code for design of domestic ceramics plant

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Pro fe s s io n a l S ta n da r d for L i g h t I n d u s try o f th e

Peo p l e ' s R e pu b l i c o f C h i na

Q B / T 6 0 1 7 - 2 0 2 0

R e p l a c e Q B / T 6 0 1 7 - 9 7

Code for design of domestic

ceramics plant (Draf t fo r approval )

I s s u e d o n 2 0 X X - X X - X X I m p l e m e n t e d o n 2 0 X X - X X X X

I s s ue d b y th e Min i s t r y o f I ndu s t ry a nd In fo r ma t i on

Te ch no log y o f th e P eop l e ' s Re pub l i c o f C h in a

I C S 8 1 . 0 6 0 . 0 1

P 8 8

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Profess ional Standard for Light Industry of

the People ' s Republ ic o f China

Code for design of domestic

ceramics plant

QB/T 6017-2020

C h i e f d e v e l o p m e n t

d e p a r t m e n t :

M i n i s t r y o f I n d u s t r y a n d

I n f o r m a t i o n T e c h n o l o g y o f

t h e P e o p l e ' s R e p u b l i c o f

C h i n a

A p p r o v a l d e p a r t m e n t : M i n i s t r y o f I n d u s t r y a n d

I n f o r m a t i o n T e c h n o l o g y o f

t h e P e o p l e ' s R e p u b l i c o f

C h i n a

I m p l e m e n t a t i o n d a t e : X X m o n t h , X X d a y , X X y e a r

China XXXXXXXXXX

2 0 X X B e i j i n g

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Announcement of the Ministry of

Industry and Information Technology of

the People's Republic of China

N o .

The Code for Design of Domestic Ceramics Plant is now approved as the

professional standard with a serial number of QB/T 6017-2020, which will be

implemented on November 1st,2020. The original Code for Design of Domestic

Ceramics Plant QB/T 6017-97 shall be abolished simultaneously.

This code is published and distributed by China Planning Press, which is

authorized by the Planning department of Ministry of Industry and Information

Technology.

Ministry of Industry and Information Technology of

the People's Republic of China

**month ** day, **year

1

Pr e fa c e

According to the requirements of the " The Notice of Printing and

Distributing the Revision Plan for the First Batch of Industry Standards in 2017 "

Ref. 40 (2017) issued by the General Office of the Ministry of Industry and

Information Technology, the development department revised this code after

making comprehensive investigation and study, summarizing the practical

experience, conducting extensive solicitation of opinions and referring to

relevant standard.

The technical contents of the code are comprised of 16 chapters: 1 General

provisions; 2 Terms and symbols;3 Location selection and general layout; 4

Process;5 Kiln;6 Fuel;7 Thermal power;8 Power supply;9Automatic control

instrument and information;10 Architecture and structure;11Water supply and

drainage; 12Heating ventilation and air conditioning;13 Fire fighting; 14

Engergy saving; 15 Enviromental Protection and 16 Occupational safety and

health.

The main contents of the revision of the code are as follows::

1. “Chapter 2 Terms and symbols”, “Chapter 14 Energy saving” and

“Chapter 16 Occupational Safety and health” are added.

2. The original “Chapter 2 General layout” is revised as “Chapter 3

Location selection and general layout”. Location selection related

content is added.

Q B / T 6 0 1 7— 2 0 2 0

2

3. The original Article 8 “Maintennance Workshop” of Chapter 3 is

deleted.

4. The provisions of original “Chapter 5 Fuel” has been substantially

deleted, and the provisions on clean fuel such as natural gas have been

added.

5. The original Chapter “Water supply and drainage amd fire fighting” is

split into two two chapters, namerly “Chapter 11 Water supply and

drainage” and “Chapter13 Fire fighting” .

6. The content of calculation of tunnel kiln length is deleted.

7. Article 4.7 “Packaging and warehousing workshop” and related

provisions have been added to “Chapter 4 Process”.

8. Contents that are not suitable for technological progress are modified

and adjusted.

9. In accordance with the relevant regulations and requirements in the

Provisions for the Compilation of Engineering Construction

Specifications, some of the provisions in the original code have been

modified and adjusted in writing.

The code development is supervised by the Planning Department of the

Ministry of Industry and Information Technology, authorized by China

Engineering Construction Association of Light Industry, and explained by China

CEC Engineering Corporation. The relevant opinions and advice in

implementation may be posted or passed on to China CEC Engineering

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Corporation (Contact and address: No. 268, Xinxing Road, Yuhua District,

Changsha City, Hunan Province, Post Code: 410114; E-Mail:

[email protected]).

Chief development department: China CEC Engienering Corporation

Participating development organization:

China Haisum Engineering Co., Ltd

Chengdu Engineering Co., Ltd of China Light Industry

Main drafting staff: Zhang Jianjun, Jiang Shanhong, Guo Qiang, Li Ning,

Yang Zehong, Yang Weixiang, Lei Ping, Cao Yu, Wang Shuyun, Hou

Yonggang, Zhang Yue and Rao Jia

Main reviewing staff: Qi Yongyi, Xu Jiaxin, Jin Fuming, Xu Lin, Chen

Baowu, Zhou Kaixiang, Yang Xiaozhen, Lin Hongyang, Rao Shengdi, Lu

Heming, Zhang Zhong, Luo Lilan, Ma Yunjie, Chen Jun and Li Xiaohong.

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T a b l e o f c o n t e n t s

1 G e n e r a l p r o v i s i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

2 T e r m s a n d s y m b o l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.1 T e r m i n o l o g y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

2.2 S y m b o l s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

3 L o c a t i o n s e l e c t i o n a n d g e n e r a l l a yo u t . . . . . . . . . . . . . . . . . . . . . . 1 2

3.1 Location selection. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2

3.2 General layout . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2

3.3 Buildings and Structure arrangment. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5

3.4 Passageway and roads . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 1

3.5 Technical and economic indicators . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2

4 P r o c e s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5

4.1 General provisions . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 5

4.2 Raw material workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 6

4.3 Forming workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 9

4.4 Firing workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2

4.5 Decorating Firing workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 4

4.6 Plaster moulding workshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7

4.7 Packaging warehouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8

4.8 Process piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9

5

4.9 Central laboratory and R&D center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 3

5 K i l n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6


5.2 Kiln type selection . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 6

5.3 Determination of main technical and ecomic index . . . . . . . . . . . . . . . . . . 4 6

6 F u e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8


6.2 Fuel Gas . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 8

6.3 Fuel oil . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4 9

7 T h e r m a l p o w e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 1

8 P o w e r S u p p l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5 3

9 A u t o m a t i c c o n t r o l i n s t r u m e n t a n d i n f o r m a t i o n . . . . . . . . . . 6 1

1 0 A r c h i t e c t u r e a n d S t r u c t u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 9

10.1 A r c h i t e c t u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6 9

10.2 S t r u c t u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 2

1 1 W a t e r S u p p l y a n d D r a i n a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7 5

1 2 H e a t i n g v e n t i l a t i o n a n d a i r c o n d i t i o n i n g . . . . . . . . . . . . . . 7 6

1 3 F i r e f i g h t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 2

1 4 E n e r g y s a v i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4

14.1 G e n e r a l p r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4

14.2 P r o c e s s e n e r g y s a v i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4

14.3 W a s t e h e a t r e c o v e r y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 4

6

14.4 E l e c t r i c i t y s a v i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 5

1 5 E n v i r o n m e n t a l P r o t e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7

15.1 G e n e r a l p r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7

15.2 W a s t e w a t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7

15.3 W a s t e g a s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 7

15.4 W a s t e s o l i d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 8

15.5 N o i s e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8 9

1 6 O c c u p a t i o n a l S a f e t y a n d H e a l t h . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1

16.1 G e n e r a l r u l e s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1

16.2 F i r i n g a n d e x p l o s i v e p r e v e n t i n g . . . . . . . . . . . . . . . . . . . . . . . . . . 9 1

16.3 P r o t e c t i o n a g a i n s t m e c h a n i c a l i n j u r y . . . . . . . . . . . . . . . . . . . 9 1

16.4 L i g h t n i n g P r o t e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 2

16.5 P r o t e c t i o n a g a i n s t d u s t a n d t o x i c a n t s . . . . . . . . . . . . . . . . . . . 9 2

16.6 H e a t s t r o k e p r e v e n t i o n , c o o l i n g a n d h e a t i n g . . . . . . . . . . . 9 3

16.7 N o i s e c o n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 3

A p p e n d i x A T h e t a b l e o f b u l k w e i g h t a n d i n t e r n a l f r i c t i o n

a n g l e f o r c o m m o n m a t e r i a l s i n d o m e s t i c c e r a m i c s p l a n t . 9 4

E x p l a n a t i o n o f t e r m s u s e d i n t h i s s p e c i f i c a t i o n . . . . . . . . . . . . . 9 6

L i s t o f Q u o t e d S t a n d a r d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9 7

R e v i s i o n n o t e

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1 Ge n e ra l p rov i s i on

1.0.1 The standard is formulated to implement national laws and regulations,

technical and economic policies as well as project relevant engineering codes, to

promote clean production, and to realize the objectives of advanced technology,

economic rationality, safety and reliability, energy conservation and emission

reduction, ecological environmental protection and comprehensive utilization of

resources in the design of domestic ceramics plant.

1.0.2 This standard is applicable to the design of new construction, expansion,

rebuilding and technical transformation projects of domestic ceramic plants.

1.0.3 In the design of domestic cerematics plant, advanced, reliable, economical,

applicable, environment-friendly, safe and energy-saving new process, new

technology, new materials and new equipment shall be adopted for

comprehensive utilization of resources.

1.0.4 The unit product energy consumption of the ceramics plant shall meet the

provisions of the national standards The norm of energy consumption per unit

products of domestic ceramics GB 36890, and shall meet the relevant local

standards of the place where the construction project is located.

1.0.5 In addition to conforming to this standard, the design of ceramics plant

shall also conform to relevant current national codes and standards.

8

2 Te r ms a n d s y mb o ls

2.1 T e r m i n o l o g y

2.1.1 Ceramic ware ------ a silicate product made from inorganic non-metallic

materials as the main raw material and fired through a certain production

process.

2.1.2 Domestic ceramics ------ various ceramic products for daily use.

Ceramics for daily use ------ see Domestic ceramics.

Household ceramics ------ see Domestic ceramics.

2.1.3 Pugging

Pugging is the process of kneading the plastically formed blank with a

vacuum mud mill or other methods, so that the gas in the blank escapes, the

moisture is uniform, and the plasticity is improved.

2.1.4 Shaping, Forming

Forming is the operation of making a preform into a ceramic body of a

certain shape and specification.

2.1.5 3D printing forming Three dimension printing

Three dimension printing is a technology that use adhesive materials and

printing layer by layer to build objects based on digital model files, .

2.1.6 Fettling, Trimming

Fettling is to processing and trimming the rough blank to make the shape

and surface finish meet the requirements.

2.1.7 Glazing

Glazing is the process of covering a layer of glaze on the surface of the

ceramic body.

2.1.8 Firing

9

Firing is the process of firing the preform body into ceramic products.

2.1.9 Decorating and firing

Decorating and firing are the general term for decorative and baking

processes.

2.1.10 Decorating

Decorating is the process of color decoration on ceramic preform bodies or

products by decals, raking flowers, spraying colors, and tracing gold.

2.1.11 Decorating firing

Decorating firing is process of baking the enameled colored ceramic

product at a certain temperature.

2.1.12 Tunnel kiln

Tunnel kiln is a kiln to continuously fire ceramic blanks, consisting of a

prehating zone, firing zone and a cooling zone. The tunnel kiln includes fixed

tunnel kiln type and movable veihcle type.

2.1.13 Preheat zone

Preheating zone is the area where the dried powder is pre-heated before

firing. It is a component of the continuous firing furnace.

2.1.14 Firing zone

The firing zone is the area in the firing furnace where temperatureis

maintained at the firing temperature.

2.1.15 Cooling zone

Cooling area is the area where the burned product in the red hot state are

cooled at a certain rate. It is a component of the continuous burning furnace.

2.1.16 Shuttle kiln

Shuttle kiln uses the shuttle-shaped kiln car as the bottom. The kiln car

carrtying the ceramic body is reciprocated through the kiln body to realize the

intermittent firing of ceramic products.

2.1.17 Roller kiln

10

Roller kiln is a kiln where, through the rotation of the roller at the bottom of

the kiln, the ceramic body passes through the kiln to realize the continuous firing

of ceramic products.

2.1.18 Kiln car

Kiln car is vehicle with high temperature resistance carrying ceramic

product in and out of tunnel kiln or shuttle kiln.

The comprehensive energy consumption per unit products of domestic

ceramics

During the reporting period, the total amount of energy consumed per unit

of qualified products in the entire production process of household ceramics.

2.2 S y m b o l s

𝐴0―― Plant area of the plant, m2

𝐴1―― Plant area of buildings (structures), m2

𝐴2―― The area of open-air storage yard, m2

𝐴3―― Plant area of outdoor equipment, m2

𝐴4―― Plant area of roads and squares, m2

L ―― Total line spacing of green belt, m

B ―― Length of green belt, m

―― Qualified rate of kiln firing,%

―― The minimum firing qualification rate specified by the project

location,%

― ― B u i l d i n g c o e f f i c i e n t , %

―― Greenbelt rate,%

𝐿𝑒—— Effective length of kiln (m)

G —— Annual output (kg/year or piece/year)

t —— firing period (h)

11

T ——Total operating time of tunnel kiln throughout the year (h)

g —— The amount of product loaded per car (kg/car or piece/car)

𝐿1—— Kiln car length (m)

12

3 Lo ca t io n s e l e c t io n a n d g e n e ra l l ayo u t

3.1 Location selection

3.1.1 The site selection shall meet the requirements of the industrial layout and

land space planning of the project site.

3.1.2 The site selection shall be based on the construction scale of the plant,

sources of raw materials and fuels, product flow, existing facilities on the site,

transportation, power supply, water supply, and external cooperation conditions.

Comprehensive consideration will be made of local society, culture, cultural

heritage protection, ecological environmental protection and other factors.

Location selection is made after comprehensive comparison.

3.1.3 The plant site shall meet the engineering geological and hydrogeological

conditions required for project construction and be located close to the resource

location.

3.1.4 The plant site shall not be located in an area prone to natural disasters

such as floods, landslides, mudslides, and collapses.

3.2 General layout

3.2.1 The general layout plan of the domestic ceramic plant shall meet the

requirements of the land space planning and future development plan of the site.

Comprehensive consideration shall be made to suit the measures to local

conditions, with rational layout and economical use of land.

3.2.2 The general layout plan of the domestic ceramics plant shall comply with

the related regulations of Code for Design of General Plan of Industrial

Enterprises GB 50187, Code of Design on Building Fire Protection and

Prevention GB 50016, Hygienic Standards for the Design of Industrial

13

Enterprises GBZ 1 and Emission Standard for Industrial Enterprise Noise at

Boundary GB 1234.

3.2.3 The general layout shall meet the requirements of the production process

and material handling, and the transportation routes of raw materials,

semi-finished products and finished products shall be short and without

cross-interference.

3.2.4 The general layout shall consider the space design and greening

configuration of the plant building group, so that the plant has a clean and

beautiful environment.

3.2.5 Plant, warehouses and auxiliary buildings with close production

connections and similar nature should form a joint plant or adopt a multi-storey

plant under the conditions of process, transportation, fire protection, safety,

lighting, and ventilation.

3.2.6 Based on proces flow, workshops, warehouses and storage yards that emit

dust or harmful gases and have a high fire risk shall be arranged on the upwind

side of the minimum wind frequency or the downwind side of the prevailing

wind direction.

3.2.7 The orientation of the main building shall have good natural ventilation

and lighting conditions. East-west orientation shall be avoided in plant or

sections with a large number of personnel, fixed operating positions, and high

natural lighting requirements.

3.2.8 For rebuilding and expansion of the domestic ceramics plant shall rationally use the original facilities in the layout. In the process of improving the

original unreasonable layout, impact of the renovation and expansion on the

production shall be reduced.

3.2.9 The reserved land for development should follow the following

principles:

14

1 When the overall construction plan has clearly been defined phased

construction, near-term and long-term projects shall be fully considered and

planned in a unified manner. The near-term projects shall be arranged compact

and reasonable to create conditions for the construction and production

connection of the next phase of the project.

2 When the overall construction plan does not specify phased

construction, the subsequent development of the plant should also be considered

based on market forecasts.

3.2.10 The reserved land for development should meet the following

requirements:

1 It should be reserved on the outer edge of plant to avoid enclosing a

large empty field in advance;

2 It should not face the plant administrative zone or main passage;

3 A building should not be expanded in two different directions.

3.2.11 The vertical design shall be carried out along with the general layout,

and the determination of the site design elevation shall meet the following

requirements:

1 It shall be coordinated with neighboring enterprises and surrounding

site elevations, and meet the requirements of flood control and drainage.

2 It shall be convenient for production connection and meet the technical

conditions of transportation and drainage facilities.

3 The natural terrain shall be used rationally, the amount of earthwork

shall be reduced, and the filling and excavation shall be basically balanced.

3.2.12 The vertical design of the domestic ceramics plant should be based on

the terrain, the size of the plant area, the production process, the transportation

conditions and other factors to choose whether to adopt flat slope or stepped

layout, and the flat slope layout is preferred.

15

3.2.13 The indoor floor elevation of the building shall be no less than 0.15m

higher than the outdoor floor elevation. Under the conditions of production and

transportation, the floors in different areas of the joint plant may have height

differences.

3.2.14 The comprehensive layout of pipelines shall allow coordination

between the pipelines as well as between the pipeline with the construction and

structures in plane and vertical directions to satisfy requirements of the

construction, maintenane, and safety, so as to save land and facilitate plant

capacity.

3.2.15 The pipelines should be laid parallel to the axis of the roads and

buildings. The pipelines may be arranged on both sides of the road, but the main

pipe shall be arranged on the side with more users.

3.2.16 Liquefied petroleum gas, flammable gas, toxic gas pipelines, and fire

hazard liquid pipelines of fire hazard Class A, B, and C should be laid by pipe

racks.

3.2.17 The design office of the general layout shall comply with the provisions

of this chapter, as well as the provisions of relevant national and industry

standards and regulations.

3.3 Buildings and Structure arrangment

3.3.1 The layout of the main production plant shall meet the following

requirements:

1 Raw material workshop:

1） Raw materials workshop shall be placed away from pollution

sources that affect the quality of ceramic products, such as coal storage yards,

maintenance workshops and Plaster moulding workshop;

16

2） The raw materials workshop should be close to the forming

workshop;

3） The raw materials workshop should be near the raw material

storage yard.

2 Forming workshop:

1） The forming workhop shall be placed with good orientation and

lighting and ventilation conditions;

2） The forming workshop should be arranged in the center of the plant

area;

3） The forming workshop should be near the raw materials workshop

and the Firing workshop, or it should form a joint plant with them.

3 Firing workshop:

1） Firing workshop should be close to the forming workshop or form

a joint plant with it. When the two workshops form a joint plant, the glaze firing

section and theforming workshop should be separated by a patio;

2） The Firing workshop should be arranged on the leeward side of the

summer maximum frequency wind direction of the forming workshop, and the

angle with the summer maximum frequency wind direction should not be less

than 45°;

3） When the topographic slope of the plant area is large, the long axis

of the Firing workshop should be arranged parallel to the topographic contour.

The Firing workshop should be arranged in a section with good geological

conditions and low groundwater level.

4 Decorating firing plant:

1） The Decorating Firing workshop shall be arranged away from

sources of pollution emitted by dust;

2） The Decorating Firing workshop should be near the Firing

workshop.

17

5 Plaster moulding workshop:

1） Plaster moulding workshop should be arranged on the leeward side

of the wind direction with the highest frequency throughout the year;

2） Plaster moulding workshop should be close to the forming

workshop;

3） Plaster moulding workshop should not be close to the

administrative area.

6 Central laboratory and R&D center:

1） Laboratory and R&D center should be arranged in the

administrative area without impact of pollution and vibration;

2） Lead and cadmium dissolution testing and R&D center should be

arranged on the ground floor;

3） The office buildings and other buildings of similar nature may be

combined.

3.3.2 Arrange of public and auxiliary production facilities shall be close to the

main users and meet the following requirements:

1 Gas station:

1） Gas station location shall be convenient for the storage and

transportation of coal, ash, coal dust, and the treatment of circulating water. Fire

lanes shall be arranged in the station area;

2） Gas station should be arranged on the edge of the plant area and

located on the smallest frequency wind direction of main building;

3） Gas station should be close to the boiler room, and should share

coal dust utilization and ash storage and transportation facilities with the boiler

room;

4） The windward side of the main plant should be perpendicular to the

wind direction of the maximum frequency in summer;

18

5） Outdoor gas purification equipment, circulating water systems,

coal yards and other structures should be arranged on the leeward side of the

maximum frequency wind direction in summer, such as the main building, gas

discharge room and air blower room, and pay attention to the impact of the water

mist emitted by the cooling tower on the surrounding area.

2 Oil tank farm and pump room:

1） Oil tank fam and pump house shall keep away from open flames

and sparks;

2） Convenient transportation conditions and fire lanes shall be

provided;

3） The oil tank farm and pump room should be arranged in the edge

area of the plant with low terrain, and located on the upwind side of the annual

minimum frequency wind direction of the plant;

4） When railway transportation is adopted, the railway siding should

be arranged at the end.

3 City gas or natural gas pressure regulating station:

1） Gas regulation station shall keep away from open flames and

sparks;

2） The station shall be located at the edge of the plant area, separated

into an area with additional walls;

3） The gas regulating should be close to the area where the gas main

enters the plant, and it is convenient to send gas to the main users such as the

glaze firing and biscuit firing sections of the Firing workshop.

4 Coal-fired boiler room:

1） Coal-fired boiler shall be arranged on the upwind side of the annual

minimum frequency wind direction in the plant area;

2） The boiler should be arranged on the edge of the plant area;

19

3） The boiler should be arranged adjacent to the gas station and share

the coal yard and slag yard.

5 General step-down substation and plant substation:

1） The general step-down substation shall be located in the inlet

direction of the high voltage power supply. The substation should be

independent and close to the load center.

2） The general step-down substation should be arranged on the edge

of the plant and in the higher terrain;

3） The general step-down substation should not be arranged in the

area affected by vibration, water mist, dust and corrosive gas;

4） The plant substation shall be close to the plant power load center,

and should have a good environment and natural ventilation conditions.

6 Sewage treatment station:

1） The sewage treatment station shall be arranged at the edge of the

plant area, and should be arranged in the downstream section of the plant

drainage;

2） The sewage treatment of the gas station should be arranged on the

upwind side of the wind direction with the smallest frequency throughout the

year, and a proper sanitary protection distance should be left;

3） The sludge drying yard should be arranged on the leeward side of

the wind direction with the highest frequency throughout the year.

7 The layout of compressed air stations and garages shall be implemented

in accordance with relevant national regulations.

8 Water supply facilities should be arranged close to the water source or

the direction of urban water pipes entering the plant, and should be located at the

edge of the plant, with a clean environment and short water supply pipes to the

main users.

20

9 The vehicle platform scale shall be arranged on the right side with more

cars to be weighed, and shallnot affect the traffic on adjacent roads. There should

be a straight line section not less than 25m long at both ends of the ground scale.

