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.
Processing period
Mixing period: 4-6 minutes
Digestion period: 2.5~3hours
Twice mixing period: 4-5 minutes
Pressing formation: 3-3.5 times/ minute
Autoclaved curing system
Before-after autoclave: 0.5h
Vacuumize: 0.5h(0~-0.05MPa)
Lifting pressure: 1.5h(0.05~1.3MPa)
Constant pressure: 6h(1.3MPa)
Releasing pressure: 1.5h(1.3~0MPa)
Total: 10h
(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 | |
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 | |
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 |
Max pressing 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 |
Main motor power | 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 | 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 | 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 | 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 | First-class(B) | Qualified product | |
Permissible variation of dimension | | | |
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 ≤ | | | |
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
2.4 Carbonation performance
Carbonation coefficient Kc ≥ 0.8