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PRODUCTION TECHNOLOGY46 PRODUCTION TECHNOLOGY AAC WORLDWIDE %u2022 3.2025The steam trap system technology for the autoclave used in the AAC plant at the Changxing Ytong facility is specifically designed to enhance performance and efficiency. This system effectively addresses the challenge of timely discharge of low-pressure, large-flow condensate, ensuring smoother operation. Additionally, it resolves the issue of steam leakage during high-pressure drainage.Process innovation: cutting lime and cement consumption by 50%Formula optimizationIn the course of the upgrade, the Ca/Si and water/material ratios were adjusted, reducing lime and cement consumption from 210 kg/m%u00b3 to 115 kg/m%u00b3. Simultaneously, the substitution rate of return slurry and recycled AAC waste was increased to 30%, reducing annual consumption of raw materials by 120,000 tons.Water-based aluminium paste and foaming process innovationTraditional aluminium powder is limited in application due to flammability. To address this, UBlok developed a proprietary water-based aluminium paste using microencapsulation emulsification coating technology. This innovation effectively reduces oxidation exposure between aluminium powder and air, mitigates flammability risks, decreases the standard deviation of pore diameter from %u00b10.5 mm to %u00b10.2 mm, and reduces raw material waste by 15%.Product structure upgrade: transition from b06 blocks to b05 panelsExtension of low-density products: By optimizing porosity (increased from 75% to 82%), the dry density decreased from 650 kg/m%u00b3 (B06 grade) to 525 kg/m%u00b3 (B05 grade), while maintaining compressive strength values above 4.0 MPa (complying with EN 771-4 standards).Panelization transition: Large-size AAC panels (6 m %u00d7 0.6 m, thickness 50-400 mm) were developed with built-in three-dimensional steel mesh cages, achieving cutting precision errors of less than 1 mm to meet the demands of prefabricated construction.Automation upgradeThe automation upgrade led to a 30% reduction in staff while significantly boosting overall efficiency. Unmanned packaging systems enhanced stacking and packing performance by 30%, streamlining the end-of-line process. Meanwhile, the integration of PLC technology enabled real-time monitoring, which reduced ingredient errors to less than 0.5% and shortened fault response times to just 10 seconds.Post-retrofit, per capita productivity surged from 4,000 m%u00b3/year to 12,500 m%u00b3/year.Autoclave steam trap system of the Changxing Ytong plant [1].Indicators(B06)Pretransformation(B05)wPosttransformationDry Density (kg/m%u00b3)%u2264 650 %u2264 525Compressive Strength(MPa)%u2265 3.5 %u2265 4.0Thermal Conductivity (W/m%u00b7K)%u2264 0.16 %u2264 0.12Table 1: Performance comparison of new and old formulations.