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Learn how NUTEC Bickley refurbished a large gas-fired shuttle kiln with new kiln cars, upgraded insulation, and refractory restoration to improve efficiency and restore production.
The Ceramics Business Unit of NUTEC Bickley has completed a major shuttle kiln refurbishment project for Empire Comfort Systems, the Illinois-based manufacturer known for its White Mountain Hearth, American Hearth, Plaza, and Montigo fireplace brands.
The objective of the project was to return one of the company’s large gas-fired shuttle kilns to full production as quickly as possible, with a targeted completion schedule of just 10 weeks.
The contract included the design, manufacture, and supply of seven new kiln cars, restoration and relining of the kiln’s refractory bench and sand seal, and complete replacement of the door insulation and sidewall/roof seals.
Prior to engineering and fabrication, NUTEC Bickley personnel conducted detailed onsite measurements to finalize all design aspects. This work included stripping the existing kiln cars of their insulation to locate refractory post sockets and ensure compatibility with the new kiln car design.
The kiln at Empire Comfort Systems’ Poplar Bluff manufacturing facility is now fully operational and is primarily used in the production of Primo ceramic grills.
The firing process is a vitrification and sintering operation conducted in an oxidizing atmosphere, utilizing advanced high-velocity nozzle-mix burners positioned above and below the load to ensure efficient heat transfer and process consistency.
The seven new kiln cars were designed to accommodate the existing kiln furniture while providing improved durability and performance.
Each kiln car was fabricated using lightweight yet robust welded structural steel and incorporates eight single-flanged wheels operating on a four-rail track system. As part of the project, NUTEC Bickley also installed new trackwork to support the upgraded kiln car configuration.
A sand trough forms the seal between the kiln car and kiln sidewalls. The removable car blade (skirt) is bolted into position, while the end seals engage with the kiln door to create an effective car seal during operation.
The kiln car insulation utilizes NUTEC Bickley’s proven lightweight design. The perimeter is constructed from insulating firebrick, while the interior incorporates low thermal mass ceramic fiber modules to create a clean, lightweight kiln car structure. The chassis also include a hook-and-release mechanism that allows the existing transfer car to move the entire train of kiln cars through the kiln.
As part of the refurbishment, the existing refractory bench and sand seal system were demolished and removed.
The new sand trough was fabricated using 409 stainless steel for durability and long-term performance. New sidewall-to-kiln-car seals were constructed using a combination of insulating brick grades and a double labyrinth seal configuration designed to minimize heat loss, reduce radiant heat leakage, and prevent the infiltration of cold air into the kiln chamber.
An integrated sand seal further enhances sealing performance and thermal efficiency.
The kiln doors were relined using NUTEC Bickley’s proprietary high-efficiency ceramic fiber insulation system, providing excellent thermal performance, long service life, and reduced maintenance requirements.
The insulation system is rated for operation up to 1350°C (2460°F). In addition, the door-to-wall and door-to-roof seals were replaced on both ends of the kiln.
To support reliable operation, the kiln walls were modified to incorporate burner sight tubes, thermocouple mounting tubes, and chamber pressure port connections.
This project demonstrates how a well-executed kiln refurbishment can significantly extend equipment life, improve thermal efficiency, and restore production capacity without the need for a complete kiln replacement.
By combining new kiln cars, upgraded refractory systems, enhanced sealing technology, and modern insulation materials, NUTEC Bickley successfully returned this critical manufacturing asset to service within a demanding schedule, helping support continued production for one of North America's recognized fireplace and ceramic grill manufacturers.
Alberto Cantú – VP Ceramics & Advanced Materials, NUTEC Bickley
E-mail: albertocantu@nutec.com
We serve multiple industries through the design, building and installation of combustion systems, thermal insulation and highly specialized industrial furnaces, kilns and ovens. We are focused on understanding our customers’ needs and supplying the best equipment at the most competitive price.
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