Page 49 - Demo

AAC WORLDWIDE %u2022 2.2025 PRODUCTION TECHNOLOGY 49eliminating fluctuations caused by manual operations. Moreover, it facilitates the traceability and analysis of quality defects.At present, practice has proven that the adoption of an automatic autoclaved curing system is the optimal solution for controlling the autoclaved curing quality in AAC production. Considering the high cost of imported autoclaved curing systems, the AAC producer Ublok Intelligence has optimized the control logic based on the imported autoclaved curing system of Changxing%u2019s first production line. The flow control valves are of imported brands, while the electric on-off valves are of domestic brands. This not only achieves the same effect but also reduces costs by approximately 50%.Semi-automatic autoclaved curingThe technical innovation concept of this system aims to control the autoclaved curing quality while reducing the system cost. It adopts the traditional steam manifold gas distribution mode, combined with the group control logic of pipeline-type automatic autoclaves. Automatic control valves are used in each group to control the heating curve, and domestic manual stop valves are used as on-off valves. The advantages of this system are that the heating curve can be automatically controlled and that the autoclaved curing quality is not affected by fluctuations in manual operation. The cost is significantly lower than that of a fully automatic gas distribution system. However, the shortcoming is that the workload related to autoclaved curing operations cannot be reduced.Optimization of the thermal insulation planAccording to statistics, the annual steam loss caused by heat dissipation from a DN100 valve is approximately 10 tons. Autoclave rings, bottom supports, etc. all need to be insulated. The static curing room and pre-curing kiln require improvement of thermal insulation measures.The insulation thickness of the autoclave body should be no less than 150 mm. An additional 30 mm of insulation should be added to the upper third of the autoclave body. The insulation thickness of the main steam pipe should also be no less than 150 mm. Also, heat dissipating areas such as autoclaverings and supports need to be insulated. Practicehas proven that before adding a 50 mm layer of aluminium silicate, a layer of nano-reflective film and a0.6 mm layer of aluminium sheet to the original 100mm of insulation, steam supplement was required 3to 4 times during the original constant temperaturestage. After the transformation, steam supplementis no longer needed, and a pressure increase can beobserved. The steam loss caused by the thermal insulation defects of the green body is approximately3,000 tons per year.Proper selection of steam trap devicesIf the steam trap is selected incorrectly, approximately 260 tons of steam may be wasted each year due to leakage.Through nearly three years of practical application and optimization, UKeyer Intelligence has developed a dedicated steam trap system for autoclaves in AAC factories. This system addresses the issues of untimely drainage of large-volume low-pressure water and leakage of small-volume high-pressure steam. Its unique control mode eliminates the problem of steam leakage and temperature drainage during high pressure conditions. The steam trap device not only affects product quality but also energy consumption, and it is one of the key components of the entire steam system.Steam quality as a key factor The conditions for stable steam include a stable steam volume, controllable pressure and temperature, low contents of air and non-condensable gases, and a clean and dry production environment.Flow chart of the semi-automatic autoclaved curing in the Ublok Tianjin production plant. Intake ductExhaust pipeWaste heat recovery