EP1295691B1 - Plant for producing vapour-hardened building materials - Google Patents

Description

The invention relates to a plant for producing steam-hardened building materials.

Steam-hardened building materials, in particular steam-hardened lightweight building materials, for example porous or gas concrete, are produced by the following process. The ground raw materials sand, lime, cement, sulfate carrier and aluminum powder are dosed together with water in batches in a mixer. After mixing, the material is poured into an oiled mold with a volume between 4 and 9 m ³ . After the casting mold has been filled, it is brought to a fermentation place, where the mass is fermented to its final volume and remains between one and six hours until the binder component has set enough green strength for the sawing. When the green strength is sufficient, the material is removed and then cut using wires in a sawing station. After sawing, the material is either collected at further locations in front of the autoclave until there is an autoclave filling or it is fed directly into the autoclave. After autoclaving, the usual autoclaving time is approx. 12 hours, the material is removed from the autoclave, unloaded in a discharge device, packaged and transported to the warehouse.

Such a conventional system is in S. Röbert, silicate concrete, VEB Verlag für Bauwesen Berlin, Berlin 1970, described and explained below with reference to FIG. 4.

In a casting station 101, the cleaned and oiled Molds filled with an aerated concrete mixture and then on Proofing stations 102 move where the mass floats in the molds and sets. The greenest ones are turned off in a removal station 103 AAC cake tilted by 90 ° and part of the mold removed, while a mold side wall is used as a hard floor remains. Another possibility is the implementation of the cellular concrete cake on grids so that the entire shape is removed becomes. The aerated concrete cakes are then placed in a cutting station 104 driven and cut there in the desired formats. The shapes taken from the cellular concrete cakes are in a cleaning station 105 cleaned and then in one Oil station 106 oiled.

The hard floors, each with a cellular concrete cake, are now three with their long sides next to each other or with their broad sides placed one above the other on autoclave or hardening car 107 and in entered a tunnel 108, which prevents them from cooling, in particular Train to protect. From tunnel 108, the aerated concrete cakes, if sufficient autoclave trolleys for one autoclave filling stand ready, run into a free autoclave 109 and subjected to steam curing there.

After steam curing is complete, the cellular concrete cakes are made the autoclave 109 extended and then stand for an aftertreatment and / or packaging on a stand 111. If the aerated concrete cakes are equipped with reinforcements should be in a reinforcement station 112 before casting Reinforcements are inserted into the forms.

A disadvantage is that such systems have a significant Need space. There will be plenty of space for the fermentation areas and needed for the footprint in front of the autoclave, it It is sometimes customary to install heat tunnels in the area of the fermentation areas, to shorten the fermentation time and thus save space.

If you load the autoclaves individually and not in batches, the space requirement can also be reduced. For that, however expensive autoclave capacity blocked.

In order to operate such plants economically, production capacities of more than 300.00 m ³ / year are necessary.

Another disadvantage is that with the conventional method very many forms must be present, which is a significant one Investment requires.

From BE-A-556 531 it is known that in the aerated concrete forms filled mass during the expansion and during the Sawing and warming after sawing before autoclaving. While warming up and sawing brings warming up in one Tunnel takes place in which several sawing stations are arranged one behind the other are. The sawn aerated concrete blocks are placed on trolleys a large heated waiting room with several tracks. The disadvantage of this system is that it has a considerable volume Requires space and the clock rates do not optimally match each other can be coordinated.

CH-A-291 682 is a plant for the production of concrete slabs, especially the steam-hardened, frame-reinforced Lightweight concrete slabs are known. This known system is essentially housed in a temperature-controlled hall, whose interior temperature on a for the requirements of gas concrete or Foam concrete production can be adjusted to the required dimension. With this system, it is disadvantageous that it has a considerable Space requirements and a huge investment for the structural measures required.

From FR-A-1.360763 it is known the freshly filled pre-concrete forms towards a storage area above the autoclave store, whereby the released from the autoclaves to the environment Heat due to convection should warm the cellular concrete cake. at This system has the disadvantage that the waste heat from the autoclaves the aerated concrete cake cannot be specifically supplied. Farther it is disadvantageous in a system according to FR-A-1.360.763 that, due to the alternating operation of the autoclaves, the storage place only unevenly is subjected to heat. Switched off autoclaves (e.g. when loading and unloading) only contribute to a small extent Warming and cause an uneven heat distribution for the aerated concrete cakes stored above. So that's it The fermentation time cannot be optimally adjusted. Thus, to complete the Fermentation process of the aerated concrete cakes a large storage place is built become. This means that such a system requires a large amount of space and high structural investment costs are necessary.

The object of the invention is to provide a system in which the economic production capacity and the space required considerably is reduced.

The task is carried out by a system with the characteristics of Claim 1 solved. Advantageous embodiments are in the subclaims characterized.