In case the site has difficulty to satisfy the requirement, the straight line section

at both ends shall be not be less than the length of a car.

3.3.3 The setup of administrative office and living facilities shall meet the

following requirements:

1 Domestic ceramics plant should set up administrative living facilities

such as plant office buildings, staff canteens, shift dormitories, non-motorized

car sheds, parking lots and guards.

2 The land for administrative office and living service facilities shall not

exceed 7% of the total land area of the plant, and non-production supporting

facilities such as complete sets of residences, expert buildings, hotels, guest

houses and training centers shall not be built in the plant.

3 The layout of administrative office and living service facilities shall

meet the following requirements:

1） The llayout shall be convenient for management and external

contact;

2） It shall face the main traffic roads or residential areas of cities and

towns, and be located on the leeward side with the smallest frequency wind

direction of the plant throughout the year;

3） The building group space of administrative office and living

service facilities shall be coordinated with greening and beautifying facilities;

4） The location of administrative office and living service facilities

shall not affect plant expansion.

4 The plant office building shallbe arranged near the main entrance of the

plant area, and should be oriented north-south. The office building should form a

21

joint building with auxiliary production facilities and other administrative living

facilities that are pollution-free and require high external environment.

5 The location and number of entrances and exits in the plant area shall be

determined comprehensively according to factors such as enterprise scale,

overall planning, transportation method and general layout. The number of

entrances and exits should not be less than two, and the main flow of people and

goods shall not cross.

The main entrances and exits shall be arranged combined with

administrative office and living service facilities in a convenient and safe place

for employees to go to and get off from work. Guards and communication

facilities shall be set.

A duty room should be set up at the cargo entrance and exit.

3.4 Passageway and roads

3.4.1 The width of the passage in the plant area shall meet the requirements of

hygiene, safety, fire protection, transportation, pipeline laying, and greening,

and should be in harmony with the height of the buildings on both sides. The

width of the passage in plant area should meet the requirements of Table 3.4.1.

Table 3.4.1 Road width

P l a n t a r e a ( ×1 04

m2

) P a s s a g e w i d t h ( m )

M a i n

p a s s a g e

G e n e r a l

p a s s g a e < 5 1 8 ~ 2 1 1 2 ~ 1 8

5 ~ 1 0 1 8 ~ 2 4 1 2 ~ 2 1

> 1 0 2 4 ~ 3 0 1 5 ~ 2 4

N o t e : 1 ) I n c a s e t h a t t h e r e a r e m a n y p i p e l i n e s i n t h e p a s s a g e , o r t h e

t e r r a i n i s c o m p l i c a t e d , o r t h e b u i l d i n g s o n b o t h s i d e s v e r y t a l l ,

o r t h e a r e a o f t h e j o i n t p l a n t i s v e r y l a r g e , u p p e r l i m i t m a y b e

a d o p t e d .

2 ) R e c o n s t r u c t i o n a n d e x p a n s i o n o f t h e p l a n t a r e r e s t r i c t e d b y

t h e o r i g i n a l c o n d i t i o n s , a n d w h e n i t i s d i f f i c u l t t o i m p l e m e n t t h e

w i d t h o f t h e t a b l e , t h e w i d t h o f t h e p a s s a g e m a y b e a p p r o p r i a t e l y

r e d u c e d . H o w e v e r t h e r e q u i r e m e n t s o f f i r e s e p a r a t i o n d i s t a n c e

s h a l l b e m e t .

22

3.4.2 The layout of roads in the plant area should be parallel or perpendicular to

the axis of the main buildings in the area according to functional zones, and

should be arranged in a ring shape. The main road surface width should be 9m,

the secondary road should be 7m, and the fire lane shall be no less than 4m.

The minimum turning radius and longitudinal slope setting of the inner edge

of the cross road shall comply with the relevant provisions of the current code

Designing Code for Mine and Plant Road GBJ 22 and Code of Design on

Building Fire Protection and Prevention GB 50016.

3.4.3 Sufficient parking and return spaces should be reserved in the loading and

unloading operation area of vehicles to ensure the process is smooth.

3.5 Technical and economic indicators

3.5.1 The master plan design shall list the following main technical and

economic indicators:

1 The plant area . 0(m2). It shall be calculated based on the area enclosed

by the center line of the fence

2 Plant area of buildings (structures) A1(m2). Newly designed buildings

(structures) shall be calculated based on the axis; original buildings (structures)

may be calculated based on the enclosed area of the wall; round structures shall

be calculated based on the actual projected area; the storage tank area with fire

dikes shall be calculated based on Calculation of fire dike axis. The plant area of

the structure shall include the plant area of the outdoor equipment.

3 The area of open-air storage yard A2(m2). The calculation shall be

based on the edge line of the land used for the open storage of raw materials,

fuels, finished products, waste products and auxiliary production supplies.

23

4 Plant area of open-air equipment A3(m2). Independent equipment shall

be calculated according to its actual plant area, and group equipment shall be

calculated according to the paved area of the equipment site.

5 Building coefficient (%). Building coefficient shall be calculated as

follows:

( 3 . 5 . 1 - 5 )

In the formula: ——building coefficient (%)

𝐴1——Occupied area of building (structure) (m2)

𝐴2——Occupation area of open yard (m2)

𝐴3——Occupation area of open-air equipment (m2)

𝐴0——Plant area (m2)

6 Land area of road and square 4 (m 2 ). It shall include the total paved

area of plant roads and squares such as plant approach roads, sidewalks, parking

lots and return yards.

The road area of the plant area is calculated according to the following

requirements:

1） In case that the road in the plant area is an urban road, the area

occupied is the length of the road multiplied by the width of the road;

2） When the road in the plant area is a highway road, the plant area of

the road is the road length multiplied by the sum of the road width and the road

shoulder width.

7 Green area rate (%):

( 3 . 5 . 1 - 7 )

In the formula: ——green space rate

𝐴4—— Greening area (m2), including: land for small amusement

gardens, flower beds, and blocky lawns and green spaces is

calculated according to the area enclosed by the

24

surrounding boundaries; land for trees and shrubs planted

in strips and single plants is calculated as Table 3.5. 1.

Table 3.5.1 Calculation table of greening land area

P l a n t c a t e g o r y C a l c u l a t e d l a n d a r e a m2

S i n g l e t r e e 2 . 2 5

S i n g l e r o w t r e e 1 . 5 L

M u l t i - r o w a r b o r ( B + 1 . 5 ) L

S i n g l e s h r u b 1 . 0

S i n g l e h e d g e 0 . 5 L

M u l t i - r o w h e d g e ( B + 1 . 5 ) L

N o t e : L — l e n g t h o f g r e e n b e l t ( m ) , B — t o t a l l i n e s p a c i n g ( m ) .

8 Earthwork volume (m3). Earthwork volume shall be the amount of earth

and stone works for leveling the site of the plant, and shall not include the

amount of earth and stone for construction (structure) foundations, road troughs,

etc.

3.5.2 The building coefficient of domestic ceramics plant should be

32%~42%, and meet the following requirements:

1 The lower limit is adopted for complex terrain conditions;

2 The upper limit is adopted for plant with small production scales and

for plant that has joint workshop;

3 When the plant is reconstructed and expanded and the site is restricted

by land condition, the building coefficient may be appropriately increased.

25

4 Pro c e ss

4.1 General provisions

4.1.1 Process design must conform with requirements of approved documents.

Advanced manufacturing method and process shall be used based on confirmed

production capacity, type of raw material and fuel, characteristic of ceramic type

and type of product, and sure the related technical parameters and economic

indexes shall reach the advanced level domestically.

4.1.2 The selection of equipment shall be met the requirement of pracicability,

safety, environmental, lower power consumption and higher efficiency.

Homemade equipments should be used and foregien advanced equipments may

be considered if necessary.

Besides, the standardization, serialization, mechanization and automation,

as well as unity and interchangeability shall be considered.

The equipment in the production plant shall meet the production capacity

requirements. For projects with annual production scale as the target, the

capacity of key equipment shall be considered based on the effective production

time of not less than 7,200 hours per year, and 10% surplus capacity should be

considered for other equipment.

4.1.3 The process design shall be combined with the requirements of general

plot plan and layout. The process flow shall be as short as possible under the

ensuring quality. The equipment and pipeline arrangement shall be easible for

facilitate construction, installation, operation, maintenance and repairment.

Production facilities with close production connections and/or similar

properties should form a combining factory building or multi-storey factory

26

building under the conditions of technological production, fire protection,

safety, nature lighting, and ventilation.

4.1.4 Environmental protection shall be emphasized during process designing,

with carring out the principal of “Prevention First, Prevention with Control,

Comprehensive Treatment” and “Three simultaneity”. Effective measures shall

be taken to reduce the emission of harmful material and noise, with perfect

occupational health facilities and measurements regarding safety and health.

4.2 Raw material workshop

4.2.1 The production methods and select equipment must be formulated based

on production capacity, ceramic type and characteristics of raw material during

process design of the raw material workshop.

4.2.2 The process design of the raw materials workshop shall meet the

following regulations and requirements:

1 The selection of raw materials shall meet the requirements of industry

standards, and must consider the service life and quality fluctuationof mining

source, physical characteristics of raw material, transportation condition and

method, and other related factors.

2 The crudes of kaolin and clay shall be inspected and selected to remove

the impurities in the mine site before transported to the raw material workshop.

3 The storage time of raw materials shall consider the affect of various

factors such as the type of raw materials, transportation methods, once feed

volume, transportation distance, number of retransmissions, maximum days of

suspension, fluctuations of raw materials composition, as well as market

conditions, capital turnover and price factors.

4 , The different raw materials shall be stored separately in the raw

material warehouse and be not mixing stored.

27

5 The aging time of preform body shall be shorted with permitted

processing performanc of preform body, should be 2~4days.

6 Raw material shall be transported to workshop after weighting and dry

basis conversion shallbe done after moisture content is measured.

7 Weighting and moisture content measurement shall be done when clay

slip, glaze slip and dry powder are transported out of workshop.

4.2.3 Process design parameters of raw materials workshop may may refer to

Table 4.2.3.

Table4.2.3 Main process design parameters of raw material workshop

I n d e x u n i t V a l u e

Loss of transportation, storage and pulping of raw

material

Kaolin, clay

Ore powder

Chemical raw materials

%

%

%

<4

<3

<1

Consumption of body materials

Porcelain weight: dry weight

1:1.6~1:1.8

Glaze consumption

Porcelain weight:dry material weight

1:7~1:9.5

Ball milling time (determined according to

experiment or actual production)

Body materials

Glaze

h

h

12~20

36~60

Filter press time m i n 40~60

Spray drying energy consumption kJ/kgH2O <3100

4.2.4 The main equipment selection of the raw materials workshop shall meet

the following regulations and requirements:

1 Equipment with the same function should select the same model and

specification.

2 Equipments made of stainless material shall be selected.

3 Specification and amount of ball mill shall be determined based on

process demand and loading capacity of single equipment, with consideration of

28

time of loading and discharging, time of replacing ball and lining and time of

maintenance.

4 Spare feeding equipment and feeding lifting equipment of ball mill

should be considered.

5 Plunger slip pump or variable flow plunger slip pump should be used

for transport slip to filter press.

6 Three-shaft stainless steel de-airing pug mill should be selected to

pugging.

7 Necessary lifting facilities should be configured in raw materials

workshop accordineg to the configuration of production equipment.

4.2.5 The process layout of the raw materials workshop shall meet the

following regulations and requirements:

1 The process arrangement should follow the following principles:

1) It is advisable to use the self-weight of the material to realize the

gravity flow between processes. The equipment connecting to each other should

be arranged as close as possible, and the lines should be smooth and short to

reduce the quantity of conveying equipment and the resistance of pipelines;

2) Passage way of people and logistics should be arranged

coordinatively in the plant to avoid cross and mixing;

3) Equipment shall be arranged to allow workers easy access to

operation and maintenance, with considering location of power distribution and

dust removal facilities in the plant.

2 The net distance between equipment and equipment, column or wall

shall comply with the requirement showed in Table 4.2.5, and the influence

between equipment foundation and pit, trench, foundation of wall or column

shall be considered.

Table 4.2.5 Net distance of equipment

Name unit Operation side Non-operat

ing side Trolley access Forklift access

29

Net distance between equipment m 1.5~3.0 0.8~1.2 1.5~2.0 2.5~3.0

Net distance between equipment.

column or wall m 1.5~2.0 0.8~1.0 1.5~2.0 2.5~3.0

3 The reserve space for the ball mill and slip tank shall be considered

according to any factors such as process requirements, site size, and expansion

needs.

4 The storey height of the factory building shall considered with the

space need of equipment installation and maintenance.

5 The raw materials workshop should be equipped with auxiliary rooms

such as small inspection room, duty room, spare parts room and tool room.

4.3 Forming workshop

4.3.1 The production method and process flow must be considered based on

production capacity, products scheme, quality requirement and process

characteristics of body materials and glaze during the process design of forming

workshop.

4.3.2 The process design shall meet the following requirements:

1 Storage time of pugged mud body should not be more than 4 hours.

2 Stainless material shall be used as slip pipe material when producing

fine porcelain.

3 Air pipe of the dryer used to produce fine porcelain should be anti-rust

treated. Stainless plate is suggestedto used.

4 The semi-finished product should be stored in a storage container or

stored on the kiln car directly, and be not stored with too long time.

4.3.3 Process design parameters of forming workshop may may refer to Table

4.3.3.

Table 4.3.3 Main process design indicators of Forming workshop

30

I n d e x n a m e unit Value

Forming qualification rate

Ram pressing (from forming to demoulding)

Isostatic pressing (from forming to trimming)

Casting (from forming to demoulding)

%

%

%

85~90

90~95

80~85

Qualified rate of trimming

Large-sized product (φ220mm and above)

Small-sized product( (below φ220mm)

Special product

%

%

%

≥90

≥95

≥85

Mud returning rate

Isostatic pressing

other

%

%

<10

20~30

Water content of formed mud

Ram pressing (roll forming)

Isostatic pressing

Casting

%

%

%

≤ 23

≤ 3

≤ 38

Moisture content of demoulding preform body

Ram pressing

Casting

%

%

≤ 18

≤ 24

White body moisture content % ≤ 3

Drying temperature of hot air of chain-type dryer

Drying with model(Ram pressing)

Drying after demolding (Ram pressing)

°C

°C

45~60

80~120

Relative humidity of hot air of chain-type dryer

Drying with mold (Ram pressing)

Drying after demolding (Ram pressing)

%

%

45~60

25~60

Hot air drying time of chain dryer

drying with mold (Ram pressing)

Dry after demolding (Ram pressing)

min

min

20~40

60~120

Power consumption of hot air drying of chain-type dryer

General chain-type drying

Quick drying

kJ/kg water

kJ/kg water

≤ 10.45×103

≤ 6.27×104

Casting products

Drying temperature

Relative humidity of hot air

°C

%

45~60

50~80

Qualified rate of glazing

Unburned body materials

Large sized products (φ220mm and above)

Small sized products (below φ220mm)

Special product

Burned body materials

%

%

%

%

≥ 90

≥ 95

≥ 90

≥ 95

4.3.4 The main equipment selection of the Forming workshop shallmeet the


31

1 The level of mechanization and automation of the equipment and the

adaptability to different products shall be considered according to factors such as

the shape, specification, and processing technology of the product.

2 Disc products and shallow bowl products should be formed by a convex

mold roll forming machine or an isostaticpressing machine.

3 Deep bowl products should be formed by a concave mold roll forming

machine or an isostaticpressure forming machine.

4 The fish dishes should be formed by press casting machine, ram

pressing machine, or isostaticpressing machine.

5 For domestic ceramic products with complex structures, three

dimension printing technology may be used.

6 The casting material should be processed by a vacuum defoaming

mixer, and special shaped hollow products should be formed by a centrifugal

slip casting machine.

7 Body materials should be dried by high-efficient and energy-saving

chain-type dryer or other advanced drying equipment. Except for large or

special-shaped products, chamber drying rooms are not suitable.

8 Drying process test should be done before using a rapid dryer.

9 Waste heat of kiln shall be utilized fully as heat source of drying

preform body. When the waste heat is insufficient, gas fuel or steam may be used

as a supplementary heat source, and the heat source from direct coal burning is

not allowed.

4.3.5 The equipment layout of the Forming workshop shall meet the following

requirements:

1 Linear layout should be maded according to type. Process flow shall be

reasonable and compact, piping should be short to avoid cross or material

returning transportation.

32

2 When arranging the equipment, in addition to meeting the operation

and maintenance requirements of the equipment itself and its auxiliary devices,

the clear width of the front passage of the forming machine shall not be less than

3m, the clear width of other main passages shall not be less than 2m, and the net

distance between equipment or forming lines shallnot be less than 1.5m.

3 The location of the equipment starting device shall be convenient for

the operator to observe the equipment run and surrounding conditions, and the

accident stop button shall be set near the equipment.

4 Multi-storey factory buildings without freight elevators shall be set

lifting holes, and the size of the holes shall be 0.3~0.5m larger than the outer

dimensions of the equipment or the largest lifting component.

5 For the Forming workshop without permanent lifting facilities, there

shall be enough space and site for erecting temporary lifting devices, and the net

space should not be less than the height of the equipment plus 2 meters.

6 When arranging equipment, the location of the stairs, workshop power

distribution, ventilation and dust removal facilities shall be considered, and the

influence between the equipment foundation and pit, trench, and foundation of

wall and column shall be considered.

7 The Forming workshop should be equipped with auxiliary facilities and

rooms such as spare parts room and tool room according to the production scale,

the quantity and complexity of the equipment.

4.4 Firing workshop

4.4.1 The suitable furnance and producing process shall be decided based on

production capacity, products scheme and quality requirement for Firing

workshop.

4.4.2 The process design of the Firing workshop shall meet the following

requirements:

33

1 The firing process shall be decided to be single firing or double firing

according to raw material formula, porcelain quality requirements, fuel type and

supply condition. The energy-saving technology called low-tempeture fast

single firing is preferred. Double firing is suitable to produce high-grade fine

porcelain.

2 The specifications and quantity of firing kilns shall be determined

according to the production capacity and the balance of capacity of each

equipment in the whole plant, and factors such as comprehensive qualification

rate, the loss of semi-finished products during inspection and selection and

transportation shall be considered.

3 Fuel type shall be decided after analyzing technically and economically

based on national energy policy and local fuel supply condition. Clean fuel is

preferred.

4 When using clean fuel gas, naked burning firing technology shall be

used.

5 The firing schedule shall be determined according to the result of

semi-industrial test useing the raw materials. If there is sufficient mature

experience, it may be determined according to the firing schedule of similar

products and kilns.

4.4.3 The main process design indexes may be refered according to the

following data:

1 Moisture content of the preform body into the kiln: ≤ 3%

2 Comprehensive qualification rate of firing: Biscuit firing: ≥ 95%

Glaze firing: ≥ 95%

3 White porcelain inspection damage ratio: <1%

4.4.4 The main equipment selection of the Firing workshop shall meet the


34

1 Tunnel kiln or roller kiln which is easy to change firing schedule and

lower energy consumption shall be selected.

2 Kiln furniture made by cordierite, mullite cordierite, silicon carbide,

fused quartz or new manufacture technology may be used according to different

firing temperature and product classification.

3 The number of kiln cars for tunnel kiln shall be determined based on

factors such as the car number of parking in the kiln, the occupation car number

under loading and unloading, the car numberstopping on the return track, the car

numberwith load, the occupation car number of ready to unload and the number

of kiln cars in maintenance.

4.4.5 The equipment layout of the Firing workshop shall meet the following

requirements:

1 The equipment layout of the Firing workshop shall meet the needs of

production operation, transportation, and hot repair and cold repair for kiln. The

net width of the passage between the equipment shall not be less than 0.6m, and

the net space between the equipment and the building walls and columns shall

not be less than 0.8m.

2 The layout of the workshop shall make the transportation of

semi-finished products, finished products and kiln furniture smooth and

convenient. Any storage area shall be considered.

3 The outside of tunnel kiln shall be set with loading and unloading lanes,

return lanes, storage lanes, and inspection lanes. The quantity and length of each

kind of lane shall be determined according to the number of tunnel kilns, product

types, and work time of loading and unloading of kiln cars.

4.4.6 The Firing workshop shall be set the control room with thermal

instrument separately .

4.5 Decorating Firing workshop

35

4.5.1 The producing method and the selection of equipment shall be

determined based on color porcelain proportion and color-decoration

requirements during the process design of decorating firing workshop.

4.5.2 The process design of the decorating firing workshop shall meet the


1 Material such as decals, liquid gold and coloring agent for color-

decoration shall be stored in a separate room and kept by dedicated persons. The

temperature in the storage room should be kept at 18~25℃. Generally, the

storage time of liquid gold does not exceed 18 months, and that of decal dose not

exceed 6 months .

2 White porcelain shall be cleaned before decorated.

3 During returning between color-decoration and decorating firing, the

storage capacity of each section should be determined with the site conditions.

Product shall be stored in specified plastic or wood container, and enough space

shall be considered for storaging containers.

4 Added decorating firing times shall be included in decorating firing

producing capacity if there is multi-firing demand for product color.

5 Energy-saving technology of low-temperature decorating firing shall

be applied.

4.5.3 Main process design indicator of Decorating Firing workshop may be

determined based on Table 4.5.3.

Table 4.5.3 Main process design indexes of Decorating Firing workshop

Indicator name unit Value

Decoration loss rate (including transportation loss) % ≤ 0.5

Qualified rate of decorating firing % ≥ 98

Consumption of decal per 10,000 pieces piece 800~1200

liquid gold consumption per 10,000 pieces g 84~100

36

Indicator name unit Value

Energy consumption for decorating firing kJ/kg porcelain 3300~4200

4.5.4 The main equipment selection of the Decorating Firing workshop shall


1 Separate workbench shallbe used for manual decal operation, and these

workbenches may be located on both side of decal belt conveyor may .

2 Printing equipment may be transferable printing machine, wire screen

printing machine and color filling after manual printing with rubber stamp; Edge

coating equipment may be coating machine or rotary table by hand for manual

edge coating.

3 Lower energy-consuming roller kiln or other contunious kiln shall be

selected for decorating firing according to the production capacity, fuel type and

automatic control level, etc,. Firing bracket shall be made of heat-resistant steel

or refractory material.

4 Conveying equipment in the workshop may be rubber wheeled trolley,

battery car or hanging conveyor.

4.5.5 The process arrangement of the decorating firing workshop shall meet the


1 Each section of Decorating Firing workshop may be designed in one

single building or in combined workshop with the separate wall between each

section. In the multi-story building, the section such as sorting section,

packaging section and storage section should be arranged on the ground, and the

storage of decals, liquid gold and pigments should be arranged in separate room.

2 Color-decoration section may be arranged along decal belt conveyor or

as separate decal workbench, and there are a at least 2m width transportation

tunnel and storage space of product turnover on one side of the workbench.

Cleaning of white porcelain should be finished on the workbench.

37

3 Decorating firing section may be arranged based on type and quantity

of kiln, and the storage space for product turnover near loading & unloading

operation zone. Kilns should be arranged on the same side if there are two or

more kilns. High-pressure fans of kiln should be arranged in separate room, the

pipe of exhausting air and fuel gas should extend to the outside of the room.

4 The reparation location of color porcelain defects should be arranged

in the decorating firing workshop for premium fine porcelain production.

