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At present, foreign advanced dry mortar production plants are all top-down process layouts (tower dry mortar production line, depending on the site of dry mortar manufacturers and other factors, have a small footprint, but dry mix The height of the factory of the mortar manufacturer is required.) All raw materials are lifted to the top of the raw material silo, and they naturally flow out of the silo by the quality of the raw materials and become the final product after weighing, batching, mixing, and packaging processes. All production is completed under the modern microcomputer control system operation. As long as the operator determines the type and quantity of the product, all other operations are automatically controlled and no manual intervention is required. All the closed production system equipment not only cleans the site, and has no dust pollution, ensuring the health of the workers, but also has the characteristics of large production volume, high ingredient accuracy, and flexible use.
Because the production line is erected vertically and the raw material silo is located above the mixing equipment (mixer), most of the modern dry-mix mortar plants with a production volume of 40,000 to 250,000 tons/year.
The raw materials are transported to different silos at the top of the plant through the receiving system after proper quality control. The material flow is basically transferred to a high-precision hopper scale weighing system by gravity or other conveying systems (such as disc feeders, dosing screws, pneumatic methods, etc.). The entire process is controlled by a fully automated electronic control system, which injects all the raw materials required for a specific dry-mix mortar mix into the mixing equipment (mixer).
Most of the mixing equipment uses a special mixer (mixer), which is suitable for different dry mortar product series (from fine particles to coarse-grained dry mortar). Mixing equipments have different capacities and structures, enabling fast and homogeneous mixing. During the entire mixing process, the dry mortar temperature should not exceed 50°C to avoid deterioration of thermoplastic and sensitive additives. For efficient modern mixing equipment, homogeneous dry-mix mortar can be discharged into the finished product intermediate storage tank after 3 to 10 minutes of mixing. After quality control, the dry mix mortar is discharged into a transport silo or transported to a bagging or stacking equipment ready for transport to the construction site.
In the production of dry-mixed mortar, the raw materials used, especially bulk inorganic materials, must meet the requirements of national standards. If aggregates such as quartz sand do not meet the quality requirements, the dry mortar plant must be equipped with grinding, cleaning, drying and screening equipment. The residual humidity of all fillers must not exceed 0.3%, and after drying, the temperature of the sand must not exceed 60°C before use. The screening curve for different filler particle sizes should be stable without large fluctuations.
The design, capacity, quantity of the raw material silo, and the design of the entire mixing and packaging equipment depend on the raw materials used, as well as the quantity, variety, and volume of various dry mix mortars in the dry mortar manufacturing plant. For gypsum-based products, it is often necessary to use a separate production line to prevent cement-based products from contacting or mixing with the gypsum and affecting the quality of the product.
The key equipment for the production of dry-mixed mortars is quartz sand dryers (domestic drum dryers are generally used), screening machines, electronic weighing batching systems, mixers, packaging machines and computer control systems. Other equipment includes raw material pneumatic conveying equipment, bucket elevators, automatic palletizing machines, forklifts, trucks and other auxiliary equipment, which can be selected according to the needs. Some simple laboratory analytical instruments are used to test and control the quality of dry mix mortar products.
Dry mix mortar products are the same as cement. The finished products are generally bulk-packed and can also be packed in bags. The most common products in the Southeast Asian market are paper-bag-packaged dry-mix mortar products lined with plastic film. Each bag typically weighs 20 to 40 kilograms. There are large bags, each bag generally weighs 1,000 kilograms. For large quantities of products, small packages of 2 to 5 kg can be used. The packaging of dry-mixed mortar products depends not only on the needs of the market, but also on the capabilities and forms of packaging equipment.
Advanced and efficient dry mortar equipment and production analysis
The use of advanced and reliable automated dry-mix mortar equipment is the basic condition for the production of high-quality dry mortar products. The production process of dry-mix mortar is not complicated, and it mainly consists of raw material preparation and transportation, weighing and batching, mixing and dry-mixed mortar product packaging, palletizing and other production processes. Quartz sand for dry-mixed mortar raw materials generally needs to be processed through special drying equipment to make its water content less than 0.2%, and then divided into 4-5 different particle sizes by vibrating screen, and transported to a corresponding silo by a bucket elevator. In standby. Cement materials such as cement and lime powder and other fillers are generally sent to raw silos using pneumatic conveying equipment. Some raw materials may also need to be crushed and ground to meet the particle size requirements. Chemical additives (redispersible powders, cellulose ethers, etc.) can be manually added to the small raw material warehouses. The control system automatically formulates the ingredients and can also be manually weighed and then directly put into the mixer (now a good point in the domestic Dry mix mortar manufacturers generally use non-gravity mixers and coulter mixers.