China AAC Waste Remover

plant dataplant type:tilt cake system
product range-actual
-blocks :100%(optionally profiled)
dry density range : 500 - 600 kg/m3
Mould type
gross size :4120x1260x670
net size cake : 4000x1200x600
net cake volume :2.88 m³
Production data
-shifts/day:3shifts/day(7.5hours effective per shift)
-Cakes/day :122
-Production rate (cycle time) :5.5min/cake
Theoretical capacity :350 m³/day
Basic assumptions
-working days/year :300
-rising time:2hours
-autoclaving cycle: 12 hours (incl. loading/unloading)
Remarks:
The above mentioned theoretical capacity does not include possible production waste, broken material, reduction in net volume, etc.
This capacity is calculated on the basis that above mentioned rising and autoclaving times can be met and is considered at a 100% mould utilisation. These times are very depending on the quality of the raw materials and other conditions which are under the responsibility of the Purchaser. These times might also extend in case of increased future reinforced element production.
product range and pack sizesrange -blocksThe following products to be manufactured and packed on wooden pallet (pallet type wooden pallet of 1200 x 1200 mm) according following table:
Pack LenghtPack WidthPack Height 12x100=12002x600=12006x200,or 5x240,or4x250=1200mm10x120=12002x600=12006x200,or 5x240,or4x250=1200mm8x150=12002x600=12006x200,or 5x240,or4x250=1200mm6x200=12002x600=12006x200,or 5x240,or4x250=1200mm5x240=12002x600=12006x200,or 5x240,or4x250=1200mm4x300=12002x600=12006x200,or 5x240,or4x250=1200mm Dimensional accuracyAccuracy of cutting:
- length of the block: ± d2 mm (repetitive)
- height of the block: ± d1,0 mm (repetitive)
- thickness of the block: ± d1,0 mm (repetitive)
5. Indication general labour force plan
An indication of man power required to operate the plant is shown in the labour force plan below:
Per shiftCommentMixing and dosing and rising area
- Mixer & aluminium dispersion preparation1 Slurry preparation system
- Supervision of sand preparation and partial duties in
mixing section1* Production section
- Cutting plant, including tilting crane and platform
return
- Mould oiling
- frame brushing and oiling
- Platform brushing
- stacking pin insertion and extraction1
1
1
1autom. option
autom. option
automaticAutoclave section and steam production
- Autoclaves & steam boiler
- Autoclave traverser(1)*
1 Loading & unloading section
- Unloading crane
- Packaging and sorting1
2-3autom. optionEmployees needed per shift in the production plant: (excl. options)11-12 Supervision & Auxiliary - Laboratory
- Supervision
- Maintenance1
1
1 - 2 Employees needed per shift needed for Supervision & Auxiliary: (excl.options)3 - 4
Standard raw material specification and consumption values
1. Requirements for raw materials
The following raw material specifications are standard values as used in several aerated concrete plants.
1.1 Quartz Sand
SiO2min.80%by weightFe2O3max.3%by weightAl2O3max.7%by weightCaOmax.10%by weightMgOmax.3%by weightSO3max.1%by weightNa2Omax.2%by weightLoss on ignitionmax.10%by weightResidue on 0,063 mm screenmax.5% 1.2 Ground quick lime
CaOmin. 75%by weightMgOmax.2.0%by weightSO3max.1.0%by weightLoss on ignition
t 95 % passing through a 100 µm sievemax.5.0%by weightCaO values below 92% by weight increase the lime consumption correspondingly.
Typical reactivity:
2 minutes:35°C± 4°C TO 45°C± 3°C5minutes:45°C±3°C TO 50°C± 2°C10minutes:60°C± 3°C TO 67°C± 2°C20 minutes:66°C± 2°C TO 72°C± 2°C30 minutes:69°C± 2°C TO 73°C± 2°C40 minutes:70°C± 2°C TO 74°C± 2°C(Test conditions: 600 ccm distilled water at 20°C ± 0.5°C and 150 g ± 0.1 g of unslaked lime).
1.3 Portland Cement 45 N/ mm²
Fineness (Blaine)3,500~4,000 cm²/gSetting timesInitial 160~260 minutesFinal 300 minutes Compressive strength of the test cube3 days 20-25 N/mm²7days 30-35 N/mm²28days 40-45 N/mm²Alcalinity0.4 - 0.8%
1.4 Ground, natural anhydrite
CaSO4 min. 80 % by weigh
t 98 % passing through 150 µ sieve
Gypsum or synthetic anhydrite may be used as an alternative; properties have to be established by appropriate tests.
1.6 Aluminium powder
metal content 90 - 95 %
Max. oversize with 45 µ 20 - 50 %
Average grain size20 - 45 mµ
Specific surface area acc. to Blaine Fatty acids10,000 - 20,000 cm²/g max. 1.5 %
1.7 Water
Potable water without any components that are detrimental to concrete. In order to obtain the right mix temperature the water shall be supplied from a cold as well as a hot water source.
1.8 Assumed temperature of raw materials
Sand slurry35° C max.Lime20° C max.Cement20° C max.Anhydrite20° C max.Production water coldca. 15° CProduction water hotca. 90° C
2. Consumption values
According to our experience following consumption values may be used as indicative values. The specific raw material consumption will depend on the quality of the raw materials and the desired dry density and compressive strength of the finished product.For various dry density classes from 500 to 600 kg/m³ and average raw material quality, following typical consumption values may serve as a guideline for the production of 1 m3 AAC blocks:
Raw material vs. dry density500 kg/ m3600 kg/ m3Sand292 kg352 kgLime62 kg98 kgCement99 kg99 kgAnhydrite18 kg21 kgWater (total, excl. steam)382 kg442 kgAluminium (metal powder)0,46 kg0,39 kgTotal solids471 kg570 kgFor the production of AAC panels additives (e.g. MgO) are needed to adjust the shrinkage of the AAC relative to the steel reinforcement . Further it is not advisable to produce AAC panels using flyash.
average consumption
per m³ of AACElectrical power consumptionca. 18- 21 kWhSteam consumption (water)ca. 180 kgNatural gas consumption
(dependant on boiler and foiling)ca. 11 - 14 m³

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Contact Person:Dale Huang
Mob:+86 13915206061