4.6 Plaster moulding workshop

4.6.1 The process design of the Plaster moulding workshop shall meet the


1 The gypsum powder used for the plaster moulding shall meet the

quality requirements of the industry standard.

2 When gypsum slip is prepared, a vacuum deaeration mixer shall be

used for vacuum deaeration and stirring of gypsum slip.

3 Drying of gypsum model should adopt a chamber type drying room.

4 The plaster moulding workshop should be arranged close to the

Forming workshop. When they are arranged in the same building, the model

preparation section and forming section shall be separated by walls.

5 The plaster moulding workshop shall be equipped the storage site of the

model and gypsum powder for the model mold and master mold. The place for

storing gypsum powder shall be moisture proof and wet proof.

4.6.2 Main process design parameters of plaster moulding workshop may be

refer to Table 4.6.2.

Table 4.6.2 Main process design indicators of Plaster moulding workshop

Index name unit Value

Gypsum powder loss rate % 5～10

Damage rate of plaster model % 3～5

38

Gypsum slip stirring time min 3～4

Hot air temperature of model drying °C 50～60

Hot air relative humidity of model

drying % 50～80

Model drying time (chamber drying) h 12～20

Model drying final moisture content % 3～6

Model service life

Roll forming

Casting

Times

Times

≥ 60

≥ 50

4.7 Packaging warehouse

4.7.1 Domestic ceramic products shall be inspected, sorted and graded brfore

package.

4.7.2 The production line for inspection and sorting and grading should be

arranged near package line. Color ceramic products shall be separately stored

according to their grade, cup-shape products should be stored in plastic boxes or

wood boxes, and the stack height is not higher than 1.8m; dish-shape products

should be stored in layer,and the stack height is not higher than 1.2m.

4.7.3 Domestic ceramic products should be packed in cartons. Plate-shape,

dish-shape, and bowl-shape ceramic products should beseparated each other

cardpaper before package. Cup-shape products shall be separated each other

with flexible sanitary materials before package.

4.7.4 Domestic ceramic products may be stacked and stored in different areas

of warehouse according to product type and product grade.

4.7.5 Domestic ceramic products may be stored on multi-storey rack in

high-bay warehouse. The design of automated storage and retrieval system may

be carried out in accordance with the relevant provisions of Automated storage

and Retrieval System-General Rules (JB/T 10822), Automated storage and

39

retrieval system --- Design rules (JB/T 9018) and Design specification for

automated high-bay warehouse in petrochemical industry (SH/T 3186).

4.7.6 Multi-storey racks may be implemented in accordance with the

requirements of High bay welded steel rack ---- Specicfications (JB/T 5323).

4.7.7 The channel coefficient of the finish product warehouse should be

0.6~0.7.

4.7.8 The finish product warehouse should be equipped with transportation and

hoisting equipment for storage and external transportation.

4.7.9 The design of packaging material warehouse shall meet the required

storage area. The warehouse shall be covered with shed to prevent exposure to

the sunshine, rain or humidity. The cartons for inner and outer package or other

packaging materials stored in the warehouse shall be stored in piles, and the

stacking height should be 2.5 ~ 3.0m.

4.8 Process piping

4.8.1 The design of process pipe shall comply with Design code for Industrial

Metallic Piping (GB 50316), Pressure piping code ---- Industrial piping (GB/T

20801), Pressure Pipe Safety Technology Supervision Regulation for Idustrial

Pressure Pipe (TSG D0001) and other related standards.

4.8.2 The design of process pipe direction and location arrangement shall meet

the requirements of process flow, and make the short pipe line, less fittings, safe

and convenient operation and maintenance.

4.8.3 The selection of material of pipe, fitting and accessories shall be

determined based on operation condition, medium characteristic, load

distribution and other factors.

The materials of pipes and valves for the common medium in domestic

ceramic plants may be selected refering to Table 4.8.3.

Table 4.8.3 Material selection table for pipes and valves

40

Type of medium Pipe material Valve material

Body Core/ Gate

Glaze slip Stainless steel pipe, copper pipe,

engineering plastic pipe

stainless steel

Engineering

plastics

Stainless steel, copper

clay slipClay

slip

Stainless steel pipe, copper pipe,

engineering plastic pipe

Stainless steel,

carbon steel

Engineering

plastics

Stainless steel, copper

fuel Stainless steel pipe, steel pipe, PE

pipe for gas

Stainless steel,

carbon steel

Copper, titanium,

PE plastic

Stainless steel, carbon

steel

Copper, titanium, PE

plastic Metal valves for fuel gas shall meet the requirements in Metal Valves for

Gas Transmission (CJ/T 514).

4.8.4 The specification and connection type of pipe

1 The pipe specifications should be selected the preferred outside

diameter size series in the relevant standards, and the pipe fittings shall also be

selected the same outside diameter size series as pipe according to the standard

requirements.

2 The inside diameter of the pipeline shall be determined by calculation

based on factors such as the flow rate of the conveying medium, economic flow

rate, and maximum allowable pressure drop. The wall thickness of the pipeline

shall be determined based on the pressure, temperature, stiffness and flexibility

of the pipeline, and the influence of corrosion shall be considered, etc..

The flow velocity in the common medium pipes of domestic ceramic plant

may are refer to Table 4.8.4.

Table 4.8.4 Flow rate range table for different medium pipes

Medium Name Velocity range (m/s)

Glaze slip 0.5～0.8

Clay slip 0.5～1.2

3 The connection type of the pipe shall be determined by the operating

conditions of the conveying medium and the characteristics of the medium under

41

such operation condition. The connection type such as welding, threaded

connection, flange connection, union connection may be used.

4.8.5 The fuel delivery pipeline design shall meet the following requirements:

1 The design of the fuel pipeline shall meet the requirements in Code for

design and construction of filling station (GB 50156), Code for design of

liquefied petroleum gas ( LPG) supply engineering (GB 51142), Design code for

producer gas station (GB 50195), Code for design of city gas engineering

(GB50028) and Technical standard for polyethylene (PE) gaseous fuel pipeline

engineering (CJJ 63).

2 Steam heat tracing should be adopted along the heavy oil for fuel

pipeline, and pipeline cleaningdevices in steam shall be installed. Measures shall

be taken to prevent oil entering the steam pipe at the joint of the oil and steam

pipes.

3 The fuel pipeline shall be equipped with a reliable electrostatic

grounding device.

4.8.6 Pipeline layout

1 Pipe in the workshop should be laid overhead along the wall or column,

or underground if necessary. When laid underground, pipe trench shall be set,

and the elevation of trench cover top shall be the same as that of ground surface.

2 Outdoor pipelines should be laid overhead.

3 The net space of indoor pipe crossing pedestrian passage shall not be

less than 2.2m. The space of the pipe crossing the passage of transportation

equipment in the workshop shall meet requirements of equipment transportation.

4 The net space of outdoor pipe crossing the road shall not be less than

4.6m. Anti-freezing measures shall be taken for outdoor pipe in cold region.

5 There should be no welding seam, valve and other pipe accessories in

the pipeline above the equipment, motor or electrical switch cabinet, otherwise

the reliable protection measures should be taken for this electrical facilities.

42

6 The casing pipe shall be embedded for pipe crossing wall and floor.

There shall be no welding seam in the pipe section inside the casing pipe, and the

gap between the pipe and the casing and the filling material in gap shall meet the

requirements of anti-shock and anti-fire.

7 Valve arrangement shall meet the requirements of valve structure and

medium characteristics. Valve shall be arranged on location easy operation and

maintenance, and shall not hinder the disassembly and repair of higher

equipment body and pipe.

8 The layout of indoor pipe trench shall be considered in combination

with other trenches in the plant. The direction of pipe trench shall meet the needs

of production process, reducing the crossing of trenches and avoiding laying the

trench under the main passage way.

9 The pipe layout shall sure the distance between pipes and between pipe

and beam, columns and wall to meet the needs of installation, operation and

maintenance. The size of pipe spacing may refer to the relevant codes and

standards.

10 The pipe shall be designed with certain pipe slope. The slope may be

determined as following except there is special requirement:

1） Gravity flow pipe shall be slpoed along the flow direction of the

medium, and the slope of glaze slip pipeline and clay slip pipeline shall not be

less than 2%;

2） Forced flow pipe: The slope along the flow direction of glaze slip

pipeline, Clay slip pipeline and fuel oil pipeline shall not be less than 0.5% ~1%,

and the slope of fuel gas pipeline shall not be less than 0.2%.

4.8.7 Anti-corrosion, thermal insulation and coloring of pipe shall meet

requirements as following:

1 Carbon steel pipelines engineering shall comply with Design code for

external corrosion protection of chemical equipment and piping (HG/T 20679),

43

Design specification for anticorrossion coating of equipment and piping in

petrochemical engineering (SH/T 3022) and Code for construction and

acceptance of chemical equipment and pipeline anticorrosive engineering (HG

/T 20229) and other relevant standards.

2 The thermal insulation design of the pipeline shall be implemented in

accordance with the Code for design of industrial equipment and pipeline

insulation engineering GB 50264.

3 For the pipelines at the reachable location by person that do not require

thermal insulation in the process, the corresponding protective measures shall be

adopted to avoid person touching according to the temperature of the medium

transported by the pipeline.

4 The surface of the pipe or the surface of its insulation layer shall be

painted and marked with color for the different medium pipe. Pipe transporting

hazardous medium shall be painted with safety warning colors and signs in

accordance with the provisions of Safety Colours (GB 2893) and Safety signs

and guideline for the use (GB 2894). The coating color of common process

medium pipeline in domestic ceramic factory may according may refer to table

4.8.7

Table 4.8.7 Color selection for pipes of different medium

Pipe name Colour Colour ring

Glaze slip pipe white

Clay slip pipe light yellow Different slip may be marked

separately with different color rings

Fuel pipe yellow

4.8.8 The design of pipe supports and hangers shall meet requirements of Pipe

Supports and Hangers (GB/T 17116.1 ~ 3).

4.9 Central laboratory and R&D center

44

4.9.1 The central laboratory of the domestic ceramic plant shall meet the


1 Analyze and monitor the quality of raw materials, muds, glazes,

semi-finished products and finished products;

2 Analyze the factors affecting quality and provide inspection services

for each process in production;

3 Provide technical guidance for inspections in various workshops, unify

inspection methods, and calibrate equipment.

4.9.2 The central laboratory may include these function of chemical analysis,

physical testing, lead and cadmium release testing, thermal testing, sample

processing, instrument and drug storage, and file management.

4.9.3 The equipment configuration of the central laboratory should follow the

following principles:

1 The instrument and equipment configuration of the central laboratory

may be determined according to the production capacity, products

characteristics and local cooperation conditions.

2 The main equipment for chemical analysis shall be able to meet the

requirements of conventional chemical composition analysis, rapid analysis of

potassium and sodium composition, and analysis of lead and cadmium release

from finished products.

3 The main physical testing equipment shall be able to meet the

requirements of raw materials, mud and glaze performance test, sintering

performance test, product performance test, and gypsum performance test.

4 General instruments and equipment should be planned and set up

centrally.

4.9.4 A research and development center should be set up in domestic ceramic

factory. The R&D center may be set up separately or combined with the central

laboratory.

45

4.9.5 The equipment configuration in the R&D center shall be able to meet the

needs of new product trial production research. Small equipment such as blank

glaze preparation, forming, firing, mold making and pigment preparation should

be equipped.

46

5 Ki l n


5.1.1 The fuel used in the kilns of domestic ceramic plants shall be selected in

accordance with the national energy policy and the principles of local conditions

and local materials, combined with consideration of fuel cost, energy saving,

convenient operation and environmental protection regulations.

5.1.2 Newly built or rebuilt kilns shall use clean gas as fuel. For the domestic

ceramics plants that are expanded or renovated, the kilns that directly burn coal

should be converted to clean gas as fuel.

5.1.3 In addition to clean gas, electric energy may be used for newly built or

rebuilt kilns.

5.1.4 Kiln design must follow the principle of energy saving in terms of kiln

type selection, structural design, material selection and waste heat utilization.

5.2 Kiln type selection

5.2.1 For new, rebuilt and expanded domestic ceramic factories, the kiln type

shall be determined based on product type, scale and fuel.nded domestic ceramic

factories, the kiln type shall be determined based on product type, scale and fuel.

5.2.2 Shuttle kilns using clean gas as fuel may be used for the firing of small

batch products or special products or test products.

5.2.3 Roller kiln or push plate kiln may be used for product with body glaze

suiting rapid firing

5.3 Determination of main technical and ecomic index

5.3.1 The firing qualification rate of the kiln shall be calculated as follows:

𝜂 ≥ 𝜂0 +（1 − 𝜂0） ( 5 . 3 . 1 - 1 )

47

Herein: 𝜂 —— Kiln firing qualification rate,%

𝜂0 —— Local regulated minimum firing qualification rate

5.3.2 Unit energy consumption (kJ / kg) of kiln-fired products shall include the

energy consumption of single firing and double firing product, and shall be

calculated the weight of product that enter into the kiln, which shall meet the

requirements as following:

1 The energy consumption per unit product of domestic ceramic of new

or rebuilt or expanded domestic ceramic production lines shall not be higher

than the requirements of energy consumption limit level 2 specified in The norm

of energy consumption per unit products of domestic ceramics (GB 36890).

2 Fuel consumed during the kiln drying and commissioning is excluded

in the calculation of energy consumption per unit fired products.

5.3.3 Thermal efficiency of fired product in the kiln shall not be less than 40%.

The calculation of thermal efficiency may be conducted based on Measurement

and calculation method of heat balance and thermal efficiency (GB/T 23459).

48

6 F u e l


6.1.1 Domestic ceramic plants may use natural gas, liquefied petroleum gas,

town fuel gas, producer gas, fuel oil and other clean fuels. The selection of fuel

shall comply with process requirements, with focusing on proper usage of

energy-saving and environment-friendly clean fuel.

6.1.2 The design of gas station, oil depot and their pipeline shall comply with

the provision of this chapter as well as current national and industrial standards,

codes and regulations

6.1.3 Environmental protection and safety protection facilities of gas station,

liquefied petroleum gas gasification station and oil depot must be designed at the

same time with the main project, and shall comply with the provisions of

relevant national or local standards and specifications, and meet the control

requirements of harmful substance and noise emission.

6.2 Fuel Gas

6.2.1 Natural gas used for kiln fuel gas shall meet the requirements of Natural

Gas (GB 17820) and meet the following requirements:

1 Natural gas shall have a standby gas supply source, or there is other

backup fuel.

2 The hydrogen sulfide content in natural gas shall be less than

20mg/Nm3.

6.2.2 Liquefied petroleum gas used for kiln fuel gas shall comply with the

regulations of Liquefied Petroleum Gas GB 11174.

6.2.3 Coal gas used for kiln fuel gas shall meet the following requirements:

1 Coal gas shall be supplied continuously with stable flow and pressure.

49

2 The low calorific value of coal gas shall not be lower than

5.0×103kJ/m

3.

3 The coal gas shall be clear, and the content of dust and tar in coal gas

shall be controlled.

4 The content of hydrogen sulfide in coal gas shall meet the requirements

of product quality and environmental protection.

6.2.4 The design of the gas distribution station and the pressure regulating

room shall meet the regulations and requirements of the Code for design of city

gas (GB50028).

6.2.5 The fire protection design of the pressure regulating room shall meet the

regulations and requirements in the Code of Design on Building Fire Protection

and Prevention (GB 50016).

6.2.6 The storage, transportation and usage of LNG or CNG shall comply with

provision of Code for design and construction of filling station (GB 50156).

6.2.7 The storage, transportation and use of liquefied petroleum gas shall

comply with the Code for design of liquefied petroleum gas ( LPG) supply

enginering (GB51142).

6.2.8 The design of producer gas station shall meet the requirements of Design

code for producer gas station (GB 50195).

6.3 Fuel oil

6.3.1 Fuel oil system shall meet requirements as following:

1 Oil shall be supplied continuously with stable pressure and flow.

2 The oil viscosity meets the atomization requirements of burner.

3 The impurity content in the oil is few.

6.3.2 The loading, unloading, storage, transportation and use of fuel oil shall

meet the requirements of Code for Design and Construction of Automobile

50

Filling Station (GB 50156). Heating and thermal insolution system shall be

considered for storage of heavy oil.

6.3.3 The fuel oil supply design of the workshop shall meet the following

requirements:

1 When the oil tank farm is far away from the workshop user, the

intermediate storage tank should be set, and the oil storage capacity should be

met the oil consumption for 1 ~ 2 days of workshop.

2 The kiln oil supply system shall ensure the stability of the fuel oil

temperature, oil pressure and viscosity.

51

7 Th e r ma l pow e r

7.0.1 It is based on national energy saving policy and technical & economic

analysis according to the local central heating condition or plan whether

domestic ceramic plant needs to build industrial boiler or not.

7.0.2 Heating design shall comply with current national standards,

regulations and principals.

7.0.3 The design of boiler room is based on production process and heat

loading curve provided by heating & ventilation descipline. The arrangement

of boiler shall meet requirements of loading change and spare boiler shall be

arranged based on technical & economic analysis.

7.0.4 Heating supply should be designed based on possible expansion and

related requirements.

7.0.5 Maintenance and laboratory room and equipment required for heating

facilities should be considered in general plan of plant. The design of heating

supply shall be considered with operation maintenance and supervison

facilities.

7.0.6 The expansion or rebuilding design of heating design facilities shall be

based on energy-save premise, with focusing on the potential of original

equipment. Its main technical and economic indexes shall be better than those

before expansion and reconstruction.

7.0.7 For a single boiler with a capacity of less than 10t/h, the feedwater

deaeration should adopt low-level water jet vacuum deaeration or a new type

of desorption deaeration device.

7.0.8 The design capacity of the chemical water treatment in the boiler room

should include the consumption of softened water required by the

self-provided gas station and other departments.

52

7.0.9 The hydrophobic heat shall be recycled and the recovery rate shall be

greater than 60%. The make-up water from production steam, heating

ventilation and air conditioning steam should be recycled, and the condensate

water return device may be set separately or shared with the drain tank of

heating facilities.

7.0.10 The boiler room shall be equipped with necessary instruments for

monitoring the safe operating parameters of the boiler unit, as well as

instruments for monitoring the economic operation and economic accounting

of the boiler unit.

7.0.11 The fans, water pumps and other equipment in the boiler room shall be

made of high-efficiency, energy-saving and low-noise products.

53

8 Pow e r S u pp ly

8.0.1 The electrical design of domestic ceramic plant shall meet needs of

process design, and should include power transformation and distribution,

worshop power, lighting, lighting protection, grounding and so on.

8.0.2 The electrical design shall meet producing requirements, and shall

satisfy the needs of recent development, convenient management, safe

maintenance, less investment, low energy consumption and easy economic

analysis.

8.0.3 Power load classification

1 Power load of Firing workshop, fuel gas station, oil pump station,

boiler station, fire water pump station, and waste water treatment station shall be

level 2.

2 Power load of raw material workshop, Forming workshop, Decorating

Firing workshop, Plaster moulding workshop, central labtoraty and R & D

centre, auxiliary workshop, office building, warehouse, vehicle warehouse,

factory lighting, life area and so on should be level 3.

3 Power source shall be determined based on local power supply

condition, and two signle power sources are preferred. When there is only one

electricity source, diesel generator set with proper capacity shall be equipped in

the plant as standby power supply for kiln, gas station, oil pump room, boiler

room, water pump room and fire fighting system.

8.0.4 Power load should be calculated by the demand coefficient method and

compared with power consumption per unit product. Calculated load demand

factor of main electrical equipment in main workshop may be determined

according to Table 8.0.4.

54

Table 8.0.4 Calculated load demand factor of main electrical equipment

8.0.5 The voltage of power supply shall be determined based on the size and

distribution of power loading in the plant, regional power supply conditions,

power supply distance and economic rationality. 10kV power supply is

preferred, and 35kV Power supply may be used for large projects

W o r k s h o p

n a m e E q u i p m e n t n a m e K c Cosφ

R a w

m a t e r i a l

w o r k s h o p

B a l l m i l l 0 . 7 5 0 . 8

V i b r a t i n g s c r e e n 0 . 5 0 . 6 5

H o i s t , b e l t c o n v e y o r ,

e l e c t r o m a g n e t i c i r o n

a b s o r b e r

0 . 6 0 . 7

C l a y s l i p p o o l m i x e r 0 . 6 0 . 8

C l a y s l i p p u m p s , a i r

c o m p r e s s o r s a n d p u m p s 0 . 7 0 . 8

F i l t e r p r e s s 0 . 6 0 . 7 5

V a c u u m m u d r e f i n e r 0 . 8 0 . 8

E l e c t r i c h o i s t 0 . 2 0 . 5

V e n t i l a t o r 0 . 6 5 — 0 . 7 0 . 8

F o r m i n g

w o r k s h o p

G l a z i n g m a c h i n e , f o r m i n g

m a c h i n e , c h a i n d r y e r 0 . 5 0 . 7

G r o u t i n g m a c h i n e 0 . 6 0 . 7

C h a i n c o n v e y o r 0 . 6 5 0 . 8

e l e v a t o r 0 . 3 0 . 6

F i r i n g

w o r k s h o p

E l e c t r i c p i g g y b a c k 0 . 4 0 . 6

P o l i s h i n g m a c h i n e ,

g r i n d i n g m a c h i n e , c a r

p u s h e r

0 . 5 0 . 7

V e n t i l a t o r 0 . 7 5 0 . 8 5

G a s s t a t i o n

P u m p s a n d f a n s 0 . 7 0 . 8

T r a n s p o r t a i r c r a f t w i t h

i n t e r l o c k 0 . 6 5 0 . 7 5

T r a n s p o r t w i t h o u t

i n t e r l o c k i n g 0 . 5 0 . 7 5

55

8.0.6 When the power supply voltage is 35kV, the secondary step-down

scheme or the 35 / 0.4kV primary step-down scheme shall be determined on

the basis of technical and economic comparison.

8.0.7 The maximum capacity of a single transformer should not exceed

2000kVA, and shall consider the short-circuit working conditions of

low-voltage electrical appliances and appropriate allowance.t.

8.0.8 In the low-voltage power network of TN system grounding type, the

three-phase transformer with D,ynll connection should be selected. On-load

tap changer may be used in factories with large grid voltage deviation and

failing to meet voltage quality requirements.

8.0.9 The selection of electrical equipment and wiring should be adapted to

the natural environment characteristics of the place of use. The main

environmental characteristics of each use place of the domestic ceramic plant

may be determined according to Table 8.0.9.

56

Table 8.0.9 Table of main environmental characteristics of special use places

W o r k s h o p n a m e A p p l i c a t i o n p l a c e n a m e E n v i r o n m e n t a l

c h a r a c t e r i s t i c s

R a w m a t e r i a l

w o r k s h o p

Raw material warehouse loading and

unloading Dusty

Ball mill section Dusty and humid

Mason section humid

Around the spray drying tower Dusty

F o r m i n g w o r k s h o p

Around hot blast stove and dryer Higher temperature

Trimming machine Dusty

Grouting section Relatively humid

Glazing machine Relatively humid

F i r i n g w o r k s h o p

Around the kiln and overhaul the

trench high temperature

polisher Dusty

Bottom grinding machine Dusty

d e c o r a t i n g

f i r i n g w o r k s h o p

Around the furnace high temperature

Flower Paper Library Fire hazard area

Packaging material warehouse Fire hazard area

Finished product storage Fire hazard area

P l a s t e r m o u l d i n g

w o r k s h o p

Weighing, mold repair Dusty

drying Higher temperature

P u m p H o u s e Dosing Room corrosion

Other places humid

S e w a g e t r e a t m e n t humid

B o i l e r R o o m

Ash discharging room Non-conductive dust

Coal-fired boiler room High temperature,

non-conductive dust Broken coal room, coal powder room Explosive hazardous area

(Zone 22) Coal conveying corridor Dusty (conductive)

G a s s t a t i o n

G a s s t a t i o n

Coal bunker and belt conveyor on the

top floor of the main plant

Explosive hazardous area

(zone 2)

Main plant operation layer High temperature and dust

Main plant ground floor Humid and dusty

Machine room, voltage regulating

room, etc.

