1. This production line provides the combined advantages of AAC block production line and sand-lime brick production line. Our company is the only one in China that can provide a combined AAC block and sand-lime brick production line. 2. This combined AAC block and sand-lime brick production line is designed to produce a variety of sand-lime concrete products to fit diversified market demands. It also provides customer companies with the ability to be more responsive to the market change. 3. The sand-lime brick production process and AAC block production line can share ball mill, boiler, and partially an autoclave. This comes with financial benefits, since users do not need to purchase two ball mills, boilers, or autoclaves. It also minimizes the factory space needed to accommodate the production line, thus saving factory construction cost. Meanwhile, sharing production equipment also means reduced amount of steam needed.
(1) The lime will be crashed, ball milled after entering the factory, batch production for this section working system, the raw materials is continuous crash & stored after entering the factory, lime in the lime-grain storeroom will be rationing through speed belt scale into ball mill for levigating. When the fineness reached 3500～4000cm2/g, the lime will be sent into cement silo through bucket elevator for storage.
(2) Sand, wet fly-ash be stacked in the factory, than poured into separate batching hopper by loading car during production. After entering the factory, the dry fly-ash be put into the warehouse for storage. and be send into powder scale by screw conveyer for measurement when producing.
(3) The above raw material and water entered into forced double-shaft mixer and stir into mixture after being measured respectively, and the time is about 4mins.
(4) The made mixture entered into continuous slaking silos for slaking, which can meet the requirement of continuous production, and the slaking time ensured easily. The mixture will be sent into mixer by belt conveyor for twice mixing when complete slaking. which can play a role of excitation, mixing, fine grinding and compaction so as to increase the mixture density, improve the performance and quality of products.
(5) Mixed compound will be sent to the front-middle silo of the brick machine. Pressing machine＇s mid-silo quantitatively put the compound into the mixing chamber of skip car. Then skip car mixing device feeding the compound into mould-chamber of the pressing machine uniform through skip car movement. Formed adobe after pressing and formed 48 blocks every time. Cakes be sent to belt machine through the stacking device, then be sent to the grasper of stacker crane by belt machine, the adobe be stacked up on the curing car by stacker crane. Pressing waste and unnecessary material be returned to the dosing machine.
(6) After stacking, the curing car be transported to the marshalling area by ferry car , and be pulled into the autoclave by the kettle tractor for High temperature(200℃), high pressure(1.3Mpa), autoclaving (under 1.3MPa, 10hours)
(7) Curing car will be send to unloading orbit by ferry car when finished curing, then be sent to finished product storage yard, conduct appearance & quality test at the same time, then stacking on level. Waste will be reused as raw material after broken treatment.
(8) Empty curing car be returned to the brick machine to re-using by the return-orbit after cleaning.(1) The lime will be crashed, ball milled after entering the factory, batch production for this section working system, the raw materials is continuous crash & stored after entering the factory, lime in the lime-grain storeroom will be rationing through speed belt scale into ball mill for levigating. When the fineness reached 3500～4000cm2/g, the lime will be sent into cement silo through bucket elevator for storage.
Main technical-economic indicator
No.
Index content
Unit
Index value
I
Description
sand-lime brick
Specification
mm
240×115×53
Production scale
pcs/year
140,000,000
II
Working system（three-shift continuous weekly production）
300 days / year 22.5 hours / day 7.5 hours / shift
III
Main raw material consumption
1 .Fly ash
Ton/ year
225,400
2 .Sand
Ton / year
64,400
3 .Quick lime
Ton / year
32,200
IV
Total capacity
KW
About 1,200
V
Annual power consumption
0,000KW.h
271.72
VI
Annual water consumption
Ton
76,000
VII
Annual gas consumption
Ton
37,000
VIII
Single-shift operators（including forklift and boiler gas distribution）
People
16
IX
Total plant construction area
Hectare
3.5
Construction area
m2
5,200
Storage covering area
m2
10,000
Main technical-economic indicator
No.
