Tengyu Machinery specializes in the production of aerated block/panel equipment and aerated panel production lines. Below, we will introduce the process flow of the aerated concrete production line, hoping to help bosses who want to understand aerated block equipment.

a. Fly ash/sand is directly stored in the fly ash warehouse using tank trucks for standby. After lime and gypsum enter the factory, they are crushed and ground. When the fineness of the mixture reaches 3500-4000cm2/g, it is lifted to the fly ash warehouse for standby by a bucket elevator. The entire production line can not only produce fly ash aerated products but also produce sand aerated concrete products. The raw material handling and main dust prevention points are equipped with advanced pulse dust removal equipment to ensure compliance with the "Comprehensive Emission Standard for Air Pollutants" GB16297-3012.

b. Mixing and stirring: The gray slurry, lime powder, and cement are measured separately and added in sequence to the pouring mixer for mixing. During stirring, a certain amount of steam is introduced into the mixer according to process requirements, raising the slurry temperature to about 40-45℃. The stirring time is about 2-3 minutes. The aluminum powder metering system realizes a series of operations such as aluminum powder storage, metering, and slurry preparation, producing aluminum powder suspension for standby. Before discharging the slurry, the lower valve of the aluminum powder mixer is opened to allow the aluminum powder suspension to flow into the pouring mixer for mixing, with a stirring time not exceeding 40 seconds, and then the slurry is poured into the mold. The entire cycle takes about 4 minutes, and the whole system uses centralized computer control to achieve fully automatic batching control, enabling remote operation and fault diagnosis.

c. After pouring, the molds are de-bubbled using a bubble sorting machine, and then transferred to the static curing area via a frequency conversion ferry for initial setting. The curing temperature is about 40-45℃, and the mold box is pulled by friction wheels to ensure smooth operation to the curing room. The pre-curing temperature of the entire static curing room can be automatically controlled, with a static time of 90-130 minutes. After reaching the cutting strength, the molds are pulled out of the static curing room.

d. The green body is placed on the cutting cart using a flipping hoist. The cart processes the green body through longitudinal cutting, slotting, and die cutting to achieve six-sided cutting of the green body, reaching the corresponding Specification Size (size error within ±1mm). After cutting, the green body is hoisted to the peeling device for flipping, and the bottom waste is recycled. Then, the semi-finished product hoist lifts the green body along with the side panels to the steam curing cart for grouping. The cutting machine has high rigidity, does not deform, has high equipment precision, and good wear resistance, ensuring long-term cutting precision of the products. The wastewater and waste generated during the production process are recycled through the waste recovery system and re-mixed with new slurry for secondary use, with all waste from the cutting process being fully recovered.

e. In cold conditions, a pre-curing kiln is added in front of the autoclave to ensure that the green body is not affected by the low-temperature environment during grouping, while appropriately reducing the steam curing cycle.

f. The green body enters the autoclave for steam curing, with a curing time of about 8-10 hours. During the entire steam curing process, the autoclave generates a large amount of residual steam and condensate. The design of the entire production line fully utilizes the residual steam and condensate discharged from the autoclave. The residual steam generated by the autoclave can mainly be used to preheat the products and the autoclave body temperature, and the remaining residual steam can be used as a heat source for the static curing room and slurry heating. In cold regions, it can also be used for heating. The condensate generated by the autoclave, due to containing harmful substances and irritating odors, cannot be used directly for living purposes, but its residual heat can be used to heat production and domestic water through a heat exchanger, while the condensate can be used for batching and wet grinding processes, saving water and protecting the environment.

g. After steam curing, the green body is stacked and automatically packaged. The separated molds are transported by cart to the molding area for cleaning and oiling before being reused.