When planning an AAC block plant, the production scale needs to be decided first. It is not a random decision but a careful choice based on research on market demand for AAC blocks. Besides, the capital quantity is a restraining factor. The daily and annual capacity of the aac plant directly influences the layout of the AAC block plant. Let’s look at what are the common capacities of an aac plant first.
The capacity of the AAC block Plant
The annual capacity of an AAC block plant normally starts at 20,000 cubic meters. The typical anuual capacity are 30,000M3,50,000M3, 100,000 M3, 150,000 M3, 200,000 M3, 300,000 M3, 400,000 M3, 500,000 M3, 600,000 M3.
Among those capacities, 50,000M3 is a production scale that is easily acceptable by most investors. Since many new investors found out that when the initial production capacity is too small like 20,000M3 or 30,000M3, it is more likely that they need a second investment to upgrade the AAC block plant. Today we will list out the AAC block making machines in the 50,000 m3/year aac block plant. A simple plan for the AAC block plant layout will also be given.
The layout of 50,000 m3/year AAC block plant
The factory covers an area of 15-20 mu, according to the actual situation.
The AAC production line is equipped with raw material processing section, batching section, pouring section, pre-curing section, demolding section, cutting section, autoclaving section, and packing section.
The construction cycle is 3-5 months from civil construction to equipment installation, commissioning, trial production, and production.
AAC block machines needed in 50,000 m3/year AAC block plant
AAC block machines are necessary equipment in the manufacturing of aac blocks. The following table is a list of equipment needed in the 50,000 m3/year AAC block plant.
|1. Lime & Gypsum Crushing & Grinding|
|101||Block lime hopper||1||Lime storage, chute bucket|
|102||Jaw crusher||1||15||Crushing block lime|
|103||Bucket elevator||1||4||Lift block lime|
|104||Small-sized limestone silo||1||Storage, moisture-proof|
|105||Manual rubber-lined butterfly valve||2||Feed materials to ball mill|
|106||Electromagnetic vibration feeder||1||0.2||Adjust feed size, repair use|
|107||Ball mill||1||90||Grind lime|
|108||Bucket elevator||1||7.5||Lift block lime|
|109||Lime powder silo||1||Store lime powder|
|110||Cement silo||1||Store cement, moisture-proof|
|2. Sand making system|
|201||Sand hopper||1||Store sand|
|202||Belt conveyor||1||5.5||Transport sand|
|203||Mix hopper||1||Mixing sand and water|
|204||Ball mill||1||130||Grind sand|
|205||Vertical slurry pump||3||15*3|
|3. Dosing & batching system|
|301||Cement white ash measuring tank||1|
|302||Slurry measuring tank||1||Measuring slurry|
|303||Aluminum powder mixer||1||0.75|
|304||Uniform speed feeder||1||3|
|305||Pouring mixer||1||30||Pour mixed slurry into the mold|
|306||Pouring ferry cart||1||11||Ferry the mold to the pre-curing room via the rail|
|307||Manual rubber-lined butterfly valve||2||Opening and closing of various materials|
|309||Mold pulling machine||4||12|
|4. Cutting system|
|404||4.2m cutting machine||1||23 .5||Variable frequency variable speed|
|405||Waste material slurry mixer||2||15|
|5. Autoclaving system|
|503||Curing car pulling machine||2||4.4|
AAC plant manufacturing process
- Raw material storage and supply
All the raw materials are transported to the factory by trucks. Sand is assembled at the raw material site and loaded into hoppers. Cement is stored in the cement silo. When it is in use, it will be loaded and transported by the hopper. Chemicals and aluminum powders are placed separately in bins and transported to the workshop when in need.
- Raw material processing
The sand is sent to the ball mill by a vibrating feeder and belt conveyor. The fine ground material will be made into slurry and stored in the slurry tank. The lime block is crushed by the jaw crusher. The crushed lime is sent to the storage bin by the bucket elevator. The lime is then sent to the ball mill through the screw conveyor. The ground material is sent to the powder distribution bin by screw conveyor and bucket elevator. After manual measurement of chemicals in a certain proportion, a slurry of a certain concentration is made and sent to the storage tank for storage.
- Batching, mixing, and pouring
The lime and cement are successively delivered to the automatic measuring scale by the screw conveyor under the powder mixing bin. The screw conveyor under the scale can evenly add the material into the pouring mixer. Sand and waste pulp are measured in the metering cylinder, and the slurry can be stirred when the mold is in place after the measurement of various materials. The slurry should meet the process requirements (about 40℃) before pouring. If the temperature is not enough, the slurry metering tank can be heated by steam, and the aluminum powder suspension can be added 0.5 ~ 1 minute before the material is poured.
- Pre-curing and cutting
After pouring, the mold is pushed into the curing room with a conveyor chain for the initial setting. The room temperature is 50 ~ 70℃, and the curing time is 1.5-2 hours (according to favorable geographical conditions, this process can be eliminated). After the curing, the mold frame and the green cake are hoisted together to the cutting table where the bottom plate is placed in advance with a negative pressure sling. The mold frame is removed. The green cake is vertical and longitudinal cut by cutting machines. The mold frame is lifted back to the mold car for manual cleaning and oil removal and then lifted to the mold car for the next pouring. The cut green cake is together with the bottom plate to the curing car and stacked in two layers. Curing cars are divided into groups. The waste produced during cutting is sent to the waste slurry mixer by screw conveyor, and water is added to make the waste slurry, which is to be used when batching.
- Autoclaving & finished processing
The group of green cakes is assembled on the stop line in front of the autoclave. Open the autoclave door to exit the autoclaved blocks. First, pull out the finished autoclave with the hoist, and then pull the curing carload of green cakes into the autoclave with the hoist. The finished products are lifted to the finished product warehouse by the bridge crane and then transported to the finished product yard by the fork-loading truck. The empty curring car and the bottom plate are lifted back to the carriage return line, and the hoist is used to pull back to the yard for the next cycle after cleaning.