Aerated concrete block production line

Aerated concrete is a new type of wall building materials, with the advantages of light weight, heat preservation, heat insulation, energy saving, waste, environmental protection construction, convenient and quick, etc. It is a national key to promote environmental protection projects.

Aerated concrete production line mainly uses fly ash (slag or sand) as the raw material, lime, cement as the binder material and aluminum powder as the aerating agent, and is made into aerated concrete through the processes of crushing, measuring, mixing, pouring, static curing, cutting, steam curing and so on. Aerated concrete is a new type of wall building materials, with the advantages of light weight, heat preservation, heat insulation, energy saving, waste, environmental protection construction, convenient and quick, etc. It is a national key to promote environmental protection projects.

Process flow:

Raw material preparation → cement → lime → gypsum → additives → sand → raw material measurement and batching → pouring and mixing → for aerated concrete panels with reinforcement (optional) → static curing → turning and demolding → cutting trolley ready for cutting → cutting of the billet → turning to remove the bottom skin → grouping to be vaporized → steam curing → finished product out of the kettle → finished product holding clamps and palletizing → finished product packing → finished product transfer →

I. Raw material processing

Siliceous materials such as sand, fly ash milling, according to the requirements of raw materials and process characteristics, can be used to dry grinding into powder, or water wet grinding slurry, but also with a portion of the lime and other wet grinding. There are two ways of wet grinding: one is dry mixing and grinding to prepare binder; the other is wet grinding with water, mainly to improve the characteristics of fly ash or sand, known as hydrothermal ball milling; now the main choice of hydrothermal wet milling; Purchase of lime is mainly in two forms: one for the powder can be directly into the tank storage standby; the second for the block, you need to be crushed through the milling; gypsum is generally not milled alone, or mixed into the fly ash or sand Gypsum is usually not ground separately, or mixed with fly ash or sand, or can be wheeled with lime in a ball mill. Other auxiliary materials and chemicals are also often prepared;

Raw material preparation process, is the preparation process of ingredients, is to make raw materials in line with the process requirements of reprocessing and complete the storage of ingredients before the homogenization process, is a direct impact on the entire production can be carried out smoothly, product quality can meet the requirements of the basic process links.

    (1)Jaw crusher

     In order to make the materials meet the requirements of aerated concrete block production, generally calcium and silica materials have to be finely ground, and some lumpy materials must be crushed firstly before entering the ball mill to reach the required feed size before entering the ball mill for the second grinding.

         a. Jaw Crusher Working Principle

　　    When working, the motor drives the eccentric shaft to rotate through the belt pulley, so that the movable jaw approaches and leaves the fixed jaw periodically, thus crushing the materials in multiple ways, such as squeezing, rubbing, grinding, etc., so that the materials become smaller and smaller, and gradually fall down until they are discharged from the discharge opening.

         b. Jaw Crusher Features

　　    The jaw crusher is characterized by large crushing ratio, high output, even product size, simple structure, reliable operation, easy maintenance and economical operation cost.

         c. Main Technical Parameters of Jaw Crusher

(2)Bucket elevator

   Bucket elevator is an indispensable raw material conveying equipment in aerated concrete equipment, the main purpose is to send the limestone, gypsum and other abrasive bulk materials processed by jaw crusher into the storage silo, to prepare for the raw material mixing and processing of later aerated concrete production.

            a. Working principle of bucket elevator

　　     NE type bucket elevator consists of running part (hopper and traction belt), upper section with driving drum, lower section with tensioning drum, intermediate casing, driving device, backstop braking device, etc. It is suitable for upward conveying non-abrasive and semi-abrasive bulk materials with loose density ρ<1.5t/m3 of powder, granule and small block, such as coal, sand, coke, cement, crushed ores and so on.

            b. Characteristics of bucket elevator

　　     NE type bucket elevator is of inflow feeding, the material flows into the hopper and is lifted to the top by plate chain, and is discharged by itself under the action of gravity of the material. This series of bucket elevator has many specifications, wide lifting capacity, high production capacity, low energy consumption, the machine adopts the full-sealed shell chain speed is low, almost no back to the material phenomenon, so the reactive power loss is less, low noise, long life.

            c. Main technical parameters of bucket elevator

(3)Belt conveyor

　　Belt conveyor in aerated concrete production line is a very important conveying equipment, used to transport fly ash, sand and lime and other raw materials, in the production line is a better and efficient continuous conveying equipment, belt conveyor conveyor belt according to the principle of friction drive and movement, has a large conveying capacity, conveying a long distance, smooth conveying, materials and conveyor belt has no relative movement, less noise, simple structure, easy maintenance, The advantages of simple structure, easy maintenance, low energy consumption, standardization of components, etc.

