EQUIPMENT AND SERVICES

FOR THE INDUSTRY

 

1987

Year of Establishment

+130

Maintenance equipment facilities

+1100

Refractory projects around the world

SERVICES

REFRACTORY DESIGN AND MANUFACTURE

Forgestal/Campo is dedicated to the heavy clay industry for many years, devoting the 100% of the production to the brick and tile industry. An invaluable amount of experience has accumulated during these years, with all types of red clay products and conditions.
Only a deep knowledge of the specific issues to be faced in this technology makes possible to propose the right solutions for each application.

KILN CARS MAINTENANCE

Although the investment into an automatic vacuum-cleaning system does not influence the production process directly, it nevertheless is an installation, which pay itself back for the following reasons:
• Less repairs on kiln cars.
• No personnel required for cleaning and much lower for maintenance.
• Reduction of waste or second class ware in production.
• Increased life of all kiln cars.

ENERGY SAVING STUDIES

They are carried out in order to quantify the energy savings obtainable with a new light slabs and setting supports set on the kiln car linings. There it has been possible to compare two dierent lining designs in real conditions:
1. Kiln car lining made of dry pressed solid slabs and setting supports.
2. Kiln car lining made of extruded hollow slabs and hollow setting supports made by Forgestal /Campo.

CHASSIS DESIGN CONSULTANCY

The extensive knowledge of the sector allows us to advise and propose new design solutions in the event that the park is completely renovated. If that is not the case, our designs are completely compatible with existing ones, although revised and optimized to ensure lightness, as well as resistance.

SELECTING A GOOD KILN CAR LINING

Many points and factors need to be considered for a good design :

  • General dimensions, interlocking with kiln walls and between cars.

  • Type of material to be fired and setting pattern on kiln cars.

  • Production-system.

  • Working conditions of kiln and fuel used.

  • Special firing conditions.

  • Special additives, when present in the bricks.

  • Cooling time of kiln cars on outer tracks.

Starting from these data our engineers fix the external dimensions, the detailed design of each refractory post; the refractory and insulation-materials to be used and the size and position of joints.
Only a good knowledge of the ceramic processes together with a round knowhow acquired by developing and testing during years satisfactory solutions at new and old kiln cars, guarantees an optimal construction and design for each requirement.

 
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ABOUT US

The main activity of Forgestal/Campo is the design and supply of refractory linings for kiln cars, roofs and walls, as well as kiln car cleaning machines.
Starting in 1993, the Strategic Alliance between Forgestal S.L. and Refractarios Campo S.L. finds its foundations on a personal and business relationship started in 1979 between the owner of Campo Group and the founder of Forgestal.
The main activity of this joint venture is the design, production and supply of refractory linings for ceramic kiln cars, roofs and walls.
Refractarios Campo S.L., the operations partner based in Villalonga-Sanxenxo (Spain), is responsible for Financial Backup, Raw Materials Supply (with its own mines of refractory clays), Preparation and Mixing, Manufacturing, Quality Control, Laboratory, and Delivery.
Forgestal S.L, the engineering partner based in Esparreguera
near Barcelona (Spain), is responsible for the Commercial Operations, Product Design and Engineering, Supply of Insulating Materials, Commissioning and Customer Service. Additionally,
Forgestal designs, builds and supplies Kiln Car Vacuum Cleaning Machines, providing a significant synergy to the Campo/Forgestal product range.
Campo and Forgestal operate both internally and externally as a complete business unit, including the possibility of a turnkey assembling service.

 

TECHNICAL ARTICLES

FABRICATION PROCESS
AND TECHNOLOGICAL ADVANTAGES

All refractory parts are manufactured by the plastic shaping process, either by plain extrusion or by extrusion plus re-pressing, of the mixes composed of
refractory chamotte, refractory clays and additives.
Different refractory chamottes combined with the right proportions of own refractory clays and additives
produce a wide range of mixes with varying degrees of thermal shock resistance and refractoriness up to 1400ºC operating temperature.

Most of the raw materials we use are extracted from our own quarries. The use of our own raw materials allows us to provide the best quality, with long term stability, at competitive prices.

In a brick kiln, the fuel is used to heat up the ware to a certain temperature to get it fired.
In order to achieve a better thermal efficiency, once the ware is on its firing temperature, it is cooled down,
recovering this energy which will be used to warm the ongoing ware.

OUR RAW MATERIAL, QUALITY GUARANTEE

STUDY OF ENERGY SAVINGS WITH LIGHT LININGS

 

LIGHTWEIGHT SETTING SUPPORT SYSTEM

The setting supports have a vital role in the overall performance of a kiln car when firing ceramic materials. This is even more important whenever the ceramic materials are directly set on the kiln car in green state.
Only the air and the setting supports are in direct contact with the ware during the ceramic firing process. That’s why the behaviour of the setting supports has an enormous influence on the heating, firing and cooling of the ceramic ware supported by them.

In Spain, starting in the early eighties, pet coke was introduced as a fuel for red clay firing kilns, triggered by the petrol crisis. Pet coke remains an abundant resource in today’s market.
After the fever of the first years, the basic concepts became strengthened by experience.

  • Combining pet coke with gas or fuel oil in the first burner rows is necessary.

  • Several firing systems evolved and were replaced by more advanced systems. Only the systems assuring a controlled uniform feed of fine particles survived..

Forgestal, S.L. has developed a computer program by finite elements, specifically adapted for kiln cars. it calculates the evolution of the heat inputs and outputs in the kiln car as well as the evolution of the temperatures in all the nodes of a predefined internal network, as a function of both the kiln car properties and the evolution of conditions of temperature and gas velocity along the real firing cycle.

KILN CARS

IN KILNS FIRED

WITH PET COKE

THERMAL PERFORMANCE OF KILN CARS IN REAL FIRING CYCLES

 
 

CUSTOMERS

 

CONTACT

Questions

For all kinds of questions, comments and concerns; please call us: 937-778-707 or fill out the form below

Jobs

To apply for a job with us, send your CV and letter of recommendation to: forgestal@forgestal.com

Camí Ral, 104

Polígon Industrial Sud

08292 Esparreguera.

Tel 937 778 707

Fax 937 787 714

forgestal@forgestal.com

www.forgestal.com

© 2020 FORGESTAL S.L.   Camí Ral, 104 | Polígon Industrial Sud | 08292 ESPARREGUERA | Tel. +34 937 778 707 | Fax. +34 937 787 714 | forgestal@forgestal.com

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