50,000 m3 aac line technical introduction of zhengzhou deyi

DEYI HEAVYINDUSTRIAL

Company Profile>>>

Jointly established by national institutes, Zhengzhou Deyi Heavy Industrial Machinery Manufacturing Co., Ltd. is one of the earliest, large-sized, high-tech enterprises specialized in mass production and export of equipment for new wall materials. Integrating product development, production and marketing, Deyi is equipped with over 100 sets of production equipment, internationally advanced production lines and a first-rate modern test base. Covering a land area of 52,000 m2, the company mainly manufactures large-sized hydraulic brick-making machines, steam-pressing production line equipment, and aerated concrete equipment. Among our employees, over 20% of us are engineering technicians.

Over the past two decades, Zhengzhou Deyi Heavy Industrial Machinery Manufacturing Co., Ltd. has grown to be manufacturer strong in product development, mechanical working, rivet welding and assembly. Advanced technology, diversified products, stable quality and efficient service have made Deyi the leader in wall machinery manufacturing industry. Our products have been widely sold in twenty provinces and municipalities across the country and in such international markets as Malaysia, Egypt, Russia, Kazakhstan, Azerbaijan, Turkey, Kuwait, South Africa and India. Excellent product quality is the promise of DEYI person, perfect after-sales service and technical support is the aim of the DEYI people! DEYI sincerely welcome merchants and friends from home & abroad to visit us!

Profession from DevotionLeading from Innovation

Technological innovation & Elaborate manufacture

T e c h n i c a l P r o c e s s & E q u i m e n t C o n f i g u r a t i o n o f A n n u a l 5 0 , 0 0 0m 3 A A C P r o d u c t i o n L i n e

The whole aac production line includes four big processes, like raw material preparation, mixing & pouring, static curing & cutting, and steam curing & packing.

irst,Technical Process of AAC Production LineF

1.Raw Material Preparation SectionFirst, Raw Material Preparation (Equipments: Jaw crusher, Bucket elevator, Silo, Electronic Vibrating Feeder, Ball Mill, Mould, etc. Fly ash is conveyed into ball mill by electromagnetic vibrating feeder and belt, then sent to the pulp storage bins through fly ash pump. Lime is sent to jaw crusher to crush by electromagnetic vibrating feeder and belt, after crushed, were lifted into lime silo by bucket elevator and then grinded into fine lime by grinding ball mill conveyed by screw conveyor, material is conveyed into powder batching by screw conveyor.


3. Static Curing & Cutting Section(Equipments: Static stop maintenance room) After pouring, mold should be sent to static stop maintenance room for preliminary condensation, the temperature should be 50 to 70℃ for 1.5-2 hours. (According to the geographical advantages, the process can be discharged). (Equipments: aac block cutting machine, air compressor, Recycling mixer) After pouring and foam, green body should static stop to certain degree of hardness (about 1 hour), then cutting, before cutting, the green body will be through the flip cutting machine to turn 90 degrees, first vertically cutting, and then horizontally cutting.

4. Steam curing & Packing Section (Equipment: steaming larry, winch, autoclaves, boiler, etc.) Finished grouping steaming larry will be sent to autoclaves by the slowly winch, after 8-10 hours block in autoclaves, the finished blocks will be pulled out at the end of the autoclave. A semi-finished crane hoist will send the blocks with side panel to conveying groove, then the blocks would be sent to wooden pallets in the packing line by a finished crane hoist. The worker or automatic packing machine will pack the blocks, then they will be put together in the finished goods yard. The empty side panel return and go on its cycle after cleaning.

2. Mixing & Pouring Section (Equipments: Screw conveyor, Silo, Aluminum mixer, Pouring machine, Control system, etc. Fly ash slurry will be measured by slurry electronic measurement in ingredients center. Lime, cement are sent by spiral feeder to measure. Then all the raw materials will be sent to pouring mixer machine by feeding equipment for high-speed mixing, All measurements are through PLC automatic central ized control to assure accuracy and continuity of measurement. After a few minutes, then the arm of casting machine starts pouring




econd, Introduction of AAC BlockSAutoclaved Aerated Concrete (AAC) block plant is widely used in industrial and civil construction over 60 years, as building material with the most mature technology of production and application with many advantages as bellow:

Introduction AAC blocks can be made into wall blocks, insulation blocks, pressed panels, floor, wall and pipe insulation and other products, aerated blocks in our country have already been widely used in industrial and civil buildings in load-bearing or non-load-bearing structures and pipe insulation, and become a new an important part of building materials.

AAC Block:Length: 600mmHeight: 200, 240, 250, 300mmWidth: 75, 100,125, 150, 175, 200, 250mm 60, 120, 180, 240mm

Product Variety

Volume grade: 500, 600, 700 kg/m3 (05, 06, 07).Pressure enduring grade: 3.5, 5.0, 7.5Mpa (35, 50, 75 level).Dry shrinking: ≤0.8mm/m.Heat conduction ratio: 0.11-0.22Kcal/m.h.℃.