       Main Technical Parameters of Belt Conveyor

(4)Ball Mill

         Raw material grinding is an important process in the production of aerated concrete, lime, gypsum, sand, slag and other materials only after grinding and reach the required fineness, in order to carry out the full mixing and interaction, in order to make the products to achieve the strength of the ball mill is the material is crushed, and then crushed the key equipment.

        a. Working principle of ball mill

　　      The ball mill is a horizontal cylindrical rotating device, gear drive along the outer edge, two bins, lattice type ball mill. Materials from the feeding device through the feed hollow shaft spiral evenly into the first bin, the bin has a stepped liner or corrugated liner, filled with different specifications of steel balls, cylinder rotation generates centrifugal force will bring the steel ball to a certain height and then fall, the material to produce heavy impact and grinding effect. After the material reaches rough grinding in the first warehouse, it enters into the second warehouse through the single-layer partition board, which is set with flat lining board and steel balls inside, and further grinds the material. The powder is discharged through the discharging grate plate to complete the grinding operation.

　　 b. Structural characteristics of ball mill

　　     This machine is composed of feeding part, discharging part, rotating part, transmission part (reducer, small transmission gear, motor, electric control) and other main parts. The machine adopts external peripheral gear transmission, hollow shaft support, hollow shaft using cast steel parts, lining can be removed and replaced, rotary gear using castings hobbing processing, cylinder body set with wear-resistant liner (steel lining and rubber lining of two kinds, rubber liner weight is light, running noise is small, wear-resistant, sealing is good, for the general preferred. The rubber liner is light weight, low running noise, wear-resistant, good sealing, and is generally preferred, and has good wear resistance). The machine runs smoothly and works reliably.

       c. Main technical parameters of ball mill

(5) Mill head waste slurry mixing tank

       Mill head waste slurry mixing tank is composed of support platform, ladder guardrail, waste slurry storage tank agitator, and mixing tank and other components, in general, the aerated concrete production requirements of the pouring of waste slurry under the pouring ferry car, as well as all the cut down the waste water through the mortar pump to the mill head waste slurry tank for mixing, in the grinding of mortar as a mixing material and water to mix together, and strict control of the grinding slurry Density, you can get a good mortar effect; 

2、Dosing and casting

Batching is prepared and stored for use of various raw materials for measurement, temperature and concentration adjustment and a small amount of mixing material measurement preparation, and then according to the process requirements, once to the mixing equipment feeding. Batching is a key link in the process of aerated concrete, related to the proportion of the active ingredients between the raw materials, the relationship between the fluidity of the slurry and the viscosity is suitable for the aluminum powder aerated and billet normal hardening and so on. It has the most direct influence on the gasification and expansion, hardening process and product performance.

The casting process is one of the unique production processes that differentiate aerated concrete from other kinds of concrete. Pouring process is the batching process after measurement and necessary adjustment into the mixer after the material for mixing, made to achieve the time, temperature, consistency of the slurry specified in the process, through the mixer of the pouring port pouring into the mold. Slurry in the mold for a series of physical and chemical reactions, producing bubbles, so that the slurry expansion, thickening, hardening. The casting process is an important process to ensure a good pore structure, and together with the batching process, it constitutes the core of the aerated concrete production process.

Static stopping process is mainly to promote the pouring of slurry to continue to complete the thickening, hardening process, in fact, from the slurry pouring into the mold that is the beginning, including gas expansion and billet maintenance of the two processes, in order to enable the slurry to complete the gas expansion to form a billet, and make the billet to reach a certain level of strength, in order to carry out cutting.

