Page 47 - Demo

AAC WORLDWIDE %u2022 2.2025 PRODUCTION TECHNOLOGY 47%u2022 Around 150 kg/m%u00b3: The system provides partialsteam inversion and common steam traps. Freshsteam is used for the pre-curing, drying andpouring processes.%u00a0%u2022 Around 200 kg/m%u00b3: The system does not provideany steam inversion, has poor thermal insulation, and is characterized by serious leakage ofsteam traps. The steam replenishment results infrequent pressure reductions when operating atconstant temperatures, creating unreasonablesteam curing cycles.Problems associated with steam applicationThe main problems associated with improper steam applications include, i) product quality issues, such as cracking, uncooked cores, watermarks, sticking, and colour differences in autoclaved products, ii) low turnover rates of the autoclaves and low production efficiency due to high and unstable steam unit consumption, frequent pressure replenishment, limited steam inversion times and low waste heat utilization rates, iii) environmental impacts related to unnecessary discharge of exhaust steam, high temperature in the workshop, poor working environments in the factory area and the workshop, bad odour from condensate water, and severe corrosion of the autoclave body and insulation elements, and iv) high equipment failure rates due to valve damage, blockage and water hammer.The causes for these problems are related to i) system design flaws associated with manual control of the heating and cooling curves and the inability to Steam consumption in the AAC industry in kg/m3.Table 1: Losses and problems caused by unreasonable steam applications (the unit price of steam varies due to regional differences in energy prices. However, the quantity of steam loss provided can be used as a reference).Statistics on economic losses and carbon emissions caused by unreasonable steam utilizationQuality loss Energy consumption loss Costs (USD) Average price per cubic meter (USD) Steam flow rate (t) RemarkAnnual output 200,000 m%u00b3 Autoclave tail gas 600,000 30 20,000 The steam is not reused for a second timeDefect rate 5% Steam trap leakage 78,000 30 2,600 According to ten steam trap pointsEconomic loss 300 Poor thermal insulation 63,000 30 2,100 Six autoclavesTotal economic losses USD 741,000Increase in carbon emissions 20,800 tDistribution of steam consumption in autoclave process.