(1) Autoclave discharging area
(2) Steam pressure protection area
(3) Block organizing area
(4) No.1 Milling machine room
(6) No.1 Mixing tank
(7) No.2 Mixing tank
(8) Recycled material mixing tank
(9) Lime powder container
(10) Lime storage house
(11) Lime block crushing room
(12) Control room for the lime milling machine rooms
(13) No.2 Milling machine room
(14) Plaster container
(15) Concrete container
(16) Batching workshop
(17) Transition area for pouring process
(18) Pre-curing area
(19) Mould retrieving line
(20) Transverse cutting machine
(21) Longitudinal cutting machine
(22) Steam distribution room
(23) Trolley returning line
(25) Packaging line
(26) Reserved area for steel rebar processing
The layout of our autoclaved aerated concrete block/panel production equipment is presented in the picture. You can check the detailed information of the production process and the concrete block machines involved below.
1. Raw materials weighting and batching.
2. Feed the raw material into pouring machine to make slurry.
3. After thoroughly mixing, the slurry is poured into the mould.
4. After pre-curing under a certain temperature for a certain period of time, the cakes would become hard enough for cutting.
5. Tilt the hoister to turn the mould for over 90 degree.
6. Then de-mould and take the cake together with the side plate onto the cutting car.
7. The two vertical sides of block will be cut perpendicularly.
8. Then the longitudinal cutting will be conducted in horizontal direction.
9. Finally the horizontal cutting will be conducted in longitudinal direction.
10. After cutting, the cake is hanged to the trolley with side plates by the semi-finished product hoister.
11. Organize the cakes well and put them into autoclave.
12. Hardening the cakes at certain temperature and pressure.
13. Take finished products out of autoclave.
14. A hoister will take the finished product to the product stack.
15. The products are packed for transportation.
16. The side plates get returned by the side plate roller.
17. Side plate and empty mould would be reorganized.
18. Clean the mould and prepare for next pouring.
1. Storage and handling of raw materials
The raw material is sand: (1) Tailing sand (or quartz sand), gypsum
Transport the tailing sand to the production plant for storage. When production, use the loader to load them into the hopper, after feeding and metering, will be transported by conveyor belt to the wet mill to be finely ground and made into pulp; When pulping, add the quantitative water, it will help to the initial preparation of slurry with appropriate concentration. The finely ground pulp flows into blending chest through the mill, here add a certain amount of water to prepare a slurry with concentration suitable for production, then using the submersible slurry pump to pump the slurry into the tank (100m3) in reserve. The tailing sand with appropriate fineness may also be added directly to the drum sieve hopper, rinsed with water into the blending chest for pulping. During the production, there are two addition methods for the gypsum or phosphogypsum, first, by a certain ratio to add together with the tailing sand to wet milling machine for grinding and pulping; second, add directly the gypsum with certain amount into the blending chest for pulping, then pumped into the gypsum tank (10m3) in reserve.
The raw material is fly ash:
(1) fly ash, gypsum
Adopt the mixed pulping process for fly ash and gypsum. When production, add the fly ash and gypsum by a certain ratio to beating pool to prepare a mixed slurry. When pulping, add quantitative water to form a slurry with suitable concentration. Then pumped by slurry pump into the slurry tank in reserve.
Quicklime block shipped to the pier, then transported to the plant by truck for unloading and storage. After crushed by jaw crusher, fed by bucket elevator into the quicklime hopper. Then fed by closed type belt conveyor into the mill for grinding. The quicklime powder after finely ground transported by screw conveyor to the bucket elevator, and finally transported to the quicklime powder silo in reserve.
Consider the use of bulk cement. The bulk cement is transported by bulk cement truck to the plant, then pumped directly into cement powder silo in reserve.
(4) Aluminum powder
Store the aluminum powder paste barrels in the warehouse. Transported by electric hoist to the third floor of batch house, put manually inside the aluminum powder mixer to be stirred into a 5% of suspension in reserve. Then use the water flow meter to add a quantitative water to the aluminum powder.
(5) Steel wire rod and rust-proof paint
Store the steel wire rod and rust-proof paint in the corresponding warehouse in reserve.
(6) Scrap and waste slurry
Scrap cutted by cutting line to the bottom of chute, rinsed by water to the bottom of waste slurry pool of the cutting machine, after constantly rinsing and stirring for that the waste slurry reach a certain concentration, pumped by the submersible slurry pump to the waste slurry tank (50m3) in reserve. The waste water of slurry tanks, slurry scales and casting mixer falls down through a conduit into the waste water pool of mixer, then pumped by submersible slurry pump into the waste slurry pool of cutting machine for stirring and pulping together with waste water.
