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Sand Lime Brick Production Line

a) Smooth technology flow with advanced design idea, well matching of configuration and output exert the equipment performance as much as possible.

b) First offer turn-key project service of the industry, including products R&D, design, manufacture, EP, EPC and management control.

c) Press KDQ1300 pressing force can be 13000KN, 48 pcs standard brick can be pressed/template, 24 pcs blind hole brick can be pressed, pressing speed can be up to 3.5 times, and its annual output can be up to 60 million pcs.

d) Press KDQ1300 crossbeam stroke can be 650mm and the headroom can be up to 1290mm. It is suitable for standard brick, blind hole brick, blind hole building block and through hole building block pressing, max suitable size is 480x240x190. Single line investment for variable products is available.

e) Auto stacker functions body clamp, convey and place. Modular design enables the machine frame, lift and robot adjustable as needed. Speed regulating with inverter and servo mo

 Main technical parameters

1.Max. pressing force         
                                         13,000   KN
2.Working beam max. stroke   
                                    680   mm
3.Distance between lower plane & working table for working beam          Max. 2,040  mm 
                                                                          Min. 1,360  mm
4.De-mould cylinder max. stroke 
                                      600   mm
5.Max. de-mould force        
                                       2,000   KN
6.Clearance distance between both columns    
                             1,600   mm
7.Brick-feeding effective area in the middle frame      
                      1100×860mm
8.Front & back width of base table                  
                               1200   mm
9.Front & back width of working beam plane       
                           940   mm
10.Max. feeding depth                      
                                 320   mm
11.Max. working frequency (sand-lime brick)        
                         4.3  times/min
12.Main motor power                           
                             110   kW
13.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.
 



Main technical-economic indicator

 
No. Index content Unit Index value
I Description
sand-lime brick
Specification mm 240×115×53
Production scale 0,000pcs/year 14,000
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 0,000pcs/year 10,000
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

0,000pcs/year

7,000

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

0,000pcs/year

5,000

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


 

Main technical-economic indicator


No. Index content Unit Index value
I Description   
 sand-lime brick
Specification mm 240×115×53
Production scale 0,000pcs/year 3,000
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 48,300
2 .Sand Ton / year 13800
3 .Quick lime Ton / year 6900
IV Total capacity KW About 650
V Annual  power consumption 0,000KW.h 147.18
VI Annual  water consumption Ton 16500
VII Annual  gas consumption Ton 8000
VIII Single-shift operatorsincluding forklift and boiler gas distribution People 14
IX Total plant construction area Hectare 20
Construction  area m2 3060
Storage covering area m2 5000
 

 

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.
 

2.1 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 method0.6mm/mMeasured under condition of standard method0.5mm/m
Frost-resistance After the cycle of freezing and thawing for 15 timesweight loss5%strength loss20%
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    
Strength grade Compressive strength Breaking strength
10 pcs average value≥ Single piece value≥ 10 pcs average value≥ Single piece value≥
MU30 30.0 24.0 6.2 5.0
MU25 25.0 20.0 5.0 4.0
MU20 20.0 16.0 4.0 3.2
MU15 15.0 12.0 3.3 2.6
  MU10 10.0  8.0      2.5  2.0

 
 

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

 

(1) Quick lime

Quick lime is according to JC/T621-1996 Quick lime for Silicate building products,
CaO+MgO75%     MgO5%       CO25%    SiO25%


(2) Fly ash
The fly ash is according to JC/T4092001 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

 

 

Features


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. 
4. A few waste bricks might be left after the production process. These bricks will be crushed into aggregates, which can then be added to the autoclave for repeated use. Turning wastes into valued raw material helps customers achieve significant cost savings.

 

 

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


图片3.png

 

(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 35004000cm2/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 machines 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.  

 (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 machines 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.  

 (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 machines 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.

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