Sound insulation: 40-47.45Db.We produce according to the AAC block technology requirements of GB/T11968-2006 of People’s Republic of China.

Quality

The main raw materials are: fly ash（sand), l ime, cement, gypsum, aluminum powder, water. Power mainly from: Electricity, Steam water(energy from burning coal, diesel and natural gas, etc)Difference of blocks with sand and fly ash: Sand block is1. A little heavier; 2. Higher compressive strength; 3. Better impermeability; 4. Better product quality and performance ( due to lower shrinkage of sand); 5. More widely processed as block or plate, sheet also can bring facing;6. Higher power consumption, higher prices due to the need of mill grinding by wet type ball mill.

Main materials & differences:


1.Lightweight: usually 450-700kg/m32.High Strength3.Sound proof4.Fire Proof5.Thermal Insulation6.Eco friendly and Energy Efficient7.Easy processed

Advantages


hird, Raw Material PropotionTFly Ash: Gypsum: cement: lime = 73%: 3%: 3% :18-22%(Recommended)Sand: Gypsum: cement: lime = 63%: 3%: 10% :18-22%(Recommended)

Sand AAC Block Material ProportionParameter Name Parameter Value

Sand 55-65%

Cement 10-20%

Lime 18-22%

Gypsum 2-5%

Aluminum powder paste 0.08%

Water & material rate 0.65-0.75

Casting system 35-38 ℃

Aluminum mixing time 30-40 S

Fly Ash AAC Block Material ProportionParameter Name Parameter Value

Fly ash 65-73%

Cement 3%

Lime 18-22%

Gypsum 3-5%

Aluminum powder paste 0.08%

Water & material rate 0.60-0.65

Casting system 35-38 ℃

Aluminum mixing time 30-40 S

NO. Equipments Name Specifications Quantity(Set) Power (Kw) Function Remark

Part 1 Raw Material Preparation Section

1.1 Jaw Crusher PE250×400 1 15 Crush quicklime

1.2 Bucket Elevator HL250×11m 1 4 Lift bulk lime

1.3 Silo Φ2.5×4.7m,V=20m3 1 / Storge lime grain Self-made

1.4 Manual valve Φ300 1 Control baiting

1.5 Vibrating Feeder GZ3，Q=8-20T/h 1 0.2 Feed uniformly

1.6 Ball Mill (Dry type) Φ1.2×4.5m 1 90 Mill quicklime

1.7 Separator Φ1.2×4.5m 1 Separating fine and corse materials

1.8 Bucket Elevator HL250×18m 1 7.5 Lift fine lime to silo

1.9 Lime Silo Φ2.5×4.7, V=20m3 1 / Storge lime Self-made

1.10 Cement Silo Φ2.5×4.7, V=20m3 1 Storge cement Self-made

1.11 Manual valve DN250 2 Control baiting

1.12 Sand hopper 1 Bating Self-made

1.13 Belt conveyor B650×8m 1 5.5 (Sand only)

1.14 Ball Mill (Wet type) Φ1.5×5.7m 1 130 Making sand slurry

Part 2 Slurry Making & Pouring Section

2.1 Slurry Mixer Φ2.2×2.2m 2 22 Slurry making

2.2 Slurry storage mixer Φ4×4m 1 22 Storge slurry

2.3 Manual valve DN250 2 Control baiting

2.4 Screw Conveyor Φ250*3.5m 2 6 Convey lime and cement

2.5 Cement &Lime Measuring Tank Φ1.2*1.5m,G=700kg 1 Cement & lime measuring

2.6 Slurry flow tank Φ1.8*1.5m,G=3000kg 1 Slurry measuring

2.7 Pneumatic valve Φ200mm×2,Φ250mm×1 3 Pneumatic control baiting

2.8 Air Compressor w-1.0/8：8kg：1.0m3/min 1 7.5 Open valve

2.9 Screw Conveyor Φ250*1.2m：60r/min,14.8T/h， 1 3 Convey materials to mixer

2.10 Fluid pump 80YZ80-20 3 45 Convey slurry

2.11 Aluminum Powder Mixer Φ：500×550mmV=0.052m3 1 0.75 Ming & making slurry

2.12 Batching System DY-5W 1 Automatic control

2.13 Fly ash rotary screen 1 1.5 Screen coarse cinder

2.14 Pouring mixer Φ:1.8m,4.0m3 1 30 Mixed slurry mixing

2.15 Pouring Ferry Vehicle 4300×2600×650mm 1 11 After pouring, sent to static curing

Part 3 Static-Curing & Cutting Section

3.1 Mould Tractor QY.00 4 12 Drag green body to overturn crane

3.2 Mould 4300×1300×650mm 10 Foaming & moulding

3.3 Side Plate 4400×650×130mm 46 Support mould

Part 4 Cutting Section

4.1 Overturn Crane Q=2×5T,L=10.5M 1 22 Lift for cutting

4.2 Overturn Sling FZDJ-4.2 1 7.5 For cutting & marshalling

4.3 Rail Conveying Line 10+10 10 4.44 Convey side plate

4.4 Cutting Machine Unit JQKF4.2 1 23.5 Cut green body

