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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



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(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 systemthree-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 operatorsincluding   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   systemthree-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   operatorsincluding 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 systemthree-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 operatorsincluding 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 systemthree-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 operatorsincluding 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  timesmin

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
  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

2.55.0round hole

0

0

1.252.5square hole

10

10

0.160.25square hole

60

45

0.16square 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

240×115×53mmmulti sizes   for various requirements

Weight

2.12.4Kg/ pcscontrolled by formula

After autoclave compressive strength

1520MPa

Drying shrinkage value

Measured under condition of rapid method≤0.6mm/mMeasured under condition of standard method≤0.5mm/m

Frost-resistance

After the cycle of freezing and thawing for 15 timesweight 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-classB

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
 
 
2.4  Carbonation performance      
Carbonation coefficient Kc ≥ 0.8

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