Index content
Unit
Index value
I
Description
sand-lime brick
Specification
mm
240×115×53
Production scale
pcs/year
100,000,000
II
Working system（three-shift continuous weekly production）
300 days / year 22.5 hours / day 7.5 hours / shift
III
Main raw material consumption
1 .Fly ash
Ton/ year
161,000
2 .Sand
Ton / year
46,000
3 .Quick lime
Ton / year
23,000
IV
Total capacity
KW
About 1,150
V
Annual power consumption
0,000ＫＷ.h
260.4
VI
Annual water consumption
Ton
54,100
VII
Annual gas consumption
Ton
26,500
VIII
Single-shift operators（including forklift and boiler gas distribution）
People
16
IX
Total plant construction area
Hectare
3.5
Construction area
m2
5,000
Storage covering area
m2
10,000
Main technical-economic indicator
No.
Index content
Unit
Index value
I
Name
AAC sand-lime brick
Specification
mm
240×115×53
Production scale
pcs/year
70,000,000
II
Working system（three-shift continuous weekly production）
300 days / year
22.5 hours / day
7.5 hours / shift
III
Main raw material consumption
1 .Fly ash
Ton / year
112,700
2 .Sand
Ton / year
32,200
3 .Quick lime
Ton / year
16,100
IV
Total capacity
KW
About 820
V
Annual power consumption
0,000ＫＷ.h
185.68
VI
Annual water consumption
Ton
37,820
VII
Annual gas consumption
Ton
18,500
VIII
Single-shift operators（including forklift and boiler gas distribution）
People
14
IX
Total plant construction area
Hectare
30
Construction area
m2
3,000
Storage covering area
m2
8,000
Main technical-economic indicator
No.
Index content
Unit
Index value
I
Description
AAC sand-lime brick
Specification
mm
240×115×53
Production scale
pcs/year
50,000,000
II
Working system（three-shift continuous weekly production）
300 days / year
22.5 hours / day
7.5 hours / shift
III
Main raw material consumption
1 .Fly ash
Ton / year
80500
2 .Sand
Ton / year
23000
3 .Quick lime
Ton / year
11500
IV
Total capacity
KW
About 780
V
Annual power consumption
0,000ＫＷ.h
176.7
VI
Annual water consumption
Ton
27000
VII
Annual gas consumption
Ton
13200
VIII
Single-shift operators（including forklift and boiler gas distribution）
People
14
IX
Total plant construction area
Hectare
30
Construction area
m2
3000
Storage covering area
m2
8000
Maxpressing force
13,000 KN
Working beam max. stroke
680 mm
Distance between lower plane & working table for working beam
Max. 2,040 mm
Min. 1,360 mm
De-mould cylinder max. stroke
600 mm
Max. de-mould force
2,000 KN
Clearance distance between both columns
1,600 mm
Brick-feeding effective area in the middle frame
1100×860mm
Front & back width of base table
1200 mm
Front & back width of working beam plane
940 mm
Max. feeding depth
320 mm
Max. working frequency (sand-lime brick)
4.3 times／min
Mainmotorpower
110 kW
Total weight
62 tons
Main technology
1.Three-rows feeding type, 48pcs sand-lime bricks per time, annual production up to 70,000,000-80,000,000 pcs.
2.Main machine adopts optimized split beam & new type de-moulding structure, higher reliability, anti-fatigue.
3.Main cylinder uses large-through underneath prefill valve, hydraulic system uses a large flow constant power pump & large capacity accumulator oil supply system, to ensure the high speed, high production efficiency. The master cylinder adopts proportional pressure control technology, can realize flexible compression, better for brick-pressing.
4.Moving beam up & down , a middle frame movement & charging car front and back movement all use advanced proportion servo control technical, to ensure smooth movement, accurate positioning. For example, charging car closed-loop control ensure the positioning accurancy less than 2mm.
5.skip before and after motion moves are used advanced proportional servo control technology, to ensure that the control action of the soft and smooth, location is exact and reliable. For example, vehicle closed-loop control can ensure the precision of front and rear position error is less than 2mm, greatly reducing the probability of brick inserted stacking machine.
6.Weight system along with charging car uses new hammer type, middle frame move more freely, column positioning more reliable and accurate.
7.Stacker assembly uses servo motor control, quick & stable, accurate positioning, high accuracy for brick-stacking
8.Important purchased part, such as main cylinder, sealing of de-moulding cylinder; proportional valve & electrical control components all uses foreign famous brand, to ensure stability & reliability.