    (1)Measuring system

    Aerated concrete metering system for batching the physical form of raw materials used in liquid materials, slurry materials, powdered materials, in addition to aluminum powder and aluminum powder paste, different materials measuring said also different, the main weighing equipment has lime, cement metering bucket, slurry metering tanks and so on. And through the automatic measurement system for automatic measurement.

       a. Powder measuring tank

        Used for measuring cement and lime, and conveying the measured cement and lime to the casting mixer.

b. Slurry metering tank

　　Used to measure the slurry and deliver the measured slurry to the pouring mixer.

c. Water metering tank

　　Used to meter water and automatically deliver the measured water to the pouring mixer.

(2) Aluminum powder automatic measuring system

    Aluminum powder (paste) automatic quantitative feeding device developed specifically for the aerated block industry mechatronic products, the device from the aluminum powder paste feeding, weighing, adding water, mixing, aluminum powder liquid discharge all automatic operation, eliminating the cost of aluminum powder workers will be aluminum powder paste feeder from the boring repetitive work to be liberated, but also to avoid product quality accidents caused by operator error. Unique unloading mechanism, high-precision weighing sensor, intelligent control software, effectively solve the problem of aluminum powder (paste) dosage is small, the requirement of high precision.

　Aluminum powder automatic adding machine, as an independent unit in the batching system, can either be connected to the original system to run automatically or run separately.

(3) Pouring mixer

　The casting mixer is composed of mixing barrel, mixing shaft, transmission mechanism, deflector device, nozzle device, etc. It is the main equipment in the aerated concrete equipment, which will mix the slurry, cement, quicklime, gypsum and aluminum powder paste suspension injected into the tank according to a certain proportion, so as to make it evenly mixed and fully reacted, and inject the mixed slurry into the mold frame in time.

(4) Pouring Ferry

　Pouring ferry is an indispensable equipment for the autoclaved section of aerated concrete production line to change direction and drag, which is composed of frame, drive and positioning mechanism, the frame is welded by section steel, and the drive is composed of reducer, coupling, axle, active wheel assembly and passive wheel assembly, the assembled ferry has the characteristics of powerful dragging and pushing, and it is able to accurately stop, locate and connect the rails after the big car moves transversely and quickly. It can be frequency converted to slow speed operation when it is loaded with heavy load, and frequency converted to fast speed when it is empty for the return trip.

(5) Bubble finishing machine

　Bubble finishing machine using high-frequency vibration, for the elimination of large bubbles in the slurry after casting equipment, by the frame, vibrating rod and walking system, generally according to the installation mode is divided into fixed and swing car type.

(6) Mold frame, side plate 

　Aerated concrete equipment mold is divided into two parts of the mold frame and side panels, is an important equipment for product shaping, mixing the raw materials through the pouring mixer poured into the mold, gas static stop, curing, take off the mold frame, the blank that can be cut. The combination of mold frame and side plate can hold slurry, static maintenance foam curing into a blank, the side plate at the same time and carry the blank to the aerated concrete cutting machine for cutting, and with the autoclave trolley group code into the autoclave for autoclaving.

3、Flip cutting

Flip car, cutting machine is the main equipment in the aerated concrete production line, flip cutting process is the aerated concrete equipment billet for division and shape processing, so that it reaches the appearance of the size requirements, aerated concrete flip cutting process embodies the aerated concrete to facilitate large-volume molding, flexible and diverse dimensions and can be large-scale mechanization of the production of the characteristics of the process.

(1) Turning truck

      Tipping truck is the main supporting equipment in the production of aerated concrete, mainly consists of spreader, ring, rotary lock, ear plate and rigging buckles, etc., and double beam double hook crane supporting the use of aerated concrete production process for demolding and transfer of billet and other operations.

　   The tilting truck turns the billet (with mold frame and side plate) over 90° in the air, lifts and places it on the cutting table or cutting trolley, and then demolds it for cutting. In addition, the demolded mold frame and the returned side panels are molded together and transported to the casting return line for cyclic casting.