4.5 Overturn Crane Q=2×5T,L=10.5M 1 22 Lift body to curing car

4.6 Semi-product Sling BCPDJ-4.2 1 7.5 Move green body to curing car

4.7 Waste Slurry Mixer Φ2.2*2.2m 2 15 Recycling use

Part 5 Coding & Steam-curing Section

5.1 Tractor QZ.00 2 4.4 For static curing

5.2 Steam-curing Car 4420×1200×240mm 21 Support die shoe

5.3 Winch 3T 2 15 Drag curing car in & out of autoclave

5.4 Autoclave Φ2×26.5m 2 Selective buying

5.5 Boiler 4T 1 Selective buying

5.6 Traveling Crane 5T 1 10.8 Convey finished product

5.7 Sling CPDJ-4.2 1 Lift product to vehicle

outh, Annual 50,000m3 AAC Production Line Equipment List(Sand)F


Annual output（m3) 30000-50000 100000 150000 200000 300000

Land required（m2) 7000 10000 13000 27000 40000

Construction area（m2) 1500 2000 2500 3000 3600

Finished-product storage area（m2) 1260 2520 3780 5040 7560

People required(NO.） 18 28 30 35 43

Total power（kw) 440 450 640 860 970

Electricity consumption/year(°) about 700000 about 1400000 about 2100000 about 2800000 about 4200000

Water consumption/year(T) about 25000 about 50000 about 75000 about 100000 about 150000

Coal consumption/year(T)or Natural gas consumption(T)

about 1250about 11.8




about 7500about 59

Fly ash consumption/year(T)or Sand consumption/year(T)

about 27500about 17500





Lime consumption/year(T) about 5500 about 11000 about 16500 about 22000 about 33000

Cement consumption/year（T) about 800 about 1600 about 2400 about 3200 about 4800

Gypsum consumption/year(T) about 800 about 1600 about 2400 about 3200 about 4800

Aluminium powder consumption/year（T)

about 28 about 54 about 84 about 108 about 162


ifth, Area Required &Materal,Energy ConsumptionF

t last, Cost-benefit AnalysisA

Remark: The above parameters are all based on 300 working days per year, 22 effective working hours per

day, two shift in turn, 11 hours for each shift.

The COST for making aac block in the Zhengzhou market is about 105 rmb/m3,

the MARKET PRICE is about 180-200rmb/m3.

Take the 100,000m3 as example,

The ANNUAL PROFIT is: 100,000 m3×75 RMB=7,000,0000 RMB,

One year normal operation can get the returns of investment cost and start to make profit.

NO Item Consumption(m3) Unit price(rmb) Block Cost（m3/rmb)

1 Sand/fly ash 0.420t 40 16.8

2 Cement 0.03t 320 9.6

3 Lime 0.115t 260 29.9

4 Gypsum 0.018t 50 0.90

5 Aluminium powder 0.5kg 12 6

6 Coal 0.02t 800 16

7 Power 10°C 0.7 7

8 Water 0.12t 3 0.36

9 Used oil 0.5kg 2.4 1.2

10 Consumable 1.12

11 Maintenance fee 0.05

12 Staff wages 8

13 Management fee 2.5

14 Depreciation fee 4

15 Other cost 3

16 Total cost 105.43

International Cooperation>>>


Indian clients signed 100,000m3 AAC line in Jul. 2013

Iraqi clients clients visited us in Otc. 2013

Russian clients came for goods inspection in May. 2014

Indian clients came to visit us in Jul. 2011

Indonesian clients came to

visit us in Sep. 2012

Indian clients came for goods inspection.2014

Russian clients signed 50,000m3 AAC line contract with us in Mar. 2014


Goo d s De l i v e r y>>>

Technological innovation

elaborate manufacture

Technological innovation

elaborate manufacture

DEYI Workshop>>>

Panorama of Workshop


Address：200m East to Crossing of Jingnan San Road and 107 Way, Zhengzhou

Economic and Technological Development Zone,Zhengzhou

Tel：+86-371-66783629/86599176

Fax： 86599172+86-371-

W ebsite：ht tp: / /www.deyih i .com

E-mai l：admin@dyhi .cn

Z H E N G Z H O U D E Y I H E A V Y M A C H I N E R Y M A N U F A C T U R I N G C O . , L T D .I N D U S T R I A L ............................................................................................................................................................................................................................

50,000 m3 aac line technical introduction of zhengzhou deyi

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