9.Complete function for spare parts or other choose equipments, satisfy different requests for different clients. For example, choose small de-mould valve group to increase de-moulding force, it used for pressing 15pcs large blind brick; stacking machine can choose ordinary stacker or stacker with rotation function or robot stacker etc.
(1) Quick lime
Quick lime is according to JC/T621-1996 Quick lime for Silicate building products,
CaO+MgO≥75% MgO≤5% CO2≤5% SiO2≤5%
(2) Fly ash
The fly ash is according to JC/T409—2001 fly ash for silicate building products, the main technical indexes as below: Chart 2-1 Main technical indexes for fly ash
Name Grade
SiO2%
SO3%
Ignition loss %
Fineness(residue on sieve by 0.045mm square hole sieve)%
I
≥45
≤1.0
≤5
≤30
II
≥40
≤2.0
≤10
≤45
Fly ash radioactivity should be according to GB6763-2000.
(3) Quartz sand
Selection should be according to JC/T 622 sand for silicate building product. Generally, the higher quartz content, the better AAC sand-lime quality. Chart 2-2 Main technical indexes for sand
Name Grade
SiO2%
K2O+Na2O%
Organic matter
Mica
SO3
mud
Moisture content
High-class
≥85
≤1
Qualified
≤0.5
1
3
8
First-class
≥75
≤3
5
Qualified product
≥65
≤5
≤1
2
8
Chart 2-3 Grain composition for sand
Name Grade
Content, %
High-class products
First-class
Qualified product
2.5～5.0（round hole）
0
0
1.25～2.5（square hole）
10
10
0.16～0.25（square hole）
60
45
＜0.16（square hole）
30
45
Product specification in accordance with national standard of JC 239-2001 fly ash brick, also can produce product of special specification depend on customers requirements. The standard fly ash can be used as wall & foundation of industry & civilian construction, But brick strength of grade MU15 and more than it must be used for foundation or construction site which is frost-susceptible and in the alternation of wetting - dry.
Level Strength level divided into MU30,MU25,MU20,MU15,MU10 Quality grade divided into high-class(A), first-class(B), qualified product (C) according to the size variation, appearance quality, strength grade, drying shrinkage. Chart 1-1 Fly ash brick indicator
Item
Sand lime brick
Specification
240×115×53mm，multi sizes for various requirements
Weight
2.1～2.4Kg/ pcs（controlled by formula）
After autoclave compressive strength
15～20MPa
Drying shrinkage value
Measured under condition of rapid method≤0.6mm/m；Measured under condition of standard method≤0.5mm/m
Frost-resistance
After the cycle of freezing and thawing for 15 times，weight loss≤5%，strength loss≤20%
Coefficient of thermal conductivity
≤0.16W/m.k
Chart 1-2 Appearance quality(mm)
Item
Indicator
High-class （A）
First-class（B）
Qualified product （C）
Permissible variation of dimension length width height
±2 ±2 ±1
±3 ±3 ±2
±4 ±4 ±3
Corresponding height variation ≤
1
2
3
Min. damage size of each missing angle≤
10
15
25
Finished face not less than
Two side faces and one end face or two end faces and one side face
One side face and one end face
One side face and one end face
Crack length ≤ a. Width directional cracks of bedding face (including the length extended to side face) b. Other cracks
30
50
50
70
70
100
Lamination crack
Not allowed
Remark: It is unfinished face that the damage size on side face or end face both bigger than 10mm and 20mm.
Chart 1-3 Fly ash brick strength indicator MPa
2.2 Strength grade Strength grade should be according to Chart 2, the high-class strength not less than MU15. Chart1-4 Fly ash brick frost-resistance indicator
Strength grade
Compressive strength MPA average value≥
Dry weight loss(%)of single block ≤
MU30
24.0
2.0
MU25
20.0
2.0
MU20
16.0
2.0
MU15
12.0
2.0
MU10
8.0
2.0
2.3 Drying shrinkage Drying shrinkage value: high-class and first-class not more than 0.65mm/m; qualified product not more than 0.75mm/m
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