Explosive hazardous area

(zone 2)

57

W o r k s h o p n a m e A p p l i c a t i o n p l a c e n a m e E n v i r o n m e n t a l

c h a r a c t e r i s t i c s

Electric filter, washing tower Explosive hazardous area

(zone 2)

8.0.10 The design of low-voltage power distribution system shall meet the


1 Combined system of radial and trunk distribution should be applied.

2 Chain type power distribution may be used for small capacity power

consumption equipment with low power supply reliability requirements or of the

same production line. The number of links in each circuit should not exceed 5 or

the total capacity should not exceed 10kW, and their respective protection

equipment shall be installed.

3 When the power distribution box adopts chain power distribution, the

number of links should not exceed 3 units.

4 The feeder from the main substation to each workshop shall be

equipped with a power meter, and a recording type meter should be installed.

5 Low-voltage distribution circuit active watt hour meter shall meet the

needs of economic analysis of each production section.

8.0.11 The selection of electrical facilities shall follow the following

principles:

1 For Firing workshops, gas stations, boiler rooms, water pump rooms,

sewage treatment stations, etc., starting and control equipment should be

centrally installed in a separate room with a normal environment. The operating

switches and indicating instruments installed on-site shall be reasonably selected

according to environmental characteristics.

2 Maintenance power source shall be prepared for main workshop and

the length of lead wire for electrical appliances maintenance may be determined

based on actual needs, and should be no more than 50m.

58

3 Lines along the exterior of high-temperature equipment such as tunnel

kilns and chain dryers shall adopt high temperature resistant wire crossing steel

pipes.

4 Cable line should be selected in places with corrosive medium, dust and

humidity, and plug-in bus should not be selected.

5 For the power distribution boxes and lighting distribution boxes in the

main production workshops or joint workshops, the power lines should be laid

along the cable racks.

6 Copper core cable or copper core conductor should be used in control

circuit, mobile cable, fire line, places with chemical corrosion to aluminum

conductor and places with explosion risk.

8.0.12 The lighting source and illuminance of electric lighting shall meet the


1 The lighting design shall meet the requirements of Standard for lighting

design of buildings GB 50034, and it is preferred to use a light source with high

luminous efficiency, long life, and its characteristics in line with the use

requirements and environmental characteristics. For places with high color

rendering requirements, light sources with good color rendering performance

should be used.

2 High-temperature luminaires such as tungsten halogen lamps shall not

be used in warehouses with fire risk.

3 The average illumination value of the main workshop may be

determined based on Table 8.0.12.

4 In addition to general lighting, local lighting shall also be installed

according to process requirements.

Table 8.0.12 Illuminance table of main production workshop

Production workshop name workplace General lighting

Average illuminance, LX Type of lighting

Raw material workshop Raw material

warehouse 50 general

59

Production workshop name workplace General lighting

Average illuminance, LX Type of lighting

workshop 100 general

Forming workshop workshop 150 General, partial

Firing workshop

workshop 100 General, partial

Operation control

room 300 General, partial

Decorating firingworkshop

workshop 150 General, partial

Operation control

room 300 General, partial

Decal, inspection,

packaging 200 General, partial

warehouse 50 general

Plaster moulding workshop workshop 100 General, partial

Air compressor station,

pump room, etc.

100~150 general

Boiler Room 100 General, partial

Distribution room 200 General, partial

8.0.13 The lighting power supply shall meet the following requirements:

1 The normal lighting power should be supplied by the special lighting

panel of the substation. When the main production workshop is a combined

workshop, the lighting power supply should be led from two sections of

low-voltage buses of the substation to the main lighting distribution box with

automatic switching of dual power supply.

2 The evacuation passages, power distribution rooms, and control rooms

of the production workshop shall be equipped with emergency lighting, and shall

comply with the relevant provisions of the Technical standard for fire

emergency lighting and evacuate indicating system GB 51309.

3 The normal lighting of the production workshop should be centralized

in the distribution box according to the workshop section. The switch should be

installed separately for living room, door lamp and individual scattered lamps.

60

The division and control of lighting circuit shall be adapted to the process

flow and equipment layout, and the power saving, wire saving and construction

installation and maintenance shall be considered.

4 The lighting voltage on the local lighting lamp on the equipment and

the side wall of the trench side of the tunnel kiln shall be 36V. The lighting

voltage on the maintenance in the boiler, chain dryer, ball mill, slip tank, and the

spray drying tower shall be 12V.

8.0.14 The lightning protection of buildings (structures) shall designed in

accordance with the relevant provisions of Design code for protection of

Structures against lightning GB 50057. The explosion hazardous places such

as gas station, gas station and gas distribution station shall be designed

according to the Category Two of buildings

8.0.15 Fuel gas alert system shall be set in related place in accordance with

provisions of Code for design of city gas GB 50028.

61

9 A u to ma t i c co n tro l in s t r u me n t a n d i n fo r ma t i o n

9.0.1 The design of the automatic control instrument of the domestic ceramic

plant shall meet the process design requirements and follow the following

principles:

1 The overall automation, informatization, and intelligence level of the

project shall be determined according to factors such as plant scale,

technological equipment level, production process characteristics, product

quality assurance, energy saving and consumption reduction, environmental

protection, and production operation requirements.

2 The production system should be equipped with necessary metering,

testing, monitoring and information transmission instruments.

3 The setting of test items and the design of control system should fully

consider the requirements of automation and intelligence; the instrument series,

varieties and specifications should be unified.

4 The accuracy of automatic control instruments shall be selected

according to the requirements of the process and mainstream product standards.

The process parameter instrument should be 1.5 and above, and the main

economic analysis instrument should be 1.0 and above.

5 Corresponding instruments shall be selected to meet the requirements

of the current national standards based on the classification of the hazardous

area.

6 The protection level of the instrument shall comply with the relevant

regulations of the current national standards, and the protection level of the

instrument installed on site should not be lower than IP65.

9.0.2 The main thermal equipment such as glaze firing kiln, biscuit firing

kiln, decorating firing kiln, spray dryer, hot blast stove, etc. shall be equipped

with oil, gas and other metering instruments. Thermal equipment that uses gas

62

shall also be equipped with automatic safety interlock devices such as power

shutdown and gas shutoff.

9.0.3 The design of automatic control instruments should adopt a distributed

control system (DCS), and set up a computer control system (MIS) for

plant-wide production scheduling and management.

9.0.4 Isolation device shall be installed for fuel oil pressure measurement.

Diaphragm pressure gauge and isolation diaphragm pressure transmitter

should be adopted for pressure measurement.

9.0.5 For the automatic control system based on switch value and sequence

control, programmed logic control (PLC) should be used, with three operation

modes of manual, semi-automatic and full-automatic.

9.0.6 The tunnel kiln entry and exit vehicle control system should be

equipped with a separate operation bench.

9.0.7 For the cable protection mode from the primary element and actuator to

the cable duct, the metal hose with a length of about 500mm should be used,

and the wire protection pipe should be put into the wire duct.

9.0.8 The grounding connection of instrument and control system should be

classified and collected, and finally equipotential connection with the main

grounding plate, and the grounding device should be shared with electrical

devices.

9.0.9 The grounding resistance of the common grounding system of the

instrument system shall not be greater than 1Ω, and the separate grounding

resistance of the instrument system shall not be greater than 4Ω.

9.0.10 The burning workshop and gas station shall be equipped with

instrument control room respectively, and the location shall be in accordance

with the process layout requirements. Location with frequent production

operation, centralized control points, convenient operation and good

ventilation shall be selected

63

9.0.11 The general inspection and control items of main production systems

and equipment may be determined according to the following principles:

1 Tunnel kiln inspection and control items are shown in Table 9.0.11-1.

2 Roller kiln inspection and control items are shown in Table 9.0.11-2.

3 The thermal detection and control items of the producer gas station are

shown in Table 9.0.11-3.

9.0.12 Telephone and network communication system shall be set in the

plant area, and the standby capacity of telephone system shall not be less than

20%

9.0.13 The design of telephone and network communication system in the

plant shall comply with provisons of national standard Code for engineering

design of generic cabling system GB50311.

64

Table 9.0.11-1 Measuring & Control Points List of Tunnel Kiln

M e a s u r i n g

& C o n t r o l

p o i n t

F i e l d

i n d i c a t o r

I n s t r u m e n t p a n e l

I n s t r u c t i o n s r e c o r d i n g I n t e g r a t i n g I n t e r l o c k A l a r m c o n t r o l

F l u e d u c t

t e m p e r a t u r e √

F l u e d u c t

p r e s s u r e √

K i l n r o o f

t e m p . a t

p r e h e a t i n g

s e c t i o n

√

K i l n w a l l

p r e s s u r e a t

p r e h e a t i n g

s e c t i o n

√

U p p e r &

l o w e r p a r t

t e m p . a t

p r e h e a t i n g

s e c t i o n

√

K i l n r o o f

t e m p . a t

f i r i n g

s e c t i o n

√ √ √

K i l n w a l l

p r e s s u r e a t

f i r i n g

s e c t i o n

√

U p p e r &

l o w e r t e m p .

a t f i r i n g

s e c t i o n

√

U n d e r - c a r

t e m p . a t

f i r i n g

s e c t i o n

√

K i l n w a l l

p r e s s u r e a t

c o o l i n g

s e c t i o n

√

P r e s s u r e

o f a l l f a n s √

C a r s

e n t e r i n g &

e x i t i n g

√ √ √

G a s o r

l i q u i d f u e l

f l o w i n

h e a d e r p i p e

√ √

G a s o r

l i q u i d f u e l

p r e s s u r e i n

√ √ √ √

65

M e a s u r i n g

& C o n t r o l

p o i n t

F i e l d

i n d i c a t o r

I n s t r u m e n t p a n e l

I n s t r u c t i o n s r e c o r d i n g I n t e g r a t i n g I n t e r l o c k A l a r m c o n t r o l

h e a d e r p i p e

P r e s s u r e

o f e a c h g a s

p i p e r i n g

√ √ √ √

P o w e r

f a i l u r e

p r o t e c t i o n

o f g a s

h e a d e r p i p e

F u e l o i l

h e a d e r p i p e

t e m p .

√ √

P r e s s u r e

o f

c o m b u s t i o n

a i r d u c t

√ √

C o m b u s t i o

n a i r d u c t

t e m p e r a t u r e

√ √

T a b l e 9 . 0 . 1 1 - 2 M e a s u r i n g a n d C o n t r o l P o i n t s L i s t o f R o l l e r

K i l n

M e a s u r i n g & C o n t r o l p o i n t F i e l d

i n d i c a t o r

d a s h b o a r d

I n s t r

u c t i o

n s

r e c o r

d i n g

I n t e g

r a t i n

g

I n t e r

l o c k

A l a r

m

c o n t r

o l

Flue duct temperature √

Flue duct pressure √

Upper part temperature √

Upper part pressure √

Lower part temperature √

Lower part pressure √

Kiln temperature √ √ √

Kiln pressure √

Pressure of all fans √

Roller bed operation speed √

Operation condition of entering &

exiting kiln

√ √ √

Operation condition outside kiln √ √ √

Gas or liquid fuel flow in header pipe √ √

Gas or liquid fuel pressure in header

pipe

√ √ √ √

Power failure protection of gas header

pipe

√ √

66

Fuel oil header pipe temperature √ √

Combustion air duct pressure √ √

Table 9.0.11-3 Thermal Measuring & Control Points List of Producer Gas Station

M e a s u r i n g

& C o n t r o l

p o i n t

F i e l d

I n d i c a t

o r

d a s h b o a r d

I n s t r u c t i o n

s

R e c o

r d i n g

I n t e g r a t i n

g

I n t e r l o c

k A l a r m C o n t r o l

Saturated air

temperature at

producer inlet

√ √ √ √

Saturated air

pressure at

producer inlet

√ √

Gas

temperature at

producer outlet

√ √

U p p e r

g a s

o u t l e t

o f

t w o - s t a

g e

f u r n a c e

T e m p e r

a t u r e

n e e d s t o

b e

a d j u s t e

d

a u t o m a t

i c a l l y

Gas pressure at

producer outlet √ √

Saturated air

flow at

producer inlet

√ √ √

Drum water

level (water leg

level for T-G

boiler)

√ √ √ √

Gas

temperature at

gas

purification

equipment

inlet

√ √

Gas pressure at

gas

purification

equipment

inlet

√

Gas

temperature at

gas

purification

equipment

outlet

√ √

67

M e a s u r i n g

& C o n t r o l

p o i n t

F i e l d

I n d i c a t

o r

d a s h b o a r d


s

R e c o

r d i n g

I n t e g r a t i n

g

I n t e r l o c


Gas pressure at

gas

purification

equipment

outlet

√ √

Air header

pressure √ √ √ √ √

Air pressure at

blower outlet √ √

Low pressure

header gas

pressure

√ √ √ √ √

Gas pressure at

gas exhauster

outlet

√ √ √

Gas pressure at

gas station

outlet

√ √

Gas

temperature at

outlet gas

station

√ √

Outlet gas flow

of gas station √ √

Circulating

water

temperature

√

Circulating

water pressure √

Circulating

water flow √

68

M e a s u r i n g

& C o n t r o l

p o i n t

F i e l d

I n d i c a t

o r

d a s h b o a r d


s

R e c o

r d i n g

I n t e g r a t i n

g

I n t e r l o c


Feedwater

pressure √

Feedwater

flow √ √ √

Softened water

flow √ √ √

Softened water

pressure √

External steam

pressure √

External steam

flow √ √ √

If ESP is set,

following

items shall be

added:

Gas

temperature at

ESP outlet

√

Gas pressure at

ESP outlet √ √ √ √ √

Insulator

temperature

inside insulator

box

√

√

√

√

√

Gas oxygen

content at ESP

inlet

√ √

√ √

69

10 A r ch i t e c tu r e an d S tr uc tu r e

10.1 A r c h i t e c t u r e

10.1.1 The architectural design for domestic ceramic plant building shall meet

the requirements of technological design and the requirements of regional

planning. In combination with the local meteorological conditions and

environmental conditions, the following issues shall be taken into consideration:

internal transport, sanitary facilities, safety, fire prevention, water prevention,

corrosion prevention, noise prevention, dust prevention, thermal insulation, heat

insulation, ventilation and natural lighting.

10.1.2 Pay attention to prevent possible iron rust in raw materials workshop.

All the exposed ferrous components of the building, incl. steel doors & windows,

hardware, platform, handrail and etc., shall be prevented from rust.

Steel doors and windows should not be used in the raw materials workshop.

There shall be a foot (shoe) wash basin at the entrance.

10.1.3 For plants with lots of dust such as the raw materials workshop and

Forming workshop, the indoor building components shall reduce the parts that

are easy to accumulate dust. The inner surfaces of walls and roofs shall be

smooth and flat. The dust generation parts should be properly sealed to reduce

diffusion.

10.1.4 For raw material plant, forming workshop and decorating Firing

workshop, the floor and ground shall be flat and dense to prevent dust and be

easy to clean. The floor surface shall be designed with an appropriate drainage

slope to drain to the trench or floor drain.

10.1.5 Raw material plant, aging room and preform body room shall be kept

away from direct sunlight and straight ventilation, and appropriate temperature

70

and humidity shall be maintained. Walls and floors shall be flat, smooth and

wear-resistant.

10.1.6 Inside Forming workshop, Firing workshop and Decorating Firing

workshop, major operating locations with lots of operators shall be provided

with good natural lighting and natural ventilation, and direct sunlight shall be

avoided.

Ventilation measures shall be strengthened in the painting section, and air

conditioner should be arranged. And no matter natural or mechanical ventilation,

direct blowing to the operating platform shall be avoided.

10.1.7 For Decorating firing workshop with large amount of liquid gold, the

storage room for liquid gold shall be designed as for valuables.

10.1.8 For large noise sources such as fans and air compressors, effective

building sound insulation measures shall be taken.

10.1.9 In firing and Decorating firing workshop, skylight, ventilator and high

side window shall be set above the kiln, which is the centralized source of heat.

10.1.10 Each production workshop shall set up auxiliary rooms such as

workshop offices, cloakrooms, rest rooms, shower rooms, and toilets in

accordance with production characteristics, actual needs and the principle of

convenience. Workshops with more concentrated female workers shall set up

separate female worker clinics. The setting standard of the bathroom in the

workshop may be determined according to Table 10.1.10.

Table 10.1.10 Shower room standard for each workshop

n a t u r e W o r k s h o p o r

s e c t i o n

E a c h s h o w e r

N u m b e r o f

u s e r s ( p e o p l e )

R e m a r k s

H i g h


o p e r a t i o n

F i r i n g w o r k s h o p

D e c o r a t i n g f i r i n g

k i l n

5 ~ 8 E q u i p p e d w i t h

s h o w e r r o o m

71

D u s t y

o p e r a t i o n s


w o r k s h o p

F o r m i n g w o r k s h o p

P l a s t e r m o u l d i n g

w o r k s h o p , e t c .

9 ~ 1 2

10.1.11 When the form of a joint plant building is adopted, in addition to

meeting the requirements of smooth process flow, attention shall be paid to

meeting the functional requirements of each part, and the problems of ventilation

and lighting shall be solved.

10.1.12 The operation layer of the main building of the gas station should be

enclosed. The coal storage layer shall consider explosion-proof or venting

measures, and there should be no less than two safety exits on each layer.

10.1.13 Architectural design shall comply with relevant regulations of the

current Code for Fire Protection Design of Buildings GB 50016. Fire hazard

classification of each building during the production process may be determined

in accordance with Table 10.1.13.

Table 10.1.13 Classification of building fire hazards

B u i l d i n g ( s t r u c t u r e ) n a m e P r o d u c t i o n c a t e g o r y

P r o d u c t i o n w o r k s h o p

R a w m a t e r i a l w o r k s h o p Ⅴ

F o r m i n g w o r k s h o p Ⅳ

F i r i n g w o r k s h o p Ⅳ

D e c o r a t i n g f i r i n g w o r k s h o p I I I

P l a s t e r m o u l d i n g w o r k s h o p V

C e n t r a l l a b o r a t o r y a n d R & D

c e n t e r Ⅳ

P r o d u c t i o n a u x i l i a r y b u i l d i n g

B o i l e r R o o m Ⅳ

M e c h a n i c a l r e p a i r r o o m V

E l e c t r i c r e p a i r r o o m , i n s t r u m e n t

r e p a i r r o o m I I I

S u b s t a t i o n I I I

72

A i r c o m p r e s s o r s t a t i o n V

P r o d u c e r g a s s t a t i o n I I

W a t e r g a s s t a t i o n I

S e m i - w a t e r g a s s t a t i o n I I

G a s d i s t r i b u t i o n s t a t i o n I

F u e l o i l d e p o t I I I

A l l k i n d s o f p u m p h o u s e s V

N o t e : M i n i m u m f i r e r e s i s t a n c e r a t i n g o f b u i l d i n g a n d s t r u c t u r e i s

g r a d e Ⅱ .

10.2 S t r u c t u r e

10.2.1 The production workshop of a daily-use ceramic plant shall select a

reasonable structure according to the characteristics of the production process,

and the structure layout should meet the requirements of the production process

and should conform to the uniform modulus of the building. Steel structure

should not be used when iron contamination of semi-finished mud products may

occur, otherwise effective anti-corrosion measures shall be taken.

10.2.2 Structural safety class of all production & ancillary buildings and

auxiliary facilities shall be no less than class Ⅱ, and seismic fortification

intensity no less than class Ⅲ.

10.2.3 Effective thermal insulation measures shall be taken for those structural

elements nearby the thermal equipment such as kiln in accordance with the

required standards and codes, or heat-proof materials shall be used.

10.2.4 Surface of retaining wall for raw material workshop bearing horizontal

thrust shall be flat and smooth, and should be with no vertical or transverse rib.

10.2.5 The foundations of large-vibration equipment such as ball mills and air

compressors shall not be connected to the plant foundation and other adjacent

underground facilities. When the foundation is too close, appropriate vibration

isolation measures shall be taken.

73

10.2.6 Floors of ceramic mud room and aging room and walls of retaining

structure shall be flat, smooth, wear-resistant and impact-resistant.

10.2.7 In places with high humidity and poor ventilation, such as ceramic mud

room, aging room and preform body room, the steel protection layer of the

concrete components shall be appropriately thickened, and the surface of the

components should be treated with appropriate anti-corrosion treatment.

10.2.8 Kiln foundation shall be designed in accordance with following

principles:

1 Set expansion joints in combination with kiln design.

2 Heat-resistant structural materials should be selected for the heated part,

and limestone aggregates should not be used for the concrete of the heated part;

3 The deformation of the foundation shall meet the process design

requirements, and the influence of the heating of the foundation soil on the

deformation of the foundation shall be considered;

4 The kiln foundation shall be separated from the workshop floor by a

separation seam. The width of the separation seam shall not be less than 20mm,

and it shall be filled with heat-resistant elastic materials;

5 The light kiln arranged on the floor shall be supported by overhead

structure.

10.2.9 Foundation deformation of kiln car track and trailer track shall satisfy

process design, and the soil shall be compacted and backfilled in layers to

achieve uniform and dense.

10.2.10 The determinatioFloor equivalent uniform live load of main

production workshops under installation and maintenance condition shall be

determined in line with relevant provisions in Load Code for the Design of

Building Structures GB50009 or Table 10.2.10 when conditions are satisfied.

Table 10.2.10 Uniform live load on floor of main production workshops

W o r k s h o p S e c t i o n F l o o r u n i f o r m l i v e l o a d s t a n d a r d

v a l u e ( k N / m 2 )

C o e f f i c i

e n t o f

74

S l a b S e c o n d a r y

b e a m

Ma

in b

ea

m

p e r m a n e

n t Ψ g

S p a n

≥ 1 . 2 m

S p a n

≥ 2 . 0 m

s p a c i n g

≥ 2 1 . 2 m

s p a c i n

g

≥ 2 . 0 m

R a w

m a t e r i a l

w o r k s h o p

B a l l m i l l

p l a t f o r m

P u g g i n g

s e c t i o n

F i l t e r p r e s s

s e c t i o n

C e r a m i c

m u d r o o m

1 8

1 5

1 5

1 5

1 2

1 2

1 2

1 0

1 0

1 0

8

8

1 0

8

8 0 . 6 5

F o r m i n g

w o r k s h o p

F o r m i n g ,

g l a z i n g

P r e f o r m

b o d y

w a r e h o u s e

1 5

1 5

1 2

1 2

1 0

1 0

8

8

8

8

0 . 7 5

0 . 8 5

F i r i n g

w o r k s h o p

W h i t e

p o r c e l a i n

i n s p e c t i o n

W h i t e

p o r c e l a i n

s t o r a g e

1 5

1 8

1 2

1 5

1 0

1 2

8

1 0

8

1 0

0 . 7 5

0 . 8 5

d e c o r a t i n g

f i r i n g w o r k s

h o p

C o l o r

d e c o r a t i o n

s e c t i o n

D e c o r a t i n g

f i r i n g

P a c k i n g

s e c t i o n

F i n i s h e d

p r o d u c t

w a r e h o u s e

1 2

1 2

1 5

2 0

1 0

1 0

1 2

1 6

8

8

1 0

1 4

7

7

8

1 2

7

7

8

1 2

0 . 6 5

0 . 6 5

0 . 6 5

0 . 8 5

Note: When the production process has special requirements or reliable basis, the load value in

the above table may be adjusted reasonably.