(2) Cutting unit

    Aerated concrete cutting unit is the main cutting equipment in the aerated concrete production line, the cutting unit includes longitudinal cutting machine, transverse cutting machine, aerated concrete in the pouring of gas, the formation of billet. Due to the large volume of the billet, to achieve the required size of the aerated concrete products, it must be cut and processed!

         Working principle of cutting unit

　　   The demolded billet together with the side plate is placed on the cutting trolley, the cutting trolley is driven by the gear motor to walk through the longitudinal cutting machine to complete the longitudinal cutting; the cutting trolley continues to walk to the middle of the horizontal cutting machine to stop, the trolley replacement device will be lifted up with the billet, the cutting trolley is returned to the bottom of the overturning carriage to carry the demolded billet for the next time, and the other cutting trolley to enter the bottom of the replacement device. Another cutting trolley enters under the replacement device, the replacement device will place the side plate together with the blank on the cutting trolley, the transverse cutting action starts to carry out the transverse cutting action, after the completion of the cutting, the cutting trolley and then walks to the ground under the car, and then by the turning to the bottom of the trolley will be blank to the bottom of the body (even the side plate) lifted to the steam raising trolley, the cutting trolley range of the original position to carry out the next cutting cycle.

(3) Turning to the bottom traveling car

　After the cutting is completed, the bottom surface of the billet is removed from the waste material by turning the bottom carriage and then lifted to the steam curing trolley for kettle grouping.

(4) Grouping traveling car

    Grouping traveling car is through the lifting cylinder pulling chain to realize by the bottom skinning traveling car after the bottom of the billet together with the side plate of the lift, and then through the gear motor driven wheels to realize the horizontal movement of the traveling car, so as to realize the movement of the billet to the designated kettle before the track for the grouping.

4、autoclave

Autoclave curing is a high-pressure steam curing of aerated concrete billet, for aerated concrete, only after a certain temperature and enough time of curing, the billet can complete the necessary physicochemical changes, so as to produce the strength to meet the needs of building construction.

The autoclave curing process determines the final formation of the intrinsic properties of aerated concrete.

  (1) Steam curing trolley

    Steam curing trolley by the frame and wheels, is to carry side panels with the blanks in and out of the autoclave means of transport, is the production process of special transportation vehicles, which is loaded with cut blanks, into the autoclave curing. After conditioning, the finished product will be transported to the finished product site.

(2) Autoclave 

   Autoclave is the core equipment for aerated concrete production and autoclaved brick production. It is used for high-temperature and high-pressure maintenance of the cut billet; it can also be used for high-temperature and high-pressure maintenance of autoclaved brick production, and the hydrothermal reaction of Cao-SiO2-H2O is completed in the kettle.

(3) Boiler

 The boiler provides heat and steam for the autoclave to ensure high pressure and temperature in the kettle to ensure that the blocks complete the hydration reaction of qualified AAC blocks.

5、Finished product out of kettle

(1) Finished product fixture

    Finished product fixture is mounted on a special traveling car, walking and lifting on the traveling car. Its lifting is guided by the guide frame, smooth, correct, no deflection, shaking and other defects, is the whole of the finished product after steam curing lifted off the side plate of the special spreader, gas concrete block steam curing process is an important link, the steam curing of finished products out of the kettle lifted to the packaging line for the final packaging.

(2) Mobile breaking machine

    The breaking machine is used to break off the vertical kettle billet from the layer to layer by the machinery, which is installed at the conveying end of the aerated block finished products, and it automatically completes the breaking off process and grouping of finished products.

 (3) Automatic depalletizing crane

    The automatic depalletizing crane will transport the finished products by crane, break the boards by mobile board breaking machine, and arrange the finished products after grouping, and then depalletize the finished products after depalletizing through automatic palletizing machine, and the finished products after depalletizing will be transported by the chain conveyor to the finished products packing area to be packed. 

 (4) Pallet dispenser

    Provide effective, smooth and efficient automatic pallet dispenser for the equipment at the back end of the production line, such as automatic depalletizing crane and chain conveyor.  

  (5) Chain conveyor and packer

    After the products come out of the kettle and pass through the finished product lifting and automatic plate breaking machine, they will enter the process of conveying and packing, and after packing, the products which are finished into pallets can be stacked in the finished product area directly by forklift trucks.