Knowledge Brief

How is the setting of bricks done in an Induced Draught Zigzag Kiln (IDZK)? [Brick setting type-1]

In an Induced Draught Zigzag Kiln (IDZK), the setting of bricks is different from that in a Fixed Chimney Bull’s Trench Kiln (FCBTK). Several types of brick settings are practised in IDZKs. This Knowledge Brief discusses a single zigzag brick setting widely practised in the eastern part of India. Another Knowledge Brief, titled – “How is the setting of bricks done in an Induced Draught Zigzag Kiln (IDZK)? [Brick setting type-2]“, discusses a brick setting, which is widely practised in north India.

How is the brick setting different in an IDZK compared to that in an FCBTK?

In an FCBTK, bricks are stacked in vertical columns in a line (row) across the width of the trench. The rows of brick columns are arranged one after the other in the direction of air flow.

In an IDZK, bricks are stacked in such a manner that distinct chambers of brick setting are formed in the kiln. Just like in the case of FCBTK, in IDZK also, the bricks are stacked in vertical columns in a line (row) across the width of the trench. However, unlike in FCBTK, all the brick columns are not of the same width. The rows of brick columns are arranged one ahead of the other in the forward direction of fire travel. In an IDZK, one chamber of brick setting consists of eight such rows.

Because of different brick settings, the path of air flow in the two kilns is also different. In an FCBTK, the air flows in a straight-line path along the length of the trench. In an IDZK, the air flows both across the width and along the length of the trench in a zigzag path. How the air is made to follow a zigzag path is explained in detail later in this Knowledge Brief.

What is the size of a chamber in an IDZK?

Chamber dimensions are fixed in the following way:

1. The width of a chamber is equal to the width of the trench.
2. The length of a chamber depends on the size of the brick. One chamber consists of eight rows/lines of bricks. The thickness of each row is equal to the length of a brick. A gap of about half a brick length is left between two consecutive rows. The length of a chamber usually varies between 8 and 9 feet (2.5–2.75 m).

How are bricks arranged in a chamber in an IDZK?

In a chamber, bricks are arranged according to the following method:

1. Generally, bricks are arranged in a chamber in eight lines/rows consisting of one ‘end row’ and seven ‘middle rows’. The thickness of each row is equal to the length of a brick. A gap of about half a brick length is left between two consecutive rows.
2. Middle rows of the chamber consist of several columns of bricks. All columns in a row are not of the same size in a Zigzag Kiln, unlike in an FCBTK.
3. The last row (eighth row) of the chamber is like a brick wall with a few openings at both ends (near the outer wall and Miyana of the kiln).

4. The number and size of columns depend on the production capacity of the kiln and the width of the trench.
5. Adjoining rows are joined together by bricks, called bandhan, at multiple levels to make the brick setting structurally stable.
6. Adjoining columns of a row are joined together by bricks, called jodi, at multiple levels to make the brick setting structurally stable.

How are the openings for air flow at the end of a chamber arranged in an IDZK?

In the last row in each chamber (in the direction of air flow), i.e., the chamber walls, the openings are left at one end (adjacent to the walls) in the stacked bricks. In alternate chambers, such openings are left either at the left end or at the right end of the chamber wall. This arrangement of openings in the chambers results in the zigzag flow of air, and is repeated throughout the length of the rectangular trench.

How is the air made to follow a single zigzag path in an IDZK?

In single zigzag flow, air alternately enters the chambers either through openings at the left end or through openings at the right end.

When air enters a chamber from the left end, it is made to flow towards the right across the width of the chamber. It leaves the chamber through the openings at the right end and enters the next chamber.

When air enters a chamber from the right end, it is made to flow towards the left across the width of the chamber. It leaves the chamber through the openings at the left end and enters the next chamber.

This reversal of the flow direction in alternate chambers creates a zigzag flow. This flow pattern is repeated in alternating chambers throughout the length of the rectangular trench.

How is the brick setting done in the Gully region of an IDZK?

The zigzag brick setting is done only in the longer lengths of the rectangular trench. In the shorter lengths of the rectangular trench, which is called gully, brick setting is done as in FCBTK.

In the gully region (shorter length of the rectangular trench), all the rows, except the last row, are made of equally spaced same size brick columns in exactly the same way as in an FCBTK. Air flows in a straight-line path in this region. At the entry and the exit of the gully region, the openings are left only near the outer wall end of the trench. This arrangement ensures that the air also flows through the extreme corner of the trench thereby exchanging heat with as many bricks as possible. The openings at only the outer wall end also prevent short-circuiting of the air flow near the miyana of the kiln.