10.2.11 Dynamic coefficient for main common equipment may be determined

based on the Table 10.2.11.

Table 10.2.11 Dynamic coefficient list for main common equipment

Equipment name Dynamic coefficient

Hammer crusher 3.0~4.5

Roll crusher 2.0

Electromagnetic vibration feeder 1.2

Single tube screw feeder 1.3

Bucket elevator 1.3

Belt conveyor 1.2

Stationary screen 1.5

Vibrating screen 2.0

Water ring vacuum pump or

compressor 1.0~3.0

Sand pump 3.0~3.5

Manual monorail crane 1.1

75

Electric hoist 1.2

Bridge crane 1.2

11 Wa te r S u pp ly a n d D ra i nag e

11.0.1 The design of water supply and drainage for domestic ceramics factory

shall meet the demand of safe production, firefighting and domestic water in the

factory, choose the water source properly and increase its reutilization by using

advanced technology so as to achieve environmental protection, economy,

safety and reliability.

11.0.2 Water supply & drainage system shall be planned according to the plant

capacity, with appropriate allowance. For expansion or reconstruction projects,

existing facilities, adjacent public utilities and water supply & drainage facilities

from other industrial enterprises in the same area shall be fully utilized, on the

premise of meeting relevant authorities’ requirements.

11.0.3 Water consumption of workshop production as well as its quality and

pressure shall be determined in accordance with process requirements. In

general, the water quality shall meet the drinking water quality standard, with

iron content strictly controlled and turbidity limit extended to 20mg/L. The

water pressure at the inlet of the workshop shall be 0.25~0.3MPa. In case some

equipment requires higher water pressure, .0.25~0.3MPa booster facilities shall

be arranged in the building. If the water pressure of local equipment is high,

pressurization facilities shall be installed in the workshop.

The water inlet pipes and main water-consuming equipment of each

production workshop shall be equipped with metering devices.

11.0.4 Uninterrupted water supply facilities shall be equipped for the producer

water of gas station.

76

11.0.5 Service water consumption of water treatment, unforeseen water

consumption and water leakage loss in pipeline network shall be subject to Code

for design of outdoor water supply engineer GB50013.

11.0.6 Water supply pipe network inside the plant shall be laid in a circular way

around the main production workshops and in other workshops it may be laid in

branches.

11.0.7 Drainage system design shall follow the principle of dividing the rinsing

from turbidity.General drainage shall be designed in accordance with relevant

provisions. And design of harmful sewage disposal shall be subject to

requirements in Chapter 16.

12 He a t i n g v e n t i la t io n a n d a i r co n d i t i o n i ng

12.0.1 HVAC design of domestic ceramics plant shall meet the process

engineering requirement and should include heating, ventilation, air

conditioning and dust removal.

12.0.2 Besides meeting the requirements of process and equipment, HVAC

design shall also take energy-saving, working conditions improvement and

environmental protection into consideration.

12.0.3 Central heating and air conditioning should be designed for those

plants and buildings having certain requirement for heating and air

conditioning in production or life.

12.0.4 Design calculated indoor (working zone) temperature of production

workshop and auxiliary workshop in winter and summer may be determined

as in Table 12.0.4.

Table 12.0.4 Indoor design temperature limit in winter and summer

W o r k s h o p

n a m e S e c t i o n n a m e

I n d o o r d e s i g n


l i m i t i n

h e a t i n g

s e a s o n ℃

T h e d i f f e r e n c e

b e t w e e n t h e

s u m m e r w o r k i n g

p l a c e t e m p e r a t u r e

a n d t h e c a l c u l a t e d

o u t d o o r

t e m p e r a t u r e ℃


w o r k s h o p O p e r a t i o n l a y e r 1 0 ~ 1 2 3

77

W o r k s h o p

n a m e S e c t i o n n a m e

I n d o o r d e s i g n


l i m i t i n

h e a t i n g

s e a s o n ℃

T h e d i f f e r e n c e

b e t w e e n t h e

s u m m e r w o r k i n g

p l a c e t e m p e r a t u r e

a n d t h e c a l c u l a t e d

o u t d o o r

t e m p e r a t u r e ℃

M u d s t o r a g e & a g i n g

r o o m 5 ~ 8

F o r m i n g

w o r k s h o p

P l a s t i c f o r m i n g s e c t i o n ,

i s o s t a t i c p r e s s i n g

s e c t i o n

1 6 ~ 1 8 3

G r o u t i n g s e c t i o n ,

g l a z i n g s e c t i o n 1 8 ~ 2 0

3

F i r i n g

w o r k s h o p

B i s c u i t f i r i n g s e c t i o n

G l a z e f i r i n g s e c t i o n

N o h e a t i n g

i n c o l d

a r e a s ,

p a r t i a l

h e a t i n g i n

s e v e r e c o l d

a r e a s

7

P o l i s h i n g s e c t i o n w h i t e

p o r c e l a i n i n s p e c t i o n

s e c t i o n

1 2 ~ 1 4 3

D e c o r a t i n g

f i r i n g w o r k s h

o p

D e c o r a t i n g s e c t i o n 1 8 ~ 2 0

R o o m t e m p e r a t u r e

2 6 ~ 2 8

O r f o l l o w p r o c e s s

r e q u i r e m e n t s

F i r i n g s e c t i o n 1 2 - 1 4 5

P a c k i n g s e c t i o n 1 2 ~ 1 4 R o o m t e m p e r a t u r e

2 6 ~ 2 8

Plaster model

workshop

Mold casting section

Master mould section 16~18 3

Master mold and model mold room 8~10 3

Central laboratory

16~18 Follow the process

requirement

R&D Center

Product design room 18 Room temperature 26~28

Other rooms See each section

of each workshop

Each workshop

Or section

Instrument Control Room 18 Room temperature 26~28

Low-voltage power distribution

room 16

Follow the electrical

requirements

Producer

Gas station

Bottom layer 10 3

Operation layer 12~14 5

Top coal bunker 5 3

Machine room 12~14 3

12.0.5 The heating and ventilation design of the raw material workshop shall


78

1 The dust concentration of the work area or operating point and the dust

concentration of the exhaust air shall comply with the relevant national

standards and regulations. For the dust emitted during the batching, sieving and

feeding process, a dust removal system shall be set up for purification.

2 When the dust removal system in severe cold areas keeps running for a

long period of time with large discharge air volume, make-up air system shall be

arranged, with air temperature to be determined according to the hot air balance.

3 The location of the dust collector shall be convenient for the direct

recovery of dust, the laying of dust removal ducts and the high-altitude discharge

of dust removal exhaust gas.

4 The dust collector should take form of bag filter. At the feeding port of

ball mill and other scattered dust ommission points with small air discharge

volumn, stand alone bag-type dust collector should be used.

5 Process equipment emitting dusts such as batching, sieving, de-ironing

and spray drying may be partially or entirely enclosed arranged, with

consideration of the equipment characteristics, production requirements and

principle of easy to operate and maintain.

6 The exhaust air of the dust collector shall not be directly discharged in

the workshop, but shall be discharged outdoors by devices to the high-altitude

diffusion.

7 Minimum velocity in air ducts should comply with Table 12.0.5.

Table 12.0.5 Minimum velocity in air ducts (m/s)

D u s t n a t u r e V e r t i c a l p i p e H o r i z o n t a l p i p e

P o w d e r e d c l a y 1 3 1 6

Q u a r t z s a n d 1 7 2 0

B a r i t e , f l u o r i t e 1 6 1 8

D o l o m i t e , l i m e s t o n e ,

f e l d s p a r 1 4 1 6

79

8 The raw material workshop should preferentially adopt natural

ventilation in summer.. The overall ventilation volumne of the workshop should

be calculated based on the elimination of waste heat and waste humidity.

Mechanical ventilation shall be used when natural ventilation cannot meet the

requirements.

12.0.6 The heating and ventilation design of the Forming workshop shall

meet the following requirements

1 The Forming workshop shall have good ventilation condition. Natural

ventilation should be adopted, and mechanical ventilation shall be adopted when

natural ventilation cannot meet the requirements.

2 For drying equipment such as chain dryers and chamber drying rooms,

the waste heat and waste damp air shall be discharged outdoors.

3 In the working place where workers in the Forming workshop stay for a

long time, under the conditions of outdoor ventilation calculation temperature,

when the ambient air temperature exceeds 35℃, local air supply or local cold air

supply shall be provided.

4 The Forming workshop should be heated by a radiator.

5 The glazing section should be equipped with natural ventilation or

mechanical ventilation in summer. When the process production requires the

glazing workshop to be semi-enclosed or fully enclosed, the glazing section

should be equipped with a local cooling air system.

When glaze spraying is used in the glaze application section, a wet dust

removal system should be installed, and the dust-containing sewage treatment

shall be included in the wastewater treatment system.

6 Bag filter shall be equipped for dry trimming, with discharge air

volume of each trimming point at 800 m3/h~1200m

3/h. And side suction should

be adopted for dust hood.

80

12.0.7 Heating and ventilation design of Firing workshop shall meet the


1 Natural ventilation should be preferentially adopted in the Firing

workshop.. When natural ventilation fails to meet hygienic requirements,

mechanical ventilation should be supplemented.

2 The biscuit and glaze firing sections in severe cold areas should adopt

wind shelter skylights with operatable saches, and wind shelter skylights with

rain-proof measures shall be adopted in other areas.

3 In areas with greater wind and sand, it is not advised to have open

skylights in the workshops producing high-grade fine porcelain. In summer,

mechanical ventilation shall be adopted, and the overall ventilation rate of the

workshop should be calculated according to the elimination of waste heat and

humidity in the workshop.

4 The loading and unloading work area of the Firing workshop should be

equipped with local air supply, and mobile post air blowers may be arranged if

needed.

5 Kiln flue gas should be utilized for heating in winter.

6 Dust removal system shall be installed for polishing and bottom

grinding, and bag type filter is preferred. The suction hood should be set up with

side suction, and the air volume of each dust suction point shall be 600

m3/h~800m

3/h.

7 If a fuel oil pump room is installed in the Firing workshop, the

ventilation rate shall be the larger of the following two calculation results:

1） Ventilation volume needed for eliminating waste heat;

2） Ventilation rate no less than 10 times per hour.

8 Ventilation design of oil pump house shall comply with the requirement

that hydrocarbone content in air shall not exceed 350mg/m3 and volume

81

concentration shall be not more than 0.2%, and discharge air of mechanical

ventilation shall be 10%~20% larger than its air feed.

12.0.8 The heating, ventilation and air conditioning design of the Decorating

Firing workshop shall meet the following requirements:

1 The Decorating Firing workshop shall be equipped with ventilation

measures to remove the waste heat and waste gas from the workshop, and

natural ventilation and mechanical ventilation should be combined.

2 A combination of natural ventilation and mechanical ventilation should

be used in the decorating firing section, and ventilation rate shall not be less than

5 per hour. Local air supply should be provided in the porcelain loading and

unloading work area.

3 Mechanical ventilation supplemented by natural ventilation shall be

adopted for decorating section with ventilation rate of no less than 3 times per

hour. Air-conditioner or cold air supply system may be set to keep the indoor

temperature at 26~28℃ in summer.

4 Air supply system shall be designed to supply air to the operating area

after coarse or medium efficiency filtration, which can prevent iron dust getting

into the workshop. The air duct and air outlet should not be made of steel plate.

12.0.9 Packing section should be equipped with air-conditioning system in

summer, and the indoor design temperature is 26~28℃.

12.0.10 Ventilation rate of Plaster moulding workshop in summer shall be no

less than 3 times per hour.

12.0.11 The heating, ventilation and air conditioning design of auxiliary

workshops and auxiliary buildings shall meet the following requirements:

1 Heating, ventilation and dust removal design of producer gas station

shall comply with the current national codes and standards. Explosion proof

measures shall be taken for the ventilation of machinery room. Heat dissipating

capacity of equipment at bottom floor takes 20% for heating load calculation.

82

2 Heating and ventilation design of air compressor room shall conform to

relevant regulations in Code for Design of Compressed Air Station GB 50029.

3 Compressed air stations in hot areas or workshops with heat intensity

greater than 35W/m3 shall use natural ventilation or mechanical ventilation to

eliminate waste heat.

4 Fume hoods shall be set up in the central laboratory and workshop

laboratory. The exhaust outlet of the air duct of the fume hood shall be higher

than 0.5m above the roof.

5 Ventilation rate of chlorine dosing room in pump house shall be no less

than 15 times per hour, with 1/3 of air discharged from the upper part of the room

whereas the other 2/3 from the lower part of the room.

6 The R&D center should be equipped with an air-conditioning system in

summer, and the indoor design temperature is 26~28℃.

7 For instrument control room equipped with air conditioning or

mechanical ventilation, the room shall maintain micro-positive pressure.

13 Fi r e f i gh t i ng

13.0.1 Fire-fighting design shall comply with provisions of Code for Design

on Fire Protection and Fire Prevention GB 50016, Technical code for fire

protection water supply and hydrant systems GB 50974 and other relevant

standards and codes.

13.0.2 Fire dikes shall be set up in the oil tank area. The design of the fire dike

shall comply with the requirements of in the Code for Design of Fire Dike in

Storage Tank Area GB 50351.

13.0.3 The fire protection design of the factory’s power distribution facilities

shall be implemented in accordance with the Code for fire-protection design

of power plant and substation GB50229.

83

13.0.4 Automatic fire alarm system shall be equipped for each finished

products warehouse and packaging material warehouse with plant area larger

than 1500m2 or gross building area more than 3000m

2.

84

14 En e rg y s av i n g

14.1 G e n e r a l p r o v i s i o n s

14.1.1 The design of the domestic ceramics plant shall comply with the

national laws, regulations, rules, codes and standards concerning energy saving

and comprehensive utilization of resources.

14.1.2 While preparing the basic design documents, the chapters or special

article on energy saving shall be prepared.The energy saving assessment of the

project shall be completed along with the basic design, and the energy saving

assessment report shall be prepared according to the relevant requirement.

14.1.3 Review comments on basic design and energy saving assessment report

shall be processed during detail design. Any changes to the approved

energy-saving design scheme shall be submitted for re-assessment and approval.

14.1.4 Technology and equipment about low carbon emission and

energy-saving promoted by the nation shall be actively adopted in the design of

domestic ceramic plant.

14.2 P r o c e s s e n e r g y s a v i n g

14.2.1 Select energy-saving type furnace/kiln with optimized structure.

14.2.2 Use advanced combustion device.

14.2.3 Use advanced energy-saving firing technologies such as low

temperature fast firing, single firing, naked burning firing, microwave aid gas

firing (MAGF) and etc..

14.2.4 Use energy-saving combustion technologies such as oxygen-enriched

combustion, high temperature air combustion and etc.

14.2.5 Select high-efficient insulation materials and coating technologies.

14.3 W a s t e h e a t r e c o v e r y

85

14.3.1 Set up heat exchanger to heat combustion air and fuel with waste heat

from flue gas.

14.3.2 Set up preheating section or roller dryer kiln, utilizing flue gas waste

heat to dry wet green ware or heat the air to dry the wet green ware.

14.3.3 Set up HRSG to generate steam by utilizing flue gas waste heat; the

steam may be used in power generation, production, daily life, heating and etc.

14.3.4 Waste heat recovery rate of oxidizing flame and reduction flame kiln

(porcelain, stoneware, pottery) shall be no less than 50%.

14.4 E l e c t r i c i t y s a v i n g

14.4.1 Power supply & distribution design shall comply with the following

provisions:

1 The substation or distribution station shall be located close to the load

center, cut down distribution series, shorten supply radius and select low-loss

energy saving transformer.

2 Capacity, numbers and operating mode of transformer shall be

determined in accordance with the character of load.

3 The design of power supply & distribution system should use reactive

compensation both at high voltage side and low voltage side, both centralized

and local, whichever applicable. Power factor at enterprise billing side under

maximum load shall not be less than 0.92.

4 Operating load rate of transformer should be 70~80%.

5 Ultra-harmonics of power system shall be reduced and keep the

three-phase current balance of the transformer.

14.4.2 Electrical equipment selection shall comply with the following

provisions:

86

1 Large capacity motors should be equipped with local capacitance

compensation or phase advancer; motor requiring rotary volicity adjusting

should be equipped with frequency converter.

2 High-efficient energy saving motor shall be used.

3 Appropriate feed size and discharge fineness should be selected for

crush and grinding system.

14.4.3 Energy saving design for lighting shall comply with the following

provisions:

1 Under obtain the required lighting level and visual comfort, efficient,

energy-saving and practical new light sources, lamp electrical accessories,

lighting fittings and controllers shall be adopted.

2 Street lighting controller should be equipped for the road lighting in

plant area, and solar street lighting may be used if possible.

3 Light emitting diode (LED) light source shall be used in small

illumination location such as evacuation indicator light, corridor light, courtyard

light and emergency lighting.

87

15 En vi r o n me n ta l Pro te c t io n

15.1 G e n e r a l p r o v i s i o n s

15.1.1 Design of domestic ceramics plant shall strictly abide by the current

laws and regulations, codes and standards on environmental protection issued by

the nation, industry and local government.

15.1.2 Design of domestic ceramics plant shall adopt new process and

technology and strictly control the generation of pollutants. Measures of

prevention first, prevention and treatment integrated, and comprehensive

utilization shall be taken to eliminate or minimize the pollutants.

15.1.3 Design of domestic ceramics plant shall adopt the effective schemes

with account local conditions, and the same time, considering economis defenits,

environmental benefits and social benefits.

15.2 W a s t e w a t e r

15.2.1 For the slip sewage from production workshop, the suitable treatment

process shall be built according with the sewage flow, sewage compositions and

local environmental requirements. Treated sewage may be reused as rinse water

for floor and sludge may be reclaimed for reutilization after concentration and

dehydration. Unusable wastes shall be harmless treated or sent to special

treatment company.

15.2.2 For the gypsum sewage from Plaster moulding workshop, there is one

sedimentation pond with two grids nearby the workshop,the sewage after

clarifing through this pond shall be discharged. The sediments in pond will be

cleaned manually.

15.3 W a s t e g a s

88

15.3.1 Following waste gas emissions from domestic ceramics plant shall be

controlled and treated:

1 Flue gas generated by thermal equipment;

2 Flue gas generated by boiler;

3 Tail gas from the dust removal system in each production workshop.

15.3.2 In order to eliminate pollutions during the production, thermal

equipment shall be selected with advanced combustion device and clean fuel

using. The flue gas with excessive pollutions shall be treated to reach the

requirements in relavant standard before discharging into atmosphere.

15.3.3 Dust removal device shall be selected in accordance with dust

concentration in flue gas under rated capacity of boiler, sulfur content in the fuel

and its adaptability to the load. Efficiency of bag filter shall be greater than

99.8%. Flue gas emissions shall conform to the requirements in current national

codes and standards.

15.3.4 The exhaust gas from the dust removal system in the production

workshop shall control the concentration of harmful substances, and the content

of harmful substance in exhaust gas shall meet the requirements in current

relevant national standards.

15.4 W a s t e s o l i d s

15.4.1 Waste solids generated from domestic ceramics plant, i.e. waste

porcelain, waste kiln tools, waste mold, fly ash & bottom ash from combustion

and sludge from sewage disposal, shall be controlled and treated.

15.4.2 Some of waste porcelain may be recycled to be reutilized; waste kiln

tools and waste mold shall be sent to relevant factory as raw materials; ash shall

be comprehensively utilized; the waste mud from slip sewage shall be degraded

used.

89

15.4.3 The waste solids storage yard shall be set nearby its discharge workshop,

the different waste solids stack on storage yard separately, and measures shall be

taken to prevent ash flying. The waste solids without comprehensive utilization

at site shall be sent to professional treatment company to handle periodically.

15.5 N o i s e

15.5.1 Noise generated from ball mill, HP fan, air compressor and etc. shall be

controlled and reduce its strength and affect range.

15.5.2 Noise control and treatment shall first be controlled on the sound source.

If the noise emission does exceed the limit, some measures such as sound

insulation, silencer or vibration isolation shall be taken in accordance with site

conditions.

15.5.3 The noise emission of domestic ceramic factories shall be in accordance

with the relevant regulations of Environmental quality standard for noise GB

3096, Emisson standard for industrial enterprises noise at boundary GB 12348,

and Code for design of noise control of industrial enterprises GB/T 50087. The

control strength limits at some location may refer to Table 15.5.3.

Table 15.5.3 Noise Limits of Various Locations in Domestic Ceramics Plant

Serial

number Noise location

Noise strength limit

(dB)

1

Production workshops such as raw material crushing, raw material,

forming, firing, pulverizing, packing inspection, compressed air

station, boiler house and etc. (continuously exposure time in noise

eight hours per day)

90

2

Duty room, observation room and common

room in ball mill workshop and other

workshops with high noise level (indoor

background noise level)

Without telephone

communications 75

With telephone

communications 70

3 Central control room, operating room 70

4 Office and laboratory in workshop (indoor background noise level) 70

5 Communication room, telephone switchboard room, fire duty room

(indoor background noise level) 60

6 Office, meeting room, design center, central lab incl. testing room &

metering room far away workshop (indoor background noise level) 60

90

Serial

number Noise location

Noise strength limit

(dB)

7 Medical room, workers’ dormitories (indoor background noise level) 55

91

16 Oc c u pa t io na l Sa fe ty a n d He a l th

16.1 G e n e r a l r u l e s

16.1.1 The design of safety and occupational health facilities for domestic

ceramic factories shall comply with the relevant regulations of the national

standard Hygienic Standards for the Design of Industrial Enterprises GBZ 1.

16.2 F i r i n g a n d e x p l o s i v e p r e v e n t i n g

16.2.1 The fire hazard classification of each workshop shall be determined in

accordance with the requirements in Code of Design on Building Fire Protection

and Prevention GB 50016.

16.2.2 The fire separation distance for workshops, and the arrangement and fire

separation distance of combustible oil (or combustible gas) tanks and their

auxiliary facilities shall meet related requirements of national standard Code of

Design on Building Fire Protection and Prevention GB 50016.

16.2.3 The design of electrical installations shall meet related requirements of

Code for Design of Electrical Installations in Explosive Atmospheres GB 50058.

16.2.4 The design of pressure vessels and pressure piping shall meet related

requirements of Pressure Vessels GB/T 150 and Pressure Piping Code -—

Industrial Piping GB/T 20801.

16.3 P r o t e c t i o n a g a i n s t m e c h a n i c a l i n j u r y

16.3.1 The design and installation of production equipment shall meet related

requirements of Safety of Machinery — Guards — General Requirements for the

Design and Construction of Fixed and Movable Guards GB/T 8196, Hygienic

Standards for the Design of Industrial Enterprises GBZ 1 and General Rules for

92

Designing the Production Facilities in Accordance with Safety and Health

Requirements GB5083.

