Page 48 - Demo

PRODUCTION TECHNOLOGY48 PRODUCTION TECHNOLOGY AAC WORLDWIDE %u2022 3.2025Circular economy practices: from waste recycling to low-carbon productionBreakthrough in autoclaved bottom layer removal technologyUBlok%u2019s self-developed autoclaved bottom layer removal equipment utilizes an automatic stripping system to achieve 100% waste recycling. This innovation saves 35,000 tons of sand annually, reduces carbon emissions by 1,200 tons, and has obtained EU CE certification.As part of UBlok%u00b4s commitment to low-carbon pathways and alignment with EU sustainability initiatives, the plant has implemented innovative energy and emissions strategies. Steam waste heat is now utilized through cascade systems to support district heating, enabling integration into production heating networks and achieving thermal efficiency levels above 85%. In parallel, the carbon footprint assessment reveals a significant improvement: following retrofitting, the carbon intensity per cubic meter of AAC has been reduced from 120 kg CO%u2082e/m%u00b3 to 80 kg CO%u2082e/m%u00b3, meeting the compliance standards set by the EU Carbon Border Adjustment Mechanism (CBAM).Changxing Plant: capacity leap and technology exportDual enhancement in capacity and qualityProduction cycle optimization has significantly enhanced output, with mould cycle times reduced from 6 minutes to just 3 minutes %u2013 doubling the daily production volume from 950 m%u00b3 to 1,900 m%u00b3. Looking ahead, further improvements aim to reduce cycle times to 2 minutes, targeting a daily capacity of 2,600 m%u00b3. In parallel, upgrades to the cutting process %u2013 specifically increasing the number of column pairs from 7 to 13 %u2013 have eliminated fracture defects in small-sized blocks and panels. As a result, product qualification rates have risen to over 99%.Technology export and economic validationRetrofits were successfully implemented for Shandong Lubi and Baowu Ma Steel, while technical licenses and management support were provided to Shaanxi Jingwei and the Philippines-based MVBC. These initiatives led to an average efficiency improvement of 35%, with a payback period of less than two years. Additionally, a localization rate ex- Automated retrofit site at Changxing Ytong plant [1].