I. Autoclaved Aerated Concrete (AAC) Block Production Process
Autoclaved aerated concrete (AAC) blocks are a new type of wall material made primarily from fly ash or sand, cement, and lime through a series of processes. The specific process includes raw material storage and feeding, raw material processing, batching, mixing, pouring, initial curing, cutting, and autoclaving.
1. Raw Material Storage and Feeding
Raw materials such as fly ash and sand are transported to the factory by truck and stored centrally. When needed, they are loaded via feeding hoppers. Cement is stored in a warehouse and loaded via feeding hoppers when needed. Chemicals and aluminum powder are stored separately in dedicated warehouses and transported to the production workshop via feeding hoppers when needed.
2. Raw Material Processing
Fly ash, sand, and stone powder are fed into a ball mill for grinding via an electromagnetic vibrating feeder and belt conveyor. Lime is crushed by a jaw crusher and then fed into a ball mill for grinding. Chemicals are manually measured according to proportions and then prepared into solutions. Aluminum powder is sent to the batching building via an aluminum powder warehouse.
3. Batching, Mixing, and Casting: Lime and cement are fed into an automatic weighing scale via a screw conveyor, while fly ash, sand, stone powder, and waste slurry are measured using a weighing cylinder. After all materials are weighed, the slurry is mixed. The mixed slurry must reach the required process temperature; if the temperature is insufficient, steam can be introduced into the slurry weighing tank for heating.
4. Initial Curing and Cutting: After casting, the mold is pushed into the initial curing chamber via a conveyor chain for initial setting and gas generation. The room temperature is 50-70℃, and the initial curing time is 1.5-2 hours. After initial curing, the mold frame and billet are lifted onto the cutting table using a negative pressure hoist. After demolding, the billet is cut. The cut billet, along with the autoclave bottom plate, is lifted by an overhead crane onto an autoclave car and stacked in two layers, with four supports between each layer.
5. Autoclaving and Finished Product: After the billets are grouped on the parking line in front of the autoclave, the autoclave door is opened. First, a winch is used to pull out the finished product autoclave car from inside the autoclave, and then the autoclave car prepared for autoclaving is pulled into the autoclave for curing. After curing, the finished products are lifted to the finished product warehouse by a bridge crane, and then transported to the finished product storage yard by forklift. The empty autoclave car and the bottom plate of the autoclave are lifted back to the return line, cleaned, and then pulled back to the stacking rack by a winch for the next cycle.