16.3.2 The safety devices of lifting machinery shall meet related requirements

of Safety Rules for Lifting Appliances GB 6067.1~7.

16.3.3 The construction and installation of electric lifts shall meet related

requirements of Safety Rules for the Construction and Installation of Electric

Lifts GB 7588.

16.3.4 The arrangement of equipment such as machines and workbenches shall

facilitate the safe operation of workers, and the width of passageway around

them shall not be less than 1m.

16.4 L i g h t n i n g P r o t e c t i o n

16.4.1 The lightning protection design of buildings shall be determined

according to the characteristics of geography, geology, meteorology,

environment and lightning activity and the features of protected objects.

16.4.2 The lightning protection classification of auxiliary buildings for

production plants shall be determined by the property of production, possibilities

and consequences of lightning accidents and lightning protection requirements,

and shall meet the requirements of Code for Design Protection of Structure

against Lightning GB 50057.

16.4.3 The lightning protection and grounding measures for buildings shall

meet related requirements of Code for Design Protection of Structure against

Lightning GB 50057.

16.5 P r o t e c t i o n a g a i n s t d u s t a n d t o x i c a n t s

16.5.1 In each production operation space, the maximum allowable

concentration of dust in air and the frequency of ventilation in building shall

comply with related requirements in Chapter 12 of this standard.

93

16.5.2 The design of the protection against dust and toxicants shall meet related

requirements in Chapter 12 of this standard.

16.6 H e a t s t r o k e p r e v e n t i o n , c o o l i n g a n d h e a t i n g

16.6.1 Heatstroke prevention and cooling measures shall meet related

requirements of Hygienic Standards for the Design of Industrial Enterprises

GBZ 1.

16.6.2 The heating and cold-proof design shall meet related requirements in

Chapter 12 HVAC of this standard.

16.7 N o i s e c o n t r o l

16.7.1 The noise control in factory area shall comply with relevant regulations

of Environmental Quality Standard for Noise GB 3096, Emission Standard for

Industrial Enterprise Noise at Boundary GB 1234 and Code for Design of Noise

Control of Industrial Enterprises GB/T 50087.

16.7.2 For production process with high noise such as raw material crushing

and product grinding, mechanized and automated process shall be adopted to

achieve remote operation.

16.7.3 Soundproof rooms may be set in high-noise production sites for control,

supervision and watch. High-noise equipment should be arranged in soundproof

equipment room and be separated from operation area.

16.7.4 Flexible connections shall be used between equipment with strong

vibration. The connection between the pipeline with strong vibration and

buildings, structures or supports shall not adopt rigid connection.

16.7.5 Damping and sound insulation measures shall be taken when

transporting lump materials.

16.7.6 Mufflers shall be installed at the air inlet or outlet for equipment that

generates aerodynamic noise.

94

A p pe n d ix A Th e ta b l e o f b u l k w e ig h t a n d i n t er n a l

f r i c t i on a ng l e fo r c o mmo n ma te r ia l s i n do me s t i c

c e ra mi c s p l an t

Material Name Particle Size(mm)

(mm)

Unit Weight

103kg/m

3

Internal Friction

Angle

Clay (5%~12% moisture content)

1.2~1.8 45°

Dry clay

1.2—1.5 28~40.

Crushed dry clay

1.15%~1.2 40~45°

Grinded dry clay

1—1.1 40~45.

lump fire clay

1.3—1.5

Wood-like fire clay 0~3 1~1.1 35~40°

Bulk quartz 0—300 1.4~1.6 45°

Lumpy quartz 0~75 1.4~1.5 35~45.

Powdered quartz 0~50 1.25—1.3 40~50°

Lump feldspar (1%~2% moisture

content) 5~200 1.5 45°

Powdery feldspar 0~50 1.4 40°

Lump talc 40~120 1.5 45°

Powder talc 0~40 1.2 40°

Large gypsum 100~500 1.44 45.

Lump gypsum 30~50 1.38 40~45.

Powdery gypsum 100~120 mesh 0.9~0.95 50~80°

powder anhydrite 100~120 mesh 0.75~0.8 30°

lump trona 50~200 1.5 45°

powder trona 0~50 1.4 40°

Lump limestone 50~300 1.5—1.9 45.

95

Material Name Particle Size(mm)

(mm)

Unit Weight

103kg/m

3

Internal Friction

Angle

Powdered limestone 0~50 1.45 40°

lump dolomite 100~300 1.5 45.

Powdered dolomite 0~300 1.4 40°

Waste porcelain tiles

0.8

Waste porcelain powder

1.4 40°

Lump bauxite 50~200 1.6 45.

Powder bauxite 0~50 1.5 40°

Waste saggar chip

1.0

Waste sagger powder

1.2 40°

Recovered stock (8%~14% moisture

content)

0.85

Pebble (grinding body)

1.55 45°

96

Ex p l a na t io n o f t e r ms u se d i n th i s sp e c i f i c a t io n

1.Words used for expressing different degrees of strictness are explained as

follows in order to mark the difference in executing the requirements in this

code:

1) Words denoting a very strict or mandatory requirement:

“must” is used for affirmation and “must not” is used for negation.

2) Words denoting a strict requirement under normal conditions:

“shall” is used for affirmation and “shall not” is used for negation.

3) Words denoting a permission of slight choice or an indication of the

most suitable choice when conditions allow:

“should” or “can” is used for affirmation and “should not” is used

for negation.

4) Expressing choice is permitted, if condition is allowed it is a choice

using the word “may”.

2 “shall comply with...” or “shall meet the requirements of” is used in this

code to indicate that it is necessary to implement other relative standards and

stipulations.

97

Li s t o f Qu o te d S ta n da r ds

1 Load Code for the Design of Building Structures GB 50009

2 Code for design of outdoor water supply engineer GB50013.

3 Code of Design on Building Fire Protection and Prevention GB 50016

4 Code for design of city gas engineering GB50028

5 Code for Design of Compressed Air Station GB 50029

6 Standard for lighting design of buildings GB 50034

7 Code for Design Protection of Structure against Lightning GB 50057

8 Code for Design of Electrical Installations in Explosive Atmospheres GB

50058

9 Code for Design of Noise Control of Industrial Enterprises GB/T 50087

10 Code for Design and Construction of Filling Station GB 50156

11 Code for Design of General Plan of Industrial Enterprises GB 50187

12 Design code for producer gas station GB50195

13 Standard for Design of Fire Protection for Fossil Fuel Power Plants and

Substations GB 50229

14 Code for design of industrial equipment and pipeline insulation

engineering GB 50264.

15 Code for engineering design of generic cabling system GB50311

16 Design Code for Industrial Metallic Piping GB 50316

98

17 Code for Design of Fire Dike in Storage Tank Area (GB 50351).

18 Technical Code for Fire Protection Water Supply and Hydrant Systems

GB 50974

19 Code for design of liquefied petroleum gas(LPG)supply engineering GB

51142

20 Technical standard for fire emergency lighting and evacuate indicating

system GB 51309.

21 Designing Code for Mine and Plant Road GBJ 22

22 Hygienic Standards for the Design of Industrial Enterprises GBZ 1

23 Pressure Vessels GB/T 150

24 Safety Colours GB 2893

25 Safety Signs and Guideline for the Use GB 2894

26 Environmental quality standard for noise GB 3096

27 General rules for designing the production facilities in accordance with

safety and health requirements GB5083

28 Safety rules for lifting appliance GB 6067.1～7

29 Safety Rules for the Construction and Installation of Electric Lifts GB

7588

30 Safety of Machinery—Guards—General Requirements for the Design

and Construction of Fixed and Movable Guards GB/T 8196

31 Liquefied Petroleum Gas GB 11174.

32 Emission Standard for Industrial Enterprise Noise at Boundary GB

99

12348

33 Pipe Supports and Hangers GB/T 17116.1～3

34 Natural Gas GB 17820

35 Pressure Piping Code—Industrial Piping GB/T 20801

36 Measurement and Calculation Method of Heat Balance and Thermal

Efficiency for Ceramic Industrial Kiln GB/T 23459

37 The Norm of Energy Consumption Per Unit Products of Domestic

Ceramics GB 36890

38 Technical standard for polyethylene (PE) gaseous fuel pipeline

engineering (CJJ 6

39 Metal Valves for Gas Transmission (CJ/T 514).

40 High bay welded steel rack ---- Specicfications JB/T 5323.

41 Automated storage and retrieval system-Design rules JB/T 9018

42 Automated storage and retrieval system-General rules JB/T 10822

43 Code for Construction and Acceptance of Chemical Equipment and

Pipeline Anticorrosive Engineering HG/T 20229

44 Design Code for External Corrosion Protection of Chemical Equipment

and Piping HG/T 20679

45 Design Specification for Anticorrosion Coating of Equipment and Piping

in Petrochemical Engineering SH/T 3022

46 Design specification for automated high-bay warehouse in

petrochemical industry SH/T 3186

100

47 Pressure Pipe Safety Technology Supervision Regulation for Industrial

Pressure Pipe TSG D0001

101

Indust ry Standards of the People ' s Republ ic

of China

Code for design of Domestic

Ceramics Plant

Q B / T 6 0 1 7—2 0 X X

Explana t ion of Provis ions

102

R ev is io n N o te s

Code for design of domestic ceramics plant QB/T 6017-202X is approved

and published as in Announcement of publishing numberd XX, on XX day, XX

month of 202XX by the Ministry of Industry and Information Technology.

In the process of revising this code, the development department

conducted extensive solicitation of opinions and investigations, and carefully

summarized the practical experience of engineering construction design and

consulting in China. At the same time, it referred to foreign advanced technical

regulations and technical standards, as well as the original Code for design of

domestic ceramics plant QB/T 6017-1997.

Compared with the 1997 Code, following content is revised and modified

in Code for design of domestic ceramics plant QB/T 6017-202X:

1. “Chapter 2 Terms and symbols”, “Chapter 14 Energy saving” and

“Chapter 16 Occupational safety and health” are added.

2. The original “Chapter2 General layout” is revised as “Chapter3

Location selection and general layout”. Location selection related

content is added.

3. China, as a major manufacturing country in the world, has a very

perfect industrial manufacturing system. At present, the social division

of labor is more and more refined and the external coordination and

supporting service are very complete. The repqir and maintenance

work of newly-built industrial projects are all implemented by

103

socialized services.Therefore, Article 8 “Maintennance Workshop” of

Chapter 3 in the original code is deleted.

4. The provisions of original “Chapter 5 Fuel” has been substantially

deleted, and the provisions on clean fuel such as natural gas have been

added.

5. The original Chapter “Water supply and drainage and Fir fighting” is

split into two two chapters, namerly “Chapter 11 Water supply and

drainage” and “Chapter13 Fire fighting”.

6. The content of calculation of tunnel kiln lengthis deleted.

7. Article 4.7 Packaging and warehousing workshop and related

provisions have been added to “Chapter 4 Process”.

8. Contents that are not suitable for technological progress are modified

and adjusted.

9. In accordance with the relevant regulations and requirements in the

Provisions for the Compilation of Engineering Construction

Specifications, some of the provisions in the original code have been

modified and adjusted in writing.

Chief development department of 1997 Code: Changsha Design Institute

of China National Council of Light Industry (Former name of China CEC

Engienering Corporation)

Main drafting staff of 1997 Code: Huang Binggang, Zhang Fujun, Weng

Xinfan, Shi Weizhi, Wu Ming, Ning Chengwa, Xue Ruiyuan, Pan Kailing, Zhou

104

Erhui, Li Xiangzhou, Peng Shipin, Yang Zehong, Pan Ruizhen and Dong

Guangwu.

In the process of this revision, some of the main drafters of the 1997 Code,

such as Wu Ming, Ning Chengwa, Peng Shiliang, etc., acted as consultants for

this revision. They have put forward with pertinent comments and suggestions

on the revision principles, guidelines, and the technical regulations of specific

provisions in this revision.

For the purpose of facilitating the design, construction, scientific research,

schools and other entities to correctly understand and implement the provisions

of the Code when using the Code, the articles explanation of the Code has been

compiled in the order of chapters, sections and articles, and the purpose and

basis of the provisions of the Code as well as relevant matters needing attention

in the course of implementing the Code are explained. However, the

descriptions of the provisions of this clause do not have the same legal effect as

the standard text, which is only for the user to understand and grasp the standard

provisions.

105

Ta bl e o f Co n te n ts

1 G e n e r a l P r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 L o c a t i o n s e l e c t i o n a n d g e n e r a l l a yo u t . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . 2 G e n e r a l l a y o u t . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1

3 . 3 B u i l d i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

3 . 4 P a s s a g e s a n d r o a d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

3 . 5 T e c h n i c a l a n d e c o n o m i c i n d i c a t o r s . . . . . . . . . . . . . . . . . . . . . . . . 5

4 P r o c e s s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 . 1 G e n e r a l p r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 5

4 . 2 R a w m a t e r i a l w o r k s h o p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

4 . 3 F o r m i n g w o r k s h o p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 8

4 . 4 F i r i n g w o r k s h o p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 9

4 . 5 D e c o r a t i n g f i r i n g w o r k s h o p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 0

4 . 6 P l a s t e r m o u l d i n g w o r k s h o p . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 1

4.7 Packaging warehousing worshop . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 2

4.8 Process piping . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 3

4.9 Central laboratory and R&D center . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4

5 K i l n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4

5 . 1 G e n e r a l p r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 4

5 . 2 D e t e r m i n a t i o n o f k i l n t y p e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 5

5 . 3 D e t e r m i n a t i o n o f m a i n t e c h n i c a l a n d e c o n o m i c i n d e x

1 5

106

6 F u e l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6

6 . 1 G e n e r a l p r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 6

6 . 2 F u e l g a s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 7

6 . 3 F u e l o i l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 8

8 P o w e r s u p p l y . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 1 9

9 A u t o m a t i c c o n t r o l i n s t r u m e n t a n d i n f o r m a t i o n . . . . . . . . . . 2 1

1 0 B u i l d i n g s t r u c t u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2

1 0 . 1 B u i l d i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 2

1 0 . 2 S t r u c t u r e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 3

1 1 W a t e r s u p p l y a n d d r a i n a g e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 2 4

1 2 H e a t i n g v e n t i l a t i o n a n d a i r c o n d i t i o n i n g . . . . . . . . . . . . . . 2 4

1 4 E n e r g y s a v i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2

1 4 . 1 G e n e r a l p r o v i s i o n s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2

1 4 . 2 P r o c e s s e n e r g y s a v i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 2

1 4 . 3 W a s t e h e a t r e c o v e r y a n d u t i l i z a t i o n . . . . . . . . . . . . . . . . . . . . . 3 5

1 4 . 4 P o w e r s a v i n g . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 5

1 5 E n v i r o n m e n t a l p r o t e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 6


1 5 . 2 W a s t e w a t e r . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7

1 5 . 3 W a s t e g a s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 7

1 5 . 4 W a s t e s o l i d s . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8

1 5 . 5 N o i s e . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8

107

1 6 O c c u p a t i o n a l s a f e t y a n d h e a l t h . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 8


1 6 . 4 L i g h t n i n g p r o t e c t i o n . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9

1 6 . 7 N o i s e c o n t r o l . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3 9

1

1 General Provisions

1.0.1 Define the purpose of this specification.

1.0.2 Desfine the applicable scope of this code. Cancel the requirement on

project construction scale, which has been included in the national mandatory

standard Code for Commodity Engineering Project.

1.0.3 Define the principle of adapting new process, new technologies, new

materials and new equipment in the design of domestic ceramic plants.

1.0.4 Define the specific standard for energy consumption per unit of product.

3 Location selection and general layout

3.2 General layout

3.2.1 Optimal land utilization is China’s basic national policy. This provision

emphasize that the general layout design of industrial enterprises must pay special

attention to saving land, rationally using land and improving the utilization of

land.

3.2.11 This provision is the general principle of vertical design. The vertical

design and plane position shall be closely connected, considered together and

coordinated with each other to make the entire project practical, economical and

aesthetic.

The design elevation of site shall coordinate with the outside transportation

route, drainage system and the elevation of surrounding site, otherwise there will

problems such as railway connection failure, excessive road slope, poor drainage

and high retaining wall.

3.2.12 There are many production processes for domestic ceramics. Pallet trucks,

flatbed trucks, forklifts and other transportation tools are often used for

transportion between processes. In order to ensure smooth connection between

2

processes and guarantee product quality, production plants prefer to adopt

combined workshops. When terrain conditions permit, flat slope type of general

layout is selected, which is easier to meet process requirements.

3.2.14 As an integral part of the general layout design of industrial enterprises,

comprehensive pipeline arrangement is one of the standards to measure the

reasonability of plane layout. It involves a wide range of disciplines, such as

process, water, electrical, thermal and HVAC. The comprehensive pipeline

arrangement connects the economic feasibility of the pipeline layout for each

discipline with the overall situation of the enterprise to achieve the overall

economic rationality of the enterprise.

The comprehensive pipeline of industrial enterprises almost covers the

whole plant area. Arranging the pipelines in a comprehensive, reasonable and

compact way may facilitate construction, maintenance and safety production, as

well as save land and reduce investment.

3.2.15 Parallel arrangement of pipeline, roads and building axes is an effective

way for optimal land utilization, and may also facilitate pipeline maintenance and

laying of new pipelines in the future. Arranging main pipe near the side with

higher demand is for the purpose of reducing intersection with roads and other

pipelines and shortening the length of branch pipes. The minimum horizontal

distance between the pipelines and the buildings, structure and roads shall meet

the requirements of Code for Design of General Plan of Industrial Enterprises

GB 50187.

3.2.16 The pipelines may be set above ground or underground. The pipelines

mentioned in the provisions generally refer to fuel oil, liquefied petroleum gas,

producer gas, town gas and natural gas pipelines. On account that pipeline leakage

is inevitable during long-term operation, overhead installation is adopted for

easier discovery and more convenient maintenance when leakage occurs. If the

underground pipe trench type is used, leakage cannot be easily found. Once

exposed to the ground, the accident is no longer at the initial stage and already

3

harmful. Therefore, for these pipeline, installation with pipe racks is the best way

for the sake of safety and maintenance. The minimum horizontal distance

between pipes racks and buildings and structures and the minimum vertical

distance across railways and roads shall meet the requirements of the current

Code for Design of General Plan of Industrial Enterprises GB 50187.

3.2.17 This chapter only mentions the special requirements for the general

layout design of domestic ceramic plants. Other professional requirements on

general layout design shall follow the current national standard Code for Design

of General Plan of Industrial Enterprises GB 50187.

3.3 Building

3.3.1 The layout of the main production workshop should meet the

requirements:

1 On account that the pollution of ceramic raw materials, especially the

pollution of iron dust and coal dust, will affect the quality of product directly,

bringing defects to the surface of finished product and lowering product grade,

it is proposed that the raw material workshop shall be arranged “away from

pollution sources that may affect production quality, such as coal yard,

maintenance workshop and gypsum model workshop”.

2 According to the requirements in Code of Design on Building Fire

Protection and Prevention GB 50016 (2018 Edition), raw material workshop

belongs to Category E production, while Forming workshop and Firing

workshop belong to Category D production. When the fire resistance class of

factory building is Class I or II, the maximum permitted area for total

compartment is not limited. According to the fire protection and prevention

code, these three workshops may be set together. Therefore, it is clear that the

Forming workshop should be close to or form a joint building with raw

material workshop and Firing workshop.

4

3 The length of Firing workshop building is relatively long, generally

96~120m. If the natural terrain of the plant has a large slope, the workshop

shall be arranged along the contour line to reduce the quantity of earthwork.

Setting the foundation of tunnel kiln on the terrain elevation of little change

may also reduce uneven settlement.

The Firing workshop has a high-temperature production condition, with heat

dissipation capacity of 304×104 kJ/h. Generally skylights are used for thermal

discharge. The angle between the workshop orientation and the maximum

frequency summer wind direction should be 60°~90° and should not be less than

45°. In order to reduce the influence of heat emitted by tunnel kilns, kiln cars and

products on nearby operators, the Firing workshop should be arranged on the

leeward side of the maximum frequency summer wind direction in Forming

workshop. When joint building is adopted, the Firing workshop and Forming

workshop should be separated by patio.

3.4 Passages and roads

3.4.1 The width of passageway in the factory area is mainly determined

according to various functional requirements, with due consideration to the

aesthetic needs. Based on the past engineering design experience, six

requirements on passageway are put forward as factors that shall be met when

determining the width of passageway.

Currently, there are two ways to divide the width of passageway in factory area,

one is by plant area and the other is by production scale. Considering that the

combinations of production buildings in domestic ceramic plants of the same scale

are diverse (such as single-layer and multi-layer, combined and dispersed) due to the

differences in the types and sources of fuel employed for firing, there is a huge

discrepancy in plant area, therefore deciding the width of passageway by plant area

classification is more in line with the production practice of domestic ceramic plant.

5

3.4.2 The appearance of a factory represents the image of an enterprise. In

practice, most enterprises prefer straight roads and square partitions. Roads should

be parallel to the axis of main building and avoid corners, which may facilitate the

arrangement of piping engineering to be a ring shape to realize smooth material

transportation, make the production process more reasonable and contribute to

fire protection.

3.5 Technical and economic indicators

3.5.2 The building coefficient of domestic ceramic plants is approximately

31.7%~44.12%. Considering that the coefficient is influenced by many factors,

such as the terrain and the size of the joint building, it is difficult to determine its

rationality with an average figure. Therefore the building coefficient should be

32%~42%.

4 Process


4.1.1 Process design covers raw materials, forming, firing, decorating firing,

plaster modeling, etc. According to the development plan of domestic ceramic

industry, auxiliary materials shall realize specialized production. In practice, on

account that high-quality kiln furniture and gypsum power commodities are

available in market, there is no need for new plants to consider this part of project.

Therefore, sagger (kiln furniture) production and gypsum power frying are not

included in this code.

During the construction drawing design stage, if there are major changes

to the approved preliminary design, such as the changes in plant location,

6

production scale, fuel structure, main process equipment and building

structure, the permission from the original examination and approval

authority must be obtained.

4.2 Raw material workshop

This section applies to raw material workshops employing powdered hard

raw materials and refined soft raw materials or directly using raw ore.

With the development of the domestic ceramic industry, the raw materials

for ceramic production are developing in the direction of specialized

production. At present, various ceramic production areas and mining areas

starts to develop a processing and supply system for hard raw materials;

specialized production of soft raw materials such as kaolin is under planning

and development, and a small amount of refined raw materials may be

produced and supplied. Therefore, in engineering design, hard powders

processed by specialized manufacturers are generally used, and there is no

crushing system for hard raw materials in the workshop; where conditions

permit, refined soft raw materials are used, or raw ore is directly used in the

workshop. There is no panning system.

The process design of raw material workshops should cover the following

scope: starting from the entry of raw materials into workshop, passing through

necessary production processes such as selection, storage, dosing, ball milling,

sieving, de-ironing, filter pressing, ageing and pugging, till delivering the pug

and glaze slip to the Forming workshop.

4.2.2 Process design requirements

1 Quality requirements on raw materials. For those already listed in

national or industry standards, corresponding national or industry standards

shall be followed, and for those not covered, reference may be made to

relevant group standards or corporate standards, and the content of harmful

7

substances shall be strictly controlled in accordance with the requirements of

different ceramic products.

