails inside the kiln. The speed of the trolleys inside the kiln is controlled with the help of an electrically operated pusher. The pushing time is adjusted to provide the required residence time for the type of products being fired in the kiln. For loading the greens and unloading the fired products, a side rail is provided parallel to the kiln.
The proximity of the side rails to the kiln walls also helps in drying of the greens before they are fed in the furnace. A temperature of 1130-1260 oC is maintained in the firing zone based on the type of products such as red clay products, small lamps, heavy refractory products, etc. Upon completion of soaking, the trolleys are further pushed towards cooling zone, wherein the products are cooled before taken out from unloading end.