This makes a particularly compact system achieved that all functional lines arranged parallel to each other are. There are special advantages if the individual Functional lines, i.e. Sawing station, warm-up chamber, heating chamber and the autoclave have the same length. According to the invention the saw as well as the heat chamber above the autoclave and the heating chamber may be arranged, the heating chamber over the heating chamber is arranged. By arranging the saw on the increased level of the heat chamber can internals in the floor, like sludge trap, or the establishment of a cellar avoided which lowers the investment costs. The invention Combination of this embodiment of a plant with the warming up and heating up of both the aerated concrete molds fermenting mass as well as the ready-cut cellular concrete cake enables a compact system to be achieved on the one hand, because the parking spaces in front of the autoclaves are eliminated, on the other The entire production process is significantly shortened with optimal use of energy, resulting in low production output can still be done economically.

Fig. 1

schematisch eine Porenbeton-Anlage;

Fig. 2

beispielhaft eine Ausgestaltungsform einer Anlage nach Fig. 1;

Fig. 3

beispielhaft eine weitere Ausgestaltungsform einer Anlage nach Fig. 2;

Fig. 4

eine bekannte Anlage.

The system according to the invention is explained by way of example with reference to a drawing. Show it:

Fig. 1

schematically a cellular concrete system;

Fig. 2

an exemplary embodiment of a system according to FIG. 1;

Fig. 3

another example of a system according to FIG. 2;

Fig. 4

a well-known facility.

A system 1 (Fig. 1) for the production of steam-hardened building materials has functional lines 2, 3, 4, 5, 6, 7, which are parallel are arranged to each other. Functional routes 2 to 7 are aligned parallel to each other and about the same length, the end regions of the functional sections 2 to 7 on one Height are so that the base of the system 1 is approximately rectangular is, with two longitudinal outer sides L and two end outer sides S. The functional routes 2 to 7 extend parallel to the longitudinal outer sides L of Appendix 1.

Over the end areas of the functional sections 2 to 7 are along a crane runway 8a, 8b a cross crane 9a, 9b along one each Crane runway axis 10a, 10b movable. The crane runway axes 10a, 10b are parallel to each other and to the outside S and perpendicular oriented to functional routes 2 to 7.

Instead of the cross cranes 9a, 9b in the area of the crane runways 8a, 8b sliding platforms can be provided.

The functional sections 2 to 7 each have a track 11a, 11b, 11c, 11d, 11e and 11f with two rails each, the rails being so are dimensioned that aerated concrete molds and autoclave wagons they can be moved.

The functional section 2 has a between the crane tracks 8a, 8b Cleaning station 15 for molds, a pouring buffer line 16, one Oil station 17 for molds and in the area of Krahnbahn 8b Pouring station 18 on.

The functional section 3 has a between the crane tracks 8a, 8b Hardness floor buffer section 19, which hard floors from one Unloading station 20 takes over, which is on a track 21 is located, and which is in the extension of the rail 11e of the functional route 3 extends beyond the crane runway 8b. In the area the crane runway 8a has a mold construction area 24a in which Molds and hard floors are put together.

The functional section 4 has one between the crane tracks 8a, 8b Saw buffer section 22, a saw station 23a and a stacking station 23b, with a tilting area in the area of the crane runway 8a 24b for tilting and removing the molds from the hardened cellular concrete cake is provided.

The functional section 5 has one between the crane tracks 8a, 8b Preheating chamber 5a, the longitudinal axis 5b parallel to and between the rails to the track 11a is arranged. The preheating chamber 5a has approximately a length that corresponds to the length of the Functional route 5 between the crane tracks 8a, 8b corresponds.

The functional section 6 has one between the crane tracks 8a, 8b Heating chamber 6a, the longitudinal axis 6b between the rails of the Track 11b is arranged parallel to track 11b. The heating chamber 6a has approximately a length that corresponds to the length of the Functional route 6 between the crane tracks 8a, 8b corresponds.

The functional section 7 has between the crane tracks 8a, 8b an autoclave 7a, the longitudinal axis 7b between the Rails is arranged parallel to the track 11c. The autoclave 7a has a length approximately equal to the length of the functional section 7 between the crane tracks 8a, 8b.

The track 11c of the functional section 7 is over the crane runway 8b also extends and forms an exit path 25 for batches extended from the autoclave, with hardened aerated concrete products loaded hard floors.

The procedure for the plant according to FIG. 1 is described below explained.

A cleaned mold standing on the pouring buffer line 16 will oiled in the oil station 17 and then in the pouring station 18 filled. The filled shape is by means of the cross crane 9b raised, move along a crane runway axis 10b and onto the Track 11a of the functional section 5 set and in the heating chamber 5a retracted. The shape passes through the heat chamber 5a, in the it is preferably exposed to temperatures of 40 to 70 ° C, preferably the fermentation process at a time which is sufficient complete and a green strength sufficient for cutting to get. The mold leaves the heat chamber 5a the other side and arrives at crane runway 8a, where it joins a cross crane 9a along a crane runway axis 10a onto the track 11f of the functional section 4 is shifted and there onto the saw buffer section 22 is operated.