2 At present, the kaolin raw materials used in domestic ceramic plants

in China are generally bulk kaolin ore, which may be easily mixed with

impurities in the process of exploitation, transportation and storage. Therefore,

the raw materials shall be selected to remove impurities upon arrival at

workshop. Selected kaolin raw materials are packed in bags and may be used

directly.

3 Basic requirements and principles of raw material storage shall be

applied flexibly in design, with due considerations to specific conditions of

each plant. For example, some raw materials should be weathered, so there

shall be a certain weathering period.

4.2.3 Among the main process design indicators, the loss rate of raw material

storage, transportation and pulping is determined with reference to the values

specified in Code for Design of Building and Sanitary Ceramic Plant

GB5060-2010.

According to Table 8.1.4-1 “Raw Material Loss Rate in Each Production

Section of Ceramic Tile Production Line” and Table 8.1.4-2 “Raw Material

Loss Rate in Each Production Section of Ceramic Sanitary Ware Production

Line” of Code for Design of Building and Sanitary Ceramic Plant

GB5060-2010, the loss rates of various ceramic materials in storage and

transportation (2%), ball milling and pulping (2%) and powdering (2%)

section are basically the same, much lower than the loss rate (no greater than

10%) of kaolin and clay ore and close to the loss rate (5%) of refined materials.

Therefore, the loss rate data in the original 1997 Code is revised to be

consistent with the Code for Design of Building and Sanitary Ceramic Plant.

According to Table 8.1.8 “Maximum Fuel Consumption Value of Per

Unit Product of Main Heat-consuming Equipment” of Code for Design of

Building and Sanitary Ceramic Plant GB5060-2010 and relevant energy

8

consumption data about spray drying powdering in Table 5.2.3 “Design

Quota of Energy Consumption for Main Production Processes of Dry-pressed

Ceramic Tile Production Line” in Standard for Design of Energy

Conservation of Building and Sanitary Ceramic Plant GBT50543-2019, the

energy value consumed by per kg of water is about 3094kJ, much lower than

the 4390kJ/kg in the original 1997 Code. It is recommended to make proper

amendments.

4.2.4 Main equipment selection

1 When the ball mill adopts electric hoist for feeding, standby shall be

considered. If large-tonnage ball mill employs belt conveyor for feeding,

standby is not necessary.

2 According to the actual use of filter press mud conveying pump at

home and abroad, using plunger mud pump to transport mud press filter may

improve the efficiency of press filter and reduce the moisture content of mud

cake.

3 Three-shaft stainless steel vacuum pug mill is selected to improve the

quality of mug.

4.2.5 Process layout of workshop

2 Handling the relationship between the equipment foundation, pit and

trench, wall and column foundation means that the design shall give

considerations to factors such as mutual interference, foundation forces,

foundation settlement and vibration during construction and use.

4.3 Forming workshop

4.3.1 The design of Forming workshop should include processes such as

forming, demoulding, drying, trimming, glazing, inspection and storage.

Forming may be divided into plastic forming, isostatic compaction forming,

casting forming, 3D printing forming, etc. In design or actual production,

9

plastic forming and isostatic compaction forming may be combined into

one section. In project with more casting products, casting forming may be

separated as an independent workshop.

Proper shaping process is essential for reducing product pollution, improving

product quality and cutting down energy consumption.


Types 1 to 3 are specific design measures to improve product quality.

4.3.3 The main process design indicators are production and design experience

data, which may be used in process design calculations.

4.3.4 Generally standby for equipment in Forming workshop is not necessary.

But for the selection of forming equipment, the possibility of replacing product to

adapt to market changes shall be considered.

4.3.5 Equipment layout of workshop

5 According to equipment installation, production and design

experience.

6 Same as the description in paragraph 2 of Article 4.2.5.

4.4 Firing workshop


1 In the double firing production process, generally hard porcelain

adopts low-temperature biscuit firing and high-temperature glaze firing

processes while soft porcelain employs high-temperature biscuit firing and

low-temperature glaze firing process.

4.4.4 Article 4.4.4 is the principle of process equipment selection, which should

be used flexibly in design according to the actual situation of plant, especially for

the selection of kiln type.

10

4.4.5 Article 4.4.5 is the basic principle of equipment layout in Firing workshop,

which should be used flexibly in design according to the specific conditions of

each plant.

4.5 Decorating firingworkshop

This section is applicable to the over-glaze decorating and Firing workshop.

Glaze decoration is generally divided into over-glaze, in-glaze and underglaze.

The process of these three decoration methods is different, but the

requirement for process design is basically the same. Therefore, in-glaze and

other decoration methods may refer to the provisions of this section.

The process design scope in decoration workshop should include: from the

beginning when white porcelain gets into workshop, through decorating,

firing, grading, assembling, packaging, to the storage of finished products.


1 Due to the different nature of decal, liquid gold and pigment, the

requirement for storage environment varies. Meanwhile, the process of

warehousing and picking may lead to mutual contamination, resulting in

“diphtheria infection” and loss of materials. To facilitate management and

meet the environment requirement of various materials, they shall be stored in

separate rooms.

3 In the heating area, when the white ceramic warehouse has no

heating facilities, the white ceramics shall be stored in the color baking

workshop for at least two days to avoid decorating on cold porcelain.

Decorated products shall be fired in the kiln the same day to avoid pollution.

The pasted products shall be baked in the kiln every day to avoid storage

pollution. Plastic boxes or wooden boxes for storing products shall be of

uniform size to facilitate stacking and save storage space.

11

4.5.3 Main process design index is production and design experience data,

which may be used in process design calculation. When used in practice, it shall

be adjusted according to the characteristics of the product (such as the shape of

decoration, gold ratio, etc)

4.5.4 The fuel of decorating firing kiln is generally the same as that of the

calcining kiln. If the power supply permits, it may also use electric kiln.

Continuous bogie kiln is also widely used.

4.6 Plaster moulding workshop

This section is applicable to the process design of Plaster moulding

workshop with α or β type hemihydrate plaster powder as casting material.

Domestic ceramic plants currently use α or β type hemihydrate plaster

powder as moulding material, while artificial plaster and chemical plaster is

also internationally used. Isostatic compaction soft film, microporous resin

mould formed by high pressure slip casting, and other moulding materials

may be used to increase use times. Plaster powder is supplied by professional

production plant or market.

Plaster moulding workshop may include process of plaster powder

storage, prototype, master molds, moulding preparation, moulding drying and

moulding trimming.

4.6.1 Process design shall meet the following requirements:

2 During the preparation of calcium plaster, a plaster vacuum

deaeration mixer is used to perform vacuum deaeration and stirring of calcium

plaster, which may reduce the bubbles in the plaster casting and improve its

strength.

3 Because of its slow dehydration and long drying characteristic, the

plaster moulding generally uses chamber type drying room.

12

4 The Plaster moulding workshop should be placed near the Forming

workshop or in the same plant with the Forming workshop to avoid

long-distance transportation of castings. When it is arranged in the same

factory building as the Forming workshop, the model preparation and forming

section shall be separated by a wall to prevent gypsum from polluting the

production of the Forming workshop.

5 It shall be avoided that plaster powder contaminates raw materials or

semi-finished products, which causes spots or molten holes in the finished

products. The storage place of the plaster powder shall be protected from

moisture to prevent the plaster powder from losing its efficacy due to moisture

absorption.

4.6.2 The main process design indicators are determined based on production

and design experience and may be used in process design calculations.

4.7 Packaging warehousing worshop

4.7.1 During the firing process of ceramic body, various defects may appear,

such as porosity, deformation, crack, and defects that affect the appearance

and beauty of the product but do not affect the use. Before packaging,

defective products and unqualified products shall be removed to ensure

product quality. Generally, the inspection and selection of products is mainly

done manually, and machine scanning identification technology may also be

used to complete manual inspection and selection operation.

4.7.3Ceramic products are fragile and shall be packaged with protective and

economical materials. At present, ceramic products are mainly packed in

cartons. For ceramic products of different shapes, the internal protection

materials are usually paper products, and plastic bubble materials may also be

used for protection.

13

4.7.5The use of high rack three-dimensional warehouses to store products is

the development trend, which is conductive to realize automation and

intelligence. Therefore, as conditions permit, it is recommended to use

automatic warehouse storage.

4.8 Process piping

4.8.2 Define the basic requirements of pipeline engineering design.

4.8.3 It is determined according to the actual usage in domestic ceramic plant.

According to the requirements of pressure use, engineering plastics should not be

used in the pipeline from mud pump to filter press.

4.8.4 Selection of pipe specifications

1 According to the pipe specifications widely used in domestic project

construction and combined with pipe specifications internationally used, it is

recommended to use pipes with domestically preferred specification in this

Code. For other requirements in projects, it may also use pipes with domestic

common specifications.

2 The pipeline connection may adopt the following methods:

1） Welding: It is generally used on pipelines with a design working

pressure above 1.0MPa and a pipe diameter greater than 50mm. Use socket

welding when the pipe is made of engineering plastics.

2） Thread connection: It may only be used on pipelines with a design

working pressure of 1.0MPa or less and a pipe diameter of less than 50mm;

3） Flange connection: It is generally applicable to the material

pipeline with large diameter, low sealing requirement and frequent cleaning,

as well as the connection between pipeline and valve body or equipment.

Different types of flange should be selected according to the pressure and

temperature of pipeline medium;

14

4） Adaptor union: It is applicable to the material pipeline, equipment

connecting pipe and ring connecting pipe which are often dismantled and

cleaned to facilitate maintenance and installation.

4.8.6 The net height of pipeline crossing pedestrian passage is 1.8, 2.0, 2.5 m,

etc., which is not less than 2.2 m in this code.

4.9 Central laboratory and R&D center

4.9.2 Product testing is based on product technical standards, enterprise internal

control standards, national standards and foreign standards for reference.

4.9.3 Instrument and equipment configuration of the central laboratory

2 The instruments and equipment of the central laboratory are closely

related to the characteristics of the products. If it is in-glaze or under-glaze

decoration, there is no need to determine the amount of lead and cadmium

dissolved.

4 Common instruments, including precision balance, thermal

equipment, etc, should be planned and set uniformly.

4.9.4 The R&D center is responsible for the testing of new materials, new

products, new processes, new models, new patterns, as well as the

improvement and research of process technology. The R&D center may set up

a design room to be responsible for product modeling design or pattern design,

and develop new varieties .

5 Kiln


5.1.1 Kiln selection is formulated in accordance with the national energy policy

and the actual situation of domestic ceramic tunnel kiln. According to the

"Thirteenth Five-Year Plan for Energy Conservation and Emission Reduction"

15

issued by the State Council, the "Guidance on Promoting Electricity Substitution

(NDRC Energy Bureau [2016] No.1054)" issued by the National Development

and Reform Commission, and industry technology policy industry plan, this code

does not recommend to employ tunnel kilns, and therefore shortens the contents

of tunnel kilns.

5.1.2 Clean gas refers to natural gas, liquefied petroleum gas, producer gas, etc.

5.1.3 It depends on the fuel used in new kilns with low energy consumption and

high product quality that have emerged in my country in recent years.

5.1.4 Energy saving is an important part in kiln design and an important

technical and also an economic indicator for evaluating kiln design level.

5.2 Determination of kiln type

5.3.3 Among the existing domestic ceramic kilns, old intermittent kilns such as

coal-burning down-flame kilns have been eliminated, and the kilns are

developing in the direction of energy saving, light weight and rapid development.

In recent years, among domestic ceramics firing kilns, new intermittent

kilns such as shuttle kilns and continuous kilns such as high-temperature

roller kilns have developed rapidly. The kilns use light insulation materials,

and products may be made in open-flame firing without saggers. Kilns may be

according to specific process requirements in design.

5.3 Determination of main technical and economic index

5.3.3 Kiln is the most critical thermal equipment for ceramic enterprises and the

equipment with the largest energy consumption. Its energy consumption accounts

for 60% to 80% of the total energy consumption of ceramic production. The

energy consumption of the kiln mainly depends on the structure of the kiln and the

firing technology. The structure of the kiln is the fundamental factor and the firing

technology is the guarantee. In recent years, with the optimization of the furnace

16

structure, the thermal efficiency of the furnace has been greatly improved. For

example, Stone Group Ceramics Co., Ltd. replaced the original kiln with an

optimized structure, increasing the thermal efficiency of the kiln from 19.01% to

40.65%; Chaozhou Xingye Ceramics Co., Ltd. adopted an optimized structure of

roller kiln and adopted daily use With the rapid low-temperature reduction firing

technology of porcelain, the thermal efficiency of the kiln reaches 68.8%.

Therefore, this standard determines that the firing heat efficiency of the kiln is not

less than 40%, which is feasible.

6 Fuel


6.1.2 The relevant national and industry standards, norms and regulations are

mainly listed as follows:

1 Design code for producer gas station GB50195

2 Code for design of city gas engineering GB50028

3 Code for design of oil depot GB 50074

4 Code for design and construction of filling station GB 50156

5 Safety Code for Gas of Industrial Enterprises GB 6222

6 Code for fire protection design of buildings (2018 Edition) GB 50016-

2014

7 Emission standard of pollutants for ceramics industry GB 25464

8 Emission Standard of Air Pollutants for Industrial Kiln and Furnace

GB 9078


10 Code for electric insllations in explosive atmosphere GB 50058.

6.1.3 The design of gas stations, LPG vaporization stations and oil depots

involves many specialties. In addition to the listed codes, other professional

standard and national or industry standards and regulations should also be

17

followed. For example, the current codes such as Code for fire protection design

of buildings (2018 Edition) GB 50016- 2014, Emission standard of pollutants for

ceramics industry GB 25464, Emission standard of air pollutants for industrial

kiln and furnace GB9078 , Hygienic Standards for the Design of Industrial Enter

GBZ 1-2010, Code for design of electrica iinstallations in explosive atmospheres

GB 50058-2014, etc.

6.2 Fuel gas

Fuel gas in this code mainly refers to natural gas (including pipeline

natural gas, liquefied petroleum gas and compressed natural gas), liquefied

petroleum gas, and coal gas. City gas is not limited a specific kind of gas, and

it may be any of the above-mentioned gases, so it is not listed separately. With

the popularization and application of coal gasification technology in China,

dimethylether (DME), which has developed rapidly in recent years, has good

energy-saving effects as a clean energy with good combustion performance

and thermal efficiency.

6.2.1 Natural gas is a currently widely used clean energy. This section is

added as a compulsive requirement that must be met when using natural gas in

domestic ceramic projects. Others requirements shall be implemented in

accordance with current national regulations.

The hydrogen sulfide content of natural gas shal be less than

20mg/Nm3which is determined in accordance with the technical indicators of

Class II gas in the Natural Gas GB17820.

6.2.2 Desfines the quality requirements of liquefied petroleum gas.

6.2.3 Following requirements are made based on the characteristics of the

kiln production in domestic ceramic factories. Hydrogen sulfide in the gas

will affect product quality. Dust and tar will block the pipe and affect quality

of the bare-fired ceramic products. Therefore, the content of hydrogen sulfide,

18

dust and tar in the gas should be controlled. In the design of some domestic

ceramic factories, the sum of dust and tar content in producer gas should not

exceed 50mg/m3 under standard conditions; the control of hydrogen sulfide

content in gas shall be economical and reasonable, and meet the requirements

of users and environmental protection. Some ceramic factories request the

hydrogen sulfide content in the two-stage producer gas stay below 50mg/m3.

6.3 Fuel oil

The fuel oil used by the domestic ceramics plants refers to heavy oil.

Currently, the commonly used fuel oil is No. 200 and No. 100 heavy oil.

The quality index of fuel oil shall meet the requirements of Fuel oil SH/T

0356

The quality index of light diesel oil shall meet the requirements of

General deisel fuel GB252.

6.3.1 The stability of the fuel oil supply system is of vital importance to the kiln,

which directly reflects the firing qualification rate of ceramic products. The fuel

aging effect also determines the thermal efficiency of the kiln and the firing pass

rate of the product. Therefore, this article specifies the basic requirements for fuel

oil systems.

6.3.3 Requirements for workshop oil supply design shall be met as follwoing:

1 Set of the intermediate oil tank is mainly determined by the distance

between the oil pump room and oil consumption workshop. When the the

length of the oil pipeline is larger than 2100m, it is recommended to install an

intermediate oil tank.

2 The kiln oil supply system shall generally take the following

measures to ensure the stability of the fuel oil temperature, oil pressure and

viscosity:

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1） Fuel oil is heated by steam heater or electric heater to meet burner

atomization requirements;

2） The oil supply system is equipped with a fine mesh filter behind

the electric heater;

3） A membrane pressure regulating valve is installed in front of the

burner;

4） The kiln oil supply is equipped with an oil return system, and the

oil return should not be less than twice the fuel consumption;

5） Oil metering device is set;

6） Burners that are efficient, energy-saving, low-noise and easy to

adjust and maintain are selected.

8 Power supply

8.0.1 The content included in the electrical design of a small or single project

may be determined according to the contract requirements.

8.0.3 Power load classification

1 If the tunnel kiln is out of power for more than 10 minutes, the

products in the firing zone will be scrapped, resulting in economic losses of

varying degrees; if the insulation measures are improper, the kiln will be

rapidly cooled, which will damage the kiln body and require shutdown for

repair. Therefore, the Firing workshop is classified as a secondary load.

3 The power supply conditions in the areas where domestic ceramic

plants are located are very different. With the development of the power

industry, the situation will improve. Therefore, it is stipulated to choose the

capacity of the generator set required by the security when the power supply

conditions are not sufficient.

8.0.4 Domestic ceramic plants generally adopt the demand factor method for

load calculation. This table is the demand factor of each electrical equipment and

20

plays as a reference value. The calculated load of the substation or factory shall

also be multiplied by the simultaneous coefficient, and shall be adjusted in

accordance with the actual conditions of the type of process equipment in the

engineering design and the power consumption per unit of product.

8.0.6 There are many projects that put undue emphasis on the advantages of the

35/0.4kV one-time step-down solution, while ignoring the technical and

economic comparisons. The investment does not save so much money, but it

causes low voltage, large current and long-distance power supply, high energy

consumption, high operating cost, difficulty in starting high-power equipment,

unfavorable expansion and other unreasonable conditions. Therefore, this article

is listed here as reminder.

8.0.7 Taking consideration of the improvement of the breaking capacity of

low-voltage electrical components and the concentration of enterprise power

consumption, the maximum capacity of a single transformer has been increased

from 1250kVA to 2000kVA..

8.0.8 In order to reduce power loss, to decrease harmonic currents, to improve

the sensitivity of single-phase grounding short-circuit protection and to make full

use of the transformer capacity, a transformer with a wiring group of D.yn11

should be selected.

8.0.9 The classification of explosive hazardous environments factors listed in the

table is shown in Code for electric insllations in explosive atmosphere GB 50058.

8.0.12 The illuminance table is formulated in accordance with the Standard for

lighting design of buildings GB 50034, Industrial Enterprise Lighting Design

Standard TJ 34, combined with the actual situation of the domestic ceramic

factory, and from the perspective of energy saving. The light sources, which is of

high luminous efficiency, long life, and may meet the requirements of use and

environmental characteristics, include high-efficiency fluorescent lamps,

high-pressure sodium lamps, LED lamps, metal halide lamps, etc. Certain regions

21

and enterprises may appropriately increase the illuminance value with reference

to international standards.

9 Automatic control instrument and information

9.0.1 The design of automatic control instrument shall follow the following

principles:

1. Requirements on intelligentization are added in article 1 and article 3.

With the implementation of the goal of Made in China 2025 and the development

of AI technology, the upgrade from traditional Made in China to Smart

manufacturing in China will be promoted rapidly and the traditional

labor-intensive manufacturing model will be replaced by the intelligent

manufacturing model of unmanned factory and smart factory. As a traditional

manufacturing enterprise, domestic ceramics factory can not avoid this advanced

production mode, they should actively embark on the road of intelligent

manufacturing to promote the healthy and sustainable development of the

industry.

4 This is the minimum standard required for instrument accuracy, and

higher accuracy instruments may be selected according to process

requirements and technological development.

9.0.8 According to the actual application of grounding technology, the

grounding of the instrument and control system should be classified based on PE,

TE categories and then join each other, and finally realize single point grounding.

9.0.9 Since the grounding system of the instrument of the ceramic plant

generally does not set up a separate grounding ware, it is shared with the

grounding ware of the power system. The grounding resistance of the shared

grounding system is generally not more than 1Ω, so the grounding resistance of

this code is not more than 1Ω.

9.0.11 The instrument detection and control items for the production and

22

operation of kilns and gas stations in domestic ceramic factories may generally be

configured according to the provisions of Table 9.0.11-1~3. Specific engineering

projects may be adjusted according to their own conditions, but production safety,

normal operation and management requirements shall be ensured.

10 Building structure

10.1 Building

10.1.6 The sections of biscuit firing, glaze firing and decorating firing require

large areas of vents to allow the kiln to dissipate heat timely; the decorative

section requires a large area of daylight and ventilation fans to dissipate the scent

of ethanol (alcohol) in the production process; painting, gilding and decorating

firing shall be separated to avoid dust pollution; packaging and storage of finished

products shall be placed separately and be prevented from fire and dust. The roof

waterproofing treatment of the ceramic factory shall be absolutely reliable,

dripping is not allowed, and the rain drop shall be prevented to be drifted into the

windows.

10.1.10 Refer to the classification listed in Table 10.1.10 during the design, and

determine the bathroom setting standards based on factors such as factory

conditions, production specifications, and regional characteristics. There are more

female workers in the production workshops and auxiliary rooms of domestic

ceramics factories, and sanitary facilities for women shall be considered.

10.1.13 The production categories of each building of the domestic ceramic

factory are listed according to the Code of Design on Building Fire Protection and

Prevention GB 50016-2014 (2018 edition), combined with the production

characteristics of the domestic ceramic factory. Among the buildings and work

sections that are not listed in the table, there are some production houses of

different nature, of which the production category may also be determined

according to this code.

23

10.2 Structure

10.2.1 The structure of the domestic ceramics plant is determined by the process

layout and requirements, and has not formed a certain model. The workshops are

separated or placed in a large joint workshop. The workshops generally have no

large span, of which the height is generally within 24m. It is not a high-rise

building and has no extra large load, but it should meet the requirements of the

production process and be in accordance with building's unified modulus.

Plants generally use reinforced concrete structure, and the single-storey

plant with a small span may also adopt a mixed structure. Considering that

iron pollution will affect product quality, it is not suitable to use steel structure;

otherwise reliable and effective anti-corrosion measures should be taken.

10.2.3 For structural component adjacent to kilns and other thermal equipment,

effective heat insulation protection measures should be taken where their surface

temperature is high. Specifications shall be followed in the Code for design of

concrete structures GB 50010 and Standard for design of steel structures GB

50017.

10.2.4 Due to the storage, transportation and use requirements, the retaining

structure should not be too high, generally within 3~4m. The reinforced concrete

beam and column structure with embedded masonry is more economical and

applicable.

10.2.7 For mud storage room, ageing room, ceramic body storage room and

other places that have high humidity and poor ventilation, the reinforced

protective layer of the concrete structure should be thicker than the normal value

by 5mm~10mm, and the surface should be treated with anti-corrosion to prevent

bar exposure and corrosion that causes iron pollution of mud and materials, and

affects structural safety.

