1. Aerated Concrete Raw Material Storage and Feeding: All raw materials are transported to the plant by truck. Fly ash (or sand, stone powder) is centrally located in the raw material yard and fed into hoppers when needed. Bagged or bulk cement is stored in the cement silo and fed into hoppers when needed. Chemicals and aluminum powder are stored separately in the chemical and aluminum powder silos and transported to the production workshop separately when needed.
2. Aerated Concrete/Aerated Concrete Block Raw Material Processing: Fly ash (or sand, stone powder) is fed into the ball mill via an electromagnetic vibrating feeder and belt conveyor. The ground fly ash (or sand, stone powder) is then pumped to slurry tanks for storage. Lime is fed into the jaw crusher via an electromagnetic vibrating feeder and belt conveyor for crushing. The crushed lime is then fed into the lime storage silo via a bucket elevator, and then into the ball mill via a screw conveyor. The ground material is then fed into the powder batching silo via a screw conveyor and bucket elevator. Chemicals are manually measured in a specific ratio, prepared into solutions of a certain concentration, and stored in tanks. Aluminum powder is transported from the aluminum powder warehouse to the production workshop, lifted by an electric hoist to the second floor of the batching building, poured into a mixer, and mixed with water in a measured amount to form an aluminum powder suspension.
3. Aerated Block Batching, Mixing, and Casting: Lime and cement are sequentially fed to an automatic weighing scale by a screw conveyor under the powder batching silo for cumulative weighing. A screw conveyor under the scale evenly adds the materials to the casting mixer. Fly ash (or sand, stone powder) and waste slurry are weighed in a metering cylinder. After all materials have been weighed and the mold is in place, slurry mixing can begin. The slurry should reach the process requirements (approximately 40℃) before casting. If the temperature is insufficient, steam can be introduced into the slurry metering tank for heating. The aluminum powder suspension is added 0.5–1 minute before casting.
4. Initial Curing and Cutting of Aerated Concrete Blocks: After casting, the mold is pushed into the initial curing chamber by a conveyor chain for initial gas generation and setting. The room temperature is 50-70℃, and the initial curing time is 1.5-2 hours (this process can be omitted depending on favorable geographical conditions). After initial curing, the mold frame and the billet are lifted together by a negative pressure hoist to the cutting table where the bottom plate of the autoclave is placed beforehand. The mold frame is removed. The cutting machine then performs transverse and longitudinal cuts and mills the bread-like ends of the billet. The mold frame is lifted back to the mold transport vehicle for manual cleaning and degreasing, and then lifted back onto the mold car for assembly for the next casting. The cut billets, along with the bottom plate of the autoclave, are lifted by an overhead crane onto the autoclave car and stacked in two layers, with four supports between each layer. Several autoclave cars are grouped together. The waste material from the edges of the billets generated during cutting is sent to the waste slurry mixer next to the cutting machine via a screw conveyor, where water is added to make waste slurry for use during batching.
5. Autoclaving and Finished Products of Aerated Concrete Blocks: After the billets are grouped on the parking line in front of the autoclave, open the autoclave door to be discharged. First, use a winch to pull out the finished product car from the autoclave, and then use a winch to pull the car ready for autoclaving into the autoclave for curing. The finished products on the car are lifted to the finished product warehouse by a bridge crane, and then transported to the finished product storage area by forklift trucks. The empty 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.
