Polystyrene concrete, foam concrete. Universal line capacity 80 m3 per shift (with fly ash as a filling agent)


 

#

Item

Q-ty

1

Complex of design and technological development on polystyrene concrete and foam concrete production

1

 

 - process design of the line;    
 -  layout arrangements (plan of equipment placement) on customer’s areas);   
 -  estimation of company’s work pattern and production plan;   
 -  estimation of acceptance and storage site of raw materials and components;   
 -  estimation of mixing site; 

 - estimation of foaming area;  
 -  equipment selection and specification;   
 -  description of polystyrene concrete and foam concrete products’ manufacturing techniques; 

 

 

 Technologist’s visit for compositions selection, development of processing methods for products  manufacturing, and also staff training.

 

 

 Development of individual process regulations of goods’ production.

 

Section of storage, preparation and feed of raw materials

1

 Silo for raw materials storage, 50 t

 (set of drawings)

2

 

 Set of equipment:

 

 

 Filter

 

 

 Material pipeline

 

 

 Ladder

 

 

 Hatch

 

 

 Top guard

 

 

 Aeration system

 

 

 Collector

 

 

 Vibrator

 

 

 Cement shuttle

 

2

 Cement screw conveyor*

 (L - 6 m*, gear motor (Italy), N – 4 kW)

 1

3

 Fly ash screw conveyor*

 (L - 6 m*, gear motor (Italy), N – 4 kW)

1

4

 Transfer screw conveyor*(L - 2 m*, reverse, gear motor (Italy), N – 3 kW)

1

5

 Water treatment complex (N – 27 kW)

1

 

 List of equipment:

 

 

 Bin for storage and warming of water (V – 1,0 m3)

2

 

 Electric boiler (24 kW)

1

 

 Circulating pump

1

 

 Water boosting pump

1

 

 Float switch

1

 

 Solenoid valve

1

 

 Check valve

1

 

 DV-1700 Electronic water gauge

1

 

 Control panel

1

 

 Frame

1

 

 Switching system

1

EPS Foaming area

1

 PND-500 Pre-foamer (N – 3,3 kW)

1

 

 List of equipment:

 

 

 Polystyrene foaming machine

1

 

 Intake hopper for raw materials

1

 

 Intake hopper for secondary foaming

1

 

 Raw material feeding screw

1

 

 Screw feeding granules for secondary foaming

1

 

 Frame

1

 

 Control panel

1

2

 PGES-50 Steam generator (N – 40 kW, 50 kg/hr)

1

3

 EPS granules drying machine (N – 17 kW)

1

 

 List of equipment:

 

 

 Drying machine body

1

  

 Electric calorific installation SFOC-16

1

 

 Low pressure radial fan (1,5*3000)

1

 

 Control panel

1

4

 EPS granules ageing hopper 40 m3(set of drawings)

4

5

 Pneumatic transport system (N – 3 kW)

1

 

 List of equipment:

 

 

 Low pressure radial fan (1,5*3000)

2

 

 Galvanized pipelineD – 125 mm

 

 

 Dampers

 

 

 Inserts, bypasses

 

Mixing section

1

 Bridge(set of drawings)

1

2

 Electronic control system*

1

3

 Weigh batcher

 (weighing capacity range to 1000 kg)

1

 

 List of equipment:

 

 

 Strain sensors

4

 

 Disk shutter with pneumatic drive

1

 

 El. Vibrator EV-320 (N – 0,2 kW)

1

4

 EPS volumetric batcher 1,0 m3

2

5

 Polystyrene concrete and foam concrete RSG -900 (with embedded foam generator, N – 5,5 kW)

2

6

 C200LB40 Compressor (8-10 atm., from 500 l/min)

1

7

 Gerotor pump GN-10 (N – 5,5 kW)

1

Thermal treatment sector

Thermal treatment chambers are to be made by a customer according to design

Sawing sector 

1

 ARK Automatic cutting set for vertical and horizontal sawing mass with band saws* 

 (N – 13 kW)

2

 

 List of equipment:

 

 

 Rail tracks (L – 2,4 m)

2

 

 Remote control console

1

2

 Mould for filling FM-0,85 m3

 (V – 0,85 m3)

94

* Final cost is determined after the stage of design in view of a placement 

 

List of auxiliary equipment and materials (to be purchased by a customer)

 Special vehicles

 1 

 Forklift (2-3 tons)           

1

 Auxiliary equipment

2

 Ventilation system (supply&exhaust)

1

3

 Stocking hydraulic carts

3

4

 Household equipment, tools

 

 Other

 

 

Consumption per month (25 work days)

5

 Pallets for blocks stacking (reusable), pcs.

2000

6

 Machine for strapping with polypropylene type, 2pcs

---

7

 Polypropylene string, m

30000

8

 Wrap tape, m

60000

  • Area of production site required 1000-1200 m2
  • Ceilings height – min 6m*
  • Temperature indoor min +15..+200 С
  • Electric power required 100-120* kW/hr
  • Water system required.
  • Staff required – 10 persons, technologist/supervisor – 1 person.

 

Materials consumption (polystyrene concrete).*

Mark by average density

D 200

D 300

D 400

D 500

 

Materials consumption

Cement, t

1 m3

0,2

0,25

0,27

0,32

Shift

16

20

21,6

25,6

Fly ash, t

1 m3

-

-

0,05

0,085

Shift

-

-

4

6,8

EPS, m3.

1 m3

0,6-0,8

0,6-0,8

0,6-0,8

0,6-0,8

Shift

48-64

48-64

48-64

48-64

Air retaining substance, kg

1 m3

0,25

0,2

0,15

0,12

Shift

20

16

12

9,6

* Mixes can be corrected in view of the Customer’s raw materials’ peculiar properties.

 

Materials consumption (foam concrete).*

Mark by average density

D 600

D 800

Materials consumption

Cement, t

1 m3

0,3

0,34

Shift

24

27,2

Fly ash, t

1 m3

0,2

0,35

Shift

16

28

EPS, m3.

1 m3

0,8

0,7

Shift

64

56

Air retaining substance, kg

1 m3

1,75

2

Shift

140

160

* Mixes can be corrected in view of the Customer’s raw materials’ peculiar properties.