When moving, the shape in the tilting area 24 of the crane runway 8a and the functional section 4 tilted and after weaning down to the hardness base of green firm aerated concrete cake removed.

The mold without a hard bottom becomes the mold construction area 24a of the functional section 3 move and there with an empty hardness floor assembled and moved from there to the cleaning station 15, taking these two steps also in reverse can take place.

From the saw buffer section 22, the hardness floor comes with cellular concrete cake to the sawing station 23a, where the aerated concrete cake into the desired formats is cut. In a downstream Station 23b always has three hard floors with aerated concrete cakes placed on a hardening trolley. The cut cellular concrete cake is moved into the area of the crane runway 8b and with the cross crane 9b on the track 11b of the functional section 6 and from there moved into the heating chamber 6a. In the heating chamber 6a the hardening carts are fed continuously, up to the heating chamber an autoclave batch is ready, causing the heating chamber 6a also the task of a buffer or collecting section before Autoclave takes over. The cellular concrete cake is in the heating chamber preferably exposed to a temperature ≥ 100 ° C. At the end In the heating chamber, the hardening trolley reaches the area of the crane runway 8a, where it from the cross crane 9a on the track 11c of the functional section 7 is set and from there move into the autoclave becomes. The heating chamber 6a can e.g. filled and emptied in batches be so that an autoclave batch initially complete heated, then from the heating chamber 6a in batches en bloc is extended and inserted into the autoclave 7a en bloc.

The hardening trolleys are on the other side of the autoclave 7a move onto an exit section 25 of the functional section 7 in order to free the autoclaves 7a for new batches as quickly as possible do. From the exit section 25, the hardening wagons get into the Area of the crane runway 8b, from where it with the cross crane 9b the track ile implemented the functional route 3 and in the unloading station 20 are driven. The aerated concrete cakes are made by unloaded the hardening trolley and the hardening trays and the hardening trolley are pushed into the hardness floor magazine 19, where the hardness floors collected and preferably stacked. The hardening car then become a transfer station in a suitable manner process or transported.

When using transfer platforms as transfer devices instead of cross cranes, the hardening wagons are replaced by the tracks pushed onto the sliding platforms. The transfer platforms move the Hardening car along the crane / transfer platform axes 10a, 10b to the desired track where the hardening wagon is from the transfer platform the track is pushed. The basic procedure is the same, however.

2 has two heating chambers 5a before cutting, which successively pass through a mold become. After heating the molds in a heating chamber 6a, two autoclaves 7a can optionally be loaded. Thereby, that here too the tracks are parallel to each other, in the same Length and arranged at the same height is also one here compact design of the system achieved. Between the casting station 18 and a first heat chamber 5a is not a displacement of the molds necessary because the casting station 18 on an extension of the Track of the heat chamber is located.

3 takes place instead two short a long autoclave 7a, which is indeed the Crane runway 8b extends, but the end of which is at the level of Casting station 18 is located, so that still a compact design is achieved.

In the embodiment of a plant according to the invention, the entire System mounted on level foundation plates and the heat chamber arranged above the heating chamber. There is also the Sawing station at the level of the heating chamber, results in particular advantageously with a compact design of the system little floor space consumption. In addition, at a such system no expensive foundation pits for e.g. Sludge storage tank, to be created. As transfer devices for Moving the hardening car from the lower level to the upper level Level at which the saw and the heat chamber are located The cross cranes described above also serve here.

By providing a heating chamber, the residence times of the AAC cake in an autoclave advantageously from approx. 12 Hours to about 8 hours. This can be a Autoclave now filled three times a day instead of twice become, which leads to a reduction in cycle times and to a Increasing the clock rates in production or reducing it the number of autoclaves can help.

By combining the heating of the cellular concrete cake with a warming up of the forms during the proofing and setting times can shorten the proofing and setting times and to the higher Clock rates can be matched. The number of shapes can be small being held.

Claims (3)

1. System for producing lightweight building materials and particularly gas concrete or cellular concrete, having a filling station (18) at which the cellular concrete mix is filled into moulds, having at least one heat chamber (5a) into which filled moulds are brought and in which the expansion and what is referred to as the initial setting or stiffening of the cellular concrete mix takes place, having a sawing station (23a) into which initially set cakes of porous concrete are then moved and in which they are cut to desired sizes, having at least one heating chamber (6a) into which cut cakes of cellular concrete are introduced and are stored while exposed to heat, and having at least one autoclave (7a) into which cakes of cellular concrete are slid and subjected to steam curing, all the items (18, 5a, 23a, 6a, 7a) having functional paths fitted with rails, characterised in that the heat chamber (5a) is arranged above the heating chamber (6a).
2. System according to claim 1, characterised in that the sawing station (23a) is situated on the same level as the heat chamber (5a) arranged above the heating chamber (6a).
3. System according to claim 1 or 2, characterised in that means are present which feed waste heat out of the heating chamber (6a) and to the heat chamber (5a).

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