10.2.8 The kiln foundation shall be separated from the ground of the workshop

by isolation joint to coordinate their respective temperature deformations. Except

24

for special reasons such as topographical factors, large and medium-sized kilns

shall be placed on the ground.

10.2.9 The settlement amount and settlement difference of kiln car track and the

pack car track shall strictly be controlled according to the process design

requirements. When constructing kiln car tracks, pack car tracks and tunnel kiln

foundations on unfavorable foundation soils, effective measures to prevent

settlement shall be taken, and when necessary, adjustable elevation support

cushion measures may be employed.

11 Water supply and drainage

11.0.7 Washing water of gas station is generally recycled after treatment. The

power supply of the circulating pump room should adopt dual power supplies to

ensure the stable water supply. The supply of water for water seals at gas stations

shall be guaranteed. In the event of a power outage or other accidents, measures

shall be taken to ensure uninterrupted water supply.

12 Heating ventilation and air conditioning

12.0.3 Centralized heating and air conditioning may be designed for plants and

buildings that has certain requiremnts on the heating and air conditionsing, such

as casting and forming section, decorating section, instrument room and central

laboratory etc..

12.0.4 Regarding the calculated indoor design temperature in winter and

summer, cold areas refer to areas where the average temperature of the coldest

month is 0~ -10℃, and severe cold areas refer to areas where the average

temperature of the coldest month is no higher than -10℃.

1 The calculated temperature for the heating indoor design in winter is

mainly based on the requirements of the Hygienic Standards for the Design of

Industrial Enterprises GBZ 1, and at the same time, it is formulated with

25

reference to the design standards adopted since the founding of the People's

Republic of China, combined with the production practice of household

ceramics factories, and taking into account the needs of process production.

1） For the operation layer of the raw material workshop, the

polishing and white porcelain inspection section of the Firing workshop, and

the packaging section of the decorating firing workshop, because each worker

occupies a large building area, a lower room temperature is adopted.

The operation layer of the raw material workshop shall install an air make-up

system because the labor intensity is medium, and the amount of dust removal and

exhausting air is large, also the continuous work hour of dust removal system is long.

Therefore, when the average plant area per capita is no less than 50m2,, the

workshop temperature should be considered as 10℃. When the average plant area

per capita is less than 50m2, the temperature may be increased to 12℃.

In the white porcelain inspection section of the firing workshop, the amount of

operators is large, and the labor intensity is medium. Therefore the indoor

temperature may be considered as 12~14℃ according to the average plant area per

capita.

2） The heat intensity of the biscuit firing and glaze firing sections of

the Firing workshop is greater than 116W/m3 (100kcal/h.m³), which is

sufficient to combpensate for the heat loss of the building, so no heating is

provided. In severe cold areas, local heating may be provided at certain

operation points.

3） For sections of casting and glazing sections in the forming

workshop and the decorating section in the Decorating firing workshop,

because there are some wet operations (working with water), the working

conditions are poor, and the production process also requires a slightly higher

temperature, so the indoor temperature is set at 18-20 ℃.

4） The decorating firing kiln has a low temperature and puts off a

little heat. The decorating firing section is always placed near the decorating

26

and packaging section and not set separately. In order to ensure the product

quality and improve the operating condition of workers, the indoor

temperature of the decorating firing section may be considered as 12~14℃ in

winter and 26~28℃ in summer.

5） The labor intensity in the finished products warehouse of

decorating firing workshop is relatively high, which may be classified as

heavy work type. But the work is not continuous, so the indoor temperature is

calculated as 5℃ duty heating. The work of packaging and transportation is of

moderate labor intensity, so the indoor temperature may be considered as as

12~14℃ in winter and 26~28℃ in summer.

6） In order to avoid the freezing of coal and mud in winter, which

will affect production, and to prevent the low temperature in mud storage

room from affecting mud, heating is provided in the cola transportation layer

of gas station and the mud storage and ageing room of the raw material

workshop. If there is a large amount of mud in and out of the ageing room, the

temperature should keep 8°C.

2 The indoor temperature for calculation in summer is determined by

the allowable temperature difference between the outdoor temperature of

summer ventilation and the temperature of the working place in accordance

with the relevant provisions of the Hygienic Standards for the Design of

Industrial Enterprises GBZ 1.

1） The thermal intensity of the firing section and glaze firing section

of the Firing workshop is greater than 116W/m3 (100kcal/h•m3), and the

outdoor ventilation calculation temperature is not greater than 7°C;

2） For the decorating firing section of the workshop and operation

layer of the gas station, the heat intensity is 23〜 116W/m3 （ 20〜

100kcal/h•m3）, so the outdoor ventilation temperature should be considered

as no more than 5℃;

27

3） .The thermal intensity of the other workshops or sections listed in

the table is less than 23W/m3 (20kcal/h•m

3), and the calculation temperature

of outdoor ventilation is not more than 3℃.

3 Table 12.0.4 lists the calculated temperature values for the winter

and summer interior design of each workshop or section of the ceramic plant,

and the calculated temperature values for the design of other auxiliary

workshops and auxiliary facilities (such as bathrooms, changing rooms,

offices, communication rooms, garages, nurseries, etc.) , See Hygienic

Standards for the Design of Industrial Enterprises GBZ 1.

12.0.5 The heating and ventilation design of the raw material workshop shallmeet

the following requirements:

1 The current relevant national standards mainly include: Integrated

Emission Standard of Air Pollutants GB 16297 and Hygienic Standards for

the Design of Industrial Enterprises GBZ 1.

2 The dust removal system of the raw material workshop of the

domestic ceramic plant basically runs intermittently. In cold areas, as long as

the heating system is designed (when the dust removal system is operating,

the room temperature will temporarily drop), there is basically no problem in

winter operation. In severe cold areas, when the continuous air volume of the

dust removal system is large, the mud and slip pool will freeze, which affects

production. Taking into account the needs of the production process, this

article stipulates that when the dust removal and exhaust air volume in severe

cold areas is large and the dust removal system has a long continuous

operation time, the air make-up system shall be installed.

4 The bag filter has obvious advantages in raw material recovery,

operating system reliability, dust removal efficiency, and secondary pollution.

At present, most domestic ceramic factories use bag filters, as well as most

foreign ceramic factories. For dust removal points where dust emission points

are concentrated, centralized dust removal shall be given priority. For dust

28

removal points where the dust removal points are scattered and the dust

removal air volume is small, single filter may be used. In recent years, the

single bag typefilter has developed rapidly and has been widely used in many

industries. However, many shortcomings have been found, such as frequent

and inconvenient cleaning work, insufficient residual pressure of the unit,

reduced dust removal efficiency, and insufficient air volume. Therefore, this

article restricts the use of single bag type filters.

6 At present, few factories discharge the exhaust air from the bag filter

directly into the workshop, especially the single bag type filter. Because the

residual pressure outside the machine is small, the exhaust gas is discharged to

the workshop more seriously, which is impossible to make the dust

concentration of the air in the workshop in accordance with the national

standard.

1） The exhaust gas emission concentration of the bag filter averages

between 5-20mg/m3, which greatly exceeds the national standard that the air

concentration in the workshop does not exceed 2mg/m3;

2） The exhaust gas after passing through the bag filter contains

mostly dust with small particle size and high activity, which is more harmful

to the human body;

3） In special circumstances, the use of a stand-alone bag filter for

local discharge shall be approved by the labor protection department.

8 The raw material workshop mainly includes wet operations, the heat

dissipation in the workshop is not large, and there are few operators, so the

ventilation is mainly natural ventilation. When natural ventilation fails to

meet the requirements, mechanical ventilation may be increased. The total

ventilation rate may be 2 to 4 times per hour.

12.0.6 The heating and ventilation design of the Forming workshop shallmeet

the following requirements:

29

1 There is a high density of operators in the Forming workshop, and

the chain dryer radiates heat outward, so there shall be good mechanical

ventilation and natural ventilation. The heat dissipation capacity of the chain

dryer is 1160~1740 W/m3 (1000~1500kcal/h•m

3). The full ventilation may be

4-6 times per hour.

3 The position of the operating point of the workers in the Forming

workshop is relatively fixed, and the temperature in the operating area is

relatively high, usually exceeding 35°C in summer, so this article stipulates

that the post is provided for air supply. The form of post air supply may be

determined by design. At present, a large number of post air showers are used

in China to improve the operating environment. The air supply temperature of

the post-sending cold air is calculated according to the calculation

temperature of the ventilation, which is reduced by 3~5℃ for the cooling load

calculation.

4 The production of high-grade domestic porcelain has high

requirements on the dust concentration limit in the workshop. In order to

avoid the second flying of dust, it is not suitable to use a heater for circulating

hot air in the Forming workshop. If the radiator heating fails to meet the

requirements (currently, ceramic factories mostly use joint workshops, which

are large in volume), a centralized air supply heating system may be added,

but the air supply air speed should be below 3~5m/s, and the air outlet height

should not be lower than 3.5m. The location of the centralized air return vent

must be in a place with relatively clean air, the return air vent should be

greater than 0.5m from the ground, and a filter shall be installed in the return

air system.

6 When dry triming is used in the trimming process, the dust emission

is in the horizontal tangential direction, and the dust emission angle is

between 30 and 60°, so the dust hood should be set to a horizontal side suction

type.

30

12.0.7 The heating and ventilation design of the Firing workshop shall meet the


1 The heat dissipation capacity of the kiln in the Firing workshop is

large, the heat intensity of the bisque and glaze Firing workshop may reach

116~ 350W/m3(100~300kcal/h•m

3), the heat dissipation of the kiln is 2320~

4060W/m3(2000~3500kcal/h•m

3), and the total heat dissipation of the kiln

may be over 70x104W（60x104kcal/h）. It is advantageous and reasonable in

both technology and economy to give priority to natural ventilation to make

the workshop meet the sanitary requirements. When natural ventilation fails

to meet the requirements, mechanical ventilation or natural-and-mechanical

combined ventilation should be adopted. Combined ventilation is widely used

in China.

3 Most of the newly built ceramic factories in China adopts joint

workshops. When producing high-grade fine porcelain in areas with more

wind and sand, the workshop should be closed to avoid affecting product

quality.

5 In order to save energy in China northern areas, flue gas heating

methods have been adopted,with good effect achieved.

12.0.8 The heating, ventilation and air conditioning design of the decorating

workshop shall meet the following requirements:

3 Operating workers in the decorating section are relatively

concentrated, and a small amount of exhaust gas volatilizes during the

production process, and the natural ventilation effect is poor. Therefore, this

article stipulates that it should mainly adopt mechanical ventilation and be

supplemented with natural ventilation. For the high-end porcelain decoration

section with higher requirements, air-conditioning may be installed in

summer or cold air may be sent from post to ensure product quality. Because

decorating work requires a large amount of manual work, the summer room

temperature should be 26~28℃to ensure the quality of high-end porcelain.

31

For medium and low-end porcelain, the temperature may be determined based

on the process requirement.

4 Since iron filings have a great impact on the quality of ceramic

products, and ventilation and air conditioning equipment and air ducts are

closely related to the production process of production equipment, it is not

appropriate to use equipment and air ducts made of steel plates to prevent iron

filings from adhering to the green body. product quality.

12.0.10 The heating, ventilation and air conditioning design of auxiliary

workshops and auxiliary buildings shall meet the following requirements:

1 About 80% of the heat dissipation area of the equipment at the

bottom of the gas generating station is higher than that of the work zone, so

when calculating the heat consumption of heating, only 20% is calculated.

2 The heating of the compressed air station should be designed

according to the duty heating, for the following reasons:

1） Code for Design of Compressed Air Station GB 50029 requires

that the heating temperature between machines on duty during non-working

hours shall be 5℃;

2） The heat intensity of the machine room of the compressed air

station in the ceramic factory is generally greater than 23W/m3 (20 kcal/h•m

3).

When the on-duty heating is set, plus the heat dissipation of the equipment,

the room temperature of the machine may be higher than or equal to 16°C

requirement.

3 Compressed air stations with a heat intensity greater than 35W/m3in

the workshop shalluse natural ventilation or mechanical ventilation to

eliminate residual heat as their heat dissipation capacity is large.

4 The indoor design temperature of the central laboratory in summer is

26~28℃, which may also be determined according to the process

requirements.

5 Due to the large bulk density of chlorine gas which mainly

32

accumulates in the lower part of the workshop after being emitted, 2/3 of the

gas should be exhausted from the lower part.

7 The indoor calculation temperature of the instrument control room

should be determined by the needs of the instruments.

14 Energy saving

This chapter is a new chapter. The provisions of this chapter are compiled with

reference to the relevant chapters of Code for Design of Building and Sanitary

Ceramic Plant GB5060-2010.


5 Energy conservation and comprehensive utilization of energy must be

considered in the pre-design work and design process with the site selection and

process plan. At the same time, in the preliminary design, there must be a special

discussion on the conservation and use of energy, and a comprehensive evaluation

of energy-saving measures and energy-saving effects should be made.

6 According to Decree No.44 of the National Development and Reform

Commission (NDRC) of PRC, fixed asset investment projects in China must be

conservation reviewed. Energy conservation review opinions are an important basis

for project construction, completion acceptance, and operation management.

Projects that fail to conduct energy-saving review or fail the energy-saving review in

accordance with regulations shall not start construction; projects that have been

completed shall not be put into production. Therefore, the project construction

drawing design of this provision shall implement the energy conservation review

opinions one by one.

14.2 Process energy saving

14.2.1 The kiln is the most important thermal equipment in ceramic enterprises,

33

and its energy consumption accounts for more than 60% of the total energy

consumption of ceramic production. The structure of kiln is the foundation of kiln

energy saving. The heat dissipation of the kiln wall greatly reduces the thermal

efficiency of the kiln. Lowering the height and increasing the width of the furnace

may greatly reduce the heat dissipation. For example, the Ceramics Co., Ltd. of

Sitong Group changed two two tunnel kilns with inner width of 0.95m, inner

height of 0.95m and length of 68.5m into a tunnel kiln with inner width of 2.26m,

inner height of 0.95m and length of 63.8m. Under the same other conditions, the

unit consumption decreased from 0.468kgce to 0.219kgce, which was less than

50% of the original value. The thermal efficiency of the kiln was increased from

19.01% to 40.65%, which was more than doubled.

14.2.2 It is an effective measure to enhance the heat transfer between gas and

products by using high-speed burner to increase the air flow speed. Generally, the

fuel may be saved by 25% ~ 30% compared with the traditional burner. The

high-speed regenerative burner with high efficiency, energy saving and

environmental protection may save fuel by 20% ~ 40%, and reduce the exhaust

gas temperature and a large amount of exhaust gas emission. The air excess

coefficient of premixed secondary burner, which has been listed in the national

key energy saving technology promotion project, is controlled at 1.05 ~ 1.2, and

the energy saving rate may reach 9.8%.

14.2.3 In ceramic production, the lower the firing temperature is, the lower the

energy consumption will be. According to heat balance calculations, if the firing

temperature is reduced by 100°C, the heat consumption per unit product may be

reduced by more than 10%; the firing time may be reduced by 10%, and the heat

consumption may be reduced by 4%.

The results show that the one-step firing technology is more energy-saving

and effective than once-and-half firing (900℃ low-temperature biscuit firing plus

high-temperature firing) or double firing. For example, the comprehensive fuel

consumption and power consumption of a building ceramic enterprise in Foshan

34

have decreased by more than 30% after the adoption of one-step firing; the

energy-saving rate of Yingpai Ceramics has reached 43% after changing the

double firing to single firing.

Nowadays, due to the use of clean fuel, porcelain for daily-use and art craft

are fired without package instead of being fired with saggers, which may reduce

the energy consumption.

Microwave assisted gas firing technology (MAGF) is a practical and

reasonable firing method. Microwave is used to heat the product, so that

temperature of the product quickly rises from the inside to the outside, and the

combustion of gas makes the surface of the ceramic body heat up to prevent

surface heat loss and lower the temperature. According to reports, the use of

MAGF technology may increase production by 4 times, save energy by more

than 70%, and reduce energy costs by 40%.

14.2.4 The use of oxygen-enriched combustion technology may reduce the

secondary combustion air volume, thereby reducing waste emissions, reducing

the amount of heat carried by the exhaust gas and improving thermal efficiency.

Through the oxygen-enriched combustion experiment of the shuttle kiln, its

energy saving rate reached 21%.

The use of high-temperature air combustion technology may expand the

flame combustion area and make the temperature in the furnace uniform, thereby

increasing the average temperature of the furnace, enhancing the heat transfer in

the furnace, and heating the combustion air, which greatly reduces the amount of

NOx in the flue gas and may save energy on average up to 25% or more, the fuel

saving rate may reach 50%~60%. Through experiments on the shuttle kiln, the

energy saving rate is about 26%.

14.2.5 The heat loss of the kiln is mainly divided into heat storage loss and heat

loss. For continuous kilns, it is only heat loss. The main measure to reduce heat

loss is to strengthen the effective insulation of the kiln body.

35

The use of multifunctional heat radiation coating materials on the inner wall

of the kiln may increase the inner wall heat radiation rate of the kiln. Applying a

thermal radiation coating on the refractory material on the inner wall of the high

temperature section of the kiln may increase the thermal radiation rate from 0.7 to

0.96; applying a thermal radiation coating on the low temperature section may

increase the thermal radiation rate from 0.7 to 0.97, which greatly reduces the heat

loss.

14.3 Waste heat recovery and utilization

14.3.1~ 14.3.3 proposes specific methods and uses for recovery of waste heat

from kiln flue gas, which may be used as a reference for design. The waste heat of

the domestic ceramics plant is not limited to the waste heat of the flue gas of the

kiln. Other waste heat such as the tail gas of the drying tower shall also be

considered for utilization. This code does not list it in detail. To sump up, the

utilization of plant waste heat is an important energy-saving measure, and

comprehensive consideration shall be given to make full use of waste heat during

project design.

14.3.4 The content of this provision is derived from Article 5.1 of the provencial

standard of Shandong Province Guidelines for the Utilization of Residual

Ceramic Kiln Waste Heat DB37/T 128-2007. The energy consumption of the kiln

may account for more than 70% of the energy consumption in the whole process

of domestic ceramic production, and it is also the part that generates the most

waste heat. The quality of the waste heat utilization of the kiln directly affects the

energy consumption level of domestic ceramic products. Therefore, this provision

is introduced to regulate waste heat utilization.

14.4 Power saving

14.4.1 The energy saving of power supply system is mainly to improve power

36

factor, supplemented by improving equipment utilization and reducing no-load

loss. The power factor on the electrical line of general factories may be

compensated to 0.95, with no less than 0.92 as the better. When the workshop

adopts on-site compensation, the unbalanced load shall be compensated

separately. The indirect energy consumption of nonferrous metals and other

materials shall be taken into account in the operation load rate of transformer.

14.4.2 The efficiency of electrical equipment has a great impact on power

consumption. New advanced motor and electric heating equipment shall be

applied to save power. Advanced process design is the key, which is mainly

reflected in the saving of manpower and power and the improvement of

efficiency. Therefore, selecting advanced equipment on the basis of advanced

technology may achieve the best effect of power saving.

14.4.3 Using cold light sources to improve luminous efficiency, metal halide

lamps have become the first choice for plant lamps due to their good light

efficiency and color temperature. Since human eyes are extremely sensitive to the

color of light produced by energy-saving lamps, the use of energy-saving lamps

may appropriately reduce the luminous flux, and energy-saving lamps also have

higher luminous efficiency.

15 Environmental protection


15.1.1 The national and industry environmental protection standards and

regulations that shall be implemented mainly include:

1 Regulations on the Environmental Protection Management of

Construction Projects-State Council Order [2017] No. 682

2 Code for Design of Environmental Protection of Chemical Industry

Projects GB 50483

3 Emission Standard of Pollutants for Ceramics Industry GB 25464

37

4 Integrated Wastewater Discharge Standard GB 8978

5 Emission Standard of Air Pollutants for Industrial Kiln and Furnace

GB 9078

6 Code for the Dust Protecting Technique of the Ceramic Production

GB 13691

7 Emission Standard of Air Pollutants for Boiler GB 13271

8 Ambient Air Quality Standards GB 3095

9 Emission Standard for Industrial Enterprise Noise at Boundary GB

12348


11 Safety Code for Gas of Industrial Enterprises GB 6222

12 Code for Design of Noise Control of Industrial Enterprises GB/T

50087.

15.2 Waste water

15.2.1 There is silicate mixture in raw materials of raw materials of domestic

ceramics factory, equipment of Forming workshop and ground washing sewage.

Silicate mixture is of high turbidity and large ratio. Large particles precipitate

quickly, and fine particles are difficult to settle, forming stable sol system in water.

Due to the different raw materials, the water quality changes greatly. Generally,

the pH of sewage is 6.5 ~ 8, and the turbidity is 2000 ~ 28600 mg / L. The amount

of sewage varies with the production scale and operation management methods.

Coagulation sedimentation filtration is a general treatment. The type and quantity

of coagulant added in the treatment are determined by experiment.

15.3 Waste gas

38

15.3.2 The height of the kiln exhaust chimney shall be determined by resistance

calculation, with minimum value not less than 15m. When there are buildings

within a radius of 200m around the chimney, the height of the chimney shall also

be 3m higher than the highest building.

15.3.3 The exhaust gas of the boiler shall comply with the above mentioned

codes in the articles, and the design shall be based on the higher standard

requirements.

15.4 Waste solids

15.4.2 Most of the combustion methods of heating boilers and gas station fuels

in domestic ceramics plants afopts grate-fired furnaces, and the ash may be used

for ash bricks. At present, most of the building materials departments in cities

above the county level have founded ash and slag brick factories, which are in line

with the national principle ofreducing occupy of cultivated land for building

materials. Therefore, utilization of ash and slag is prospective.

15.4.3 The ash and slag storage yard should be located in the valley near the

plant site, supplemented by water sealing or covering with layers of soil to prevent

dust from flying.

15.5 Noise

It is more economic to control the occurrence of noise or reduce the degree of

radiated noise than to control the noise after it is formed. Methods such as rubber

lining of ball mills and silent ventilator are applicable. It shall be considered in the

architectural design and general layout design to reduce the the impact of noise

equipment on the environment.

16 Occupational safety and health

39

This chapter is a new chapter. The provisions of this chapter are compiled with

reference to the relevant chapters of Code for design of building and sanitary

ceramic plant GB 50560-2010.


16.1.1 Comprehensive mechanization and automation of production design of

ceramics plant shall be improved. For various occupational hazards in the

production process, the principles of elimination, prevention, weakening, isolation,

interlocking and warning shall be followed, and corresponding technologies shall

be adopted in each descipline. Measures are taken to improve the working

codition and promoting safe and efficient production.

16.4 Lightning protection

16.4.2 Acurate statistics of the local geological and meteorological conditions

shall be aquired in the lightning design, buildings that need lightning protection

shall be classified. The classification standards should comply with the relevant

provisions in the Design code for protection of Structures against lightning GB

50057.

Plants, dormitories, and office buildings in areas prone to thunderstorms are

classified as Class II lightning protection buildings. Because the improvement of

lightning protection devices does not take up a lot of investment, in the

classification of lightning protection buildings, buildings in the fuzzy boundary

may be designed according to a higher level of lightning protection to ensure

safety.

16.7 Noise control

16.7.5 Damping and sound insulation measures are taken on the steel slide pipe

and steel silo wall to avoid noise caused by direct impact of unsmooth materials.

code for design of domestic ceramics plant

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