2. Batching, mixing, pouring and pre-curing
The lime and cement are fed by a single spiral tube feeder of silo bottom into the powder electronic measure scale, after accumulated metering, discharged by a single spiral tube feeder of measurement scale bottom into the pouring mixer.
After open the valve of each slurry tank (100m3 and 50m3), the tailing sand slurry and waste slurry are respectively discharged into the blending chest beside the tank. Then pumped into the slurry electronic measurement scale of batch house for accumulated metering. When the weight of slurry reaches the batching requirements, the automatic control system will close the discharge valve. The metered slurry will be poured into the mixer according to instructions.
After the aluminum powder weighted manually, pour into the aluminum mixer (1.5m3) to prepare the suspension in reserve. The mixed suspension is fed directly into the aluminum measurement scale, after the metering, poured into the mixer.
Before pouring the slurry, the temperature should reach the process requirements. If the temperature is not enough, can be heated by steam. When pouring, the mold is transported by special vehicle to the casting mixer.
The poured mold is transported by pre-curing vehicle to the pre-curing chamber for a static pre-curing about 1.5h-3h.
3. Cutting and grouping
After the static pre-curing and reaches the cutting strength, the blank will be transported by the special vehicle from the pre-curing chamber to the casting - Precuring - cutting cycle produciton line to be processed with five-sided cutting. The whole cutting process is controlled by the cutting machine PLC console, to achieve one-touch automatic control.
The cutted blank is transported to the turnover station on the ground to be inverted by 90° for cleaning the blank bottom. After finished, the blank is transported to the steam curing vehicle, each vehicle with three molds, each autoclave rail track with six steam curing vehicle.
4. Autoclaved and finished products
The grouped blank is transported to the autoclave by the traction mechanism of each track for steam-curing. The constant pressure steam curing time for the blank in autoclave is about 6h, the steam pressure is 1.2Mpa, the temperature is about 183℃. After the products be autoclaved and finished, will be pulled out from autoclave by winch.
5. Severing and finished products
The rollers transport the finished products (with side plates) to the severing machine to separate the block or plate. The separated finished products are transported by rollers to the crane for lifting the finished products. Among them, the plates are lifted to the transition area, and transported by forklifts to the repair area for inspection and repairing, the repaired plates are transported by forklifts to the storage yard. The blocks are lifted to the block packaging line, after packaged manually, transported by forklifts to the storage yard.
6. Side plates return, mold assembly and oil coating
After finish the lifting of finished products, the empty side plate continue to walk along the roller to the turnover system of autoclave, then the turnover spreader lift the mold frame and the side plate to be combined into the mold, and turn 90° to be lifted to the mold return line. Here the mold will be cleaned and coated with oil, then carry out the circulated pouring.
7. Rebar production and coating drying
The rebar is processed by straightening and cutting machine into different sizes and lengths and stacked on shelves.
When producing the steel mesh, put several long and short rebars into the rebar box of automatic multi-spot welding machine, then according to production needs, welded in single mesh sheet by the automatic multi-point welder , each time two pieces.
After the single mesh sheet be formed, take the upper and lower mesh sheet and several fittings to be welded in steel mesh cage by the suspended type single spot welder, then transported to the front end of coating drying box.
Transport the barreled anti-rust paint to the front end of drying box of steel processing zone, after be stirred into liquid by the preservative fluid mixer, poured into the anticorrosive immersion stirring tank in reserve.
Lift the steel mesh cage under the lifting beam, then transported by single-girder crane and put down into the anticorrosive immersion stirring tank, after that, lift the cage and place it on the conveyor chains of drying oven. The conveying speed of chains is 1.7m/min, the cage will be transported from the front end to the rear end of drying box, in this process, the mesh coating has dried. If the coating thickness can not reach the production requirements, can repeat the process of immersion and drying. The dried steel mesh cage will be lifted and transported by a single girder crane to mesh sheet shelf in reserve.
8. Mesh sheet assembly and insertion and extraction of rod
When production, the finished cage is transported to the side of mesh lifting frame of pre-curing room, then be lifted to the second floor of pre-curing room. There are two rows of placement shelves for mesh frame, one row is used to place the empty frame after extraction of rod (row A), another row is used to place the assembled frame (row B). The workers assemble the mesh sheet in the row B, after finished, to be transported to the row A for inserting the rod into mold. After die casting, carry out the insertion of rod, then after pre-curing of mold blank, carry out the extraction of rod. The finished blank will be transported to the side of cutting machine to be cut.
If you need further information of the production process of our concrete block/panel production equipment, contact us at any time. You are also welcomed to visit our company in person.