A fully automatic finished stone preparation system and a production process thereof

Abstract

This invention discloses a fully automated finished stone material preparation system and its production process, belonging to the field of building material preparation technology. The system adopts a factory-style assembly line layout, sequentially including: a raw material crushing and shaping unit, a sand making and grading unit, a finished product sorting and storage unit, a dust collection and stone powder recovery unit, a material circulation and buffer unit, a resource-based packaging unit, and a central intelligent control unit. The finished product sorting and storage unit is equipped with parallel and independently conveying No. 1 and No. 2 finished product belts, a gravel finished product belt, and a dry sand finished product belt; the dust collection unit includes a dust collector network, a stone powder silo, and a dust hopper; the resource-based packaging unit directly or in combination with other materials forms bagged products from stone powder. This invention integrates aggregate shaping, dry sand making, full stone powder recovery, and compounding and packaging processes, achieving material balance and adaptive quality adjustment through intelligent control. It produces no process wastewater, achieves 100% stone powder utilization, and maintains a dust emission concentration ≤8mg / m³, realizing green, efficient, and intelligent production.

Description

Technical Field

[0001] This invention relates to the field of building material preparation technology, specifically to a fully automated finished stone preparation system and its production process. Background Technology

[0002] Traditional sand and gravel aggregate production mainly involves two processes: dry processing and wet washing. While wet washing can produce clean aggregates, it consumes a large amount of water, generates a significant amount of mud and wastewater, incurs high treatment costs, and causes the loss of stone powder resources and environmental pollution. Although conventional dry processing is more environmentally friendly, it is typically a decentralized system with low automation, unclear stone powder recycling pathways, and difficulty in simultaneously and efficiently producing various specifications of high-quality aggregates, gravel, manufactured sand, and dry sand. Therefore, there is an urgent need for a factory-scale solution that integrates the entire process of crushing, shaping, sand making, powder selection, classification and storage, and resource utilization, achieving intelligent control and clean production. Summary of the Invention

[0003] The present invention aims to provide a fully automated finished stone preparation system and its production process to solve the problems of heavy environmental pollution, low resource utilization, single product, and low degree of automation in traditional processes, and to achieve efficient, green, intelligent and resource-based aggregate production.

[0004] To achieve the above objectives, the present invention provides the following technical solution: a fully automated finished stone preparation system, which adopts a factory-style assembly line layout, and the system includes, in sequence along the material flow path:

[0005] The unit includes a raw material crushing and shaping unit, a sand making and grading unit, a finished product sorting and storage unit, a dust collection and stone powder recovery unit, a material circulation and buffering unit, a resource-based packaging unit, and a central intelligent control unit.

[0006] The finished product sorting and storage unit includes parallel and independently conveying 1# finished product belt, 2# finished product belt, rice stone finished product belt and dry sand finished product belt, which are used to transport products of different specifications to designated areas;

[0007] The dust collection and stone powder recovery unit includes a dust collector network distributed throughout the system, a stone powder silo for centralized storage of collected dust, and a ash powder hopper for premixing powder materials.

[0008] The material circulation and buffer unit includes at least a material return conveyor for handling returned materials, a shaping line for aggregate shaping, and a buffer line for balancing the process.

[0009] The resource-based packaging unit includes a receiving line and a pressing line connected to the discharge port of the stone powder silo or ash powder hopper.

[0010] The central intelligent control unit communicates with all the above-mentioned units to achieve automated operation of the entire system.

[0011] Preferably, the sand making and grading unit includes a sand making machine and a matching sand making dust collector. The sand making machine is used to process a portion of the aggregate into manufactured sand, which is then graded and output by the dry sand finished product belt.

[0012] Preferably, the end of the finished product sorting and storage unit is provided with a finished product loading unit for bulk loading of aggregates, gravel, or manufactured sand.

[0013] Preferably, the ash powder silo receives stone powder from the stone powder silo and is equipped with an interface and mixing device for adding purchased materials such as fly ash and cement, for producing composite powder materials.

[0014] Preferably, the dust collector network adopts centralized dust collection or distributed bag filter dust collection to ensure that dust from each dust-generating point is captured and transported to the stone powder silo.

[0015] Preferably, a production process based on a fully automated finished stone preparation system includes the following steps:

[0016] Step 1: After crushing, screening, and shaping, the raw materials are used to obtain multi-grade aggregates;

[0017] Step 2: Some of the aggregate is fed into a sand making machine for processing, and after grading, it produces manufactured sand and gravel;

[0018] Step 3: Aggregates, gravel, and manufactured sand are sorted, stored, or loaded onto trucks via independent finished product conveyor belts;

[0019] Step 4: Dust generated during the entire system's production process is collected and stored in a stone powder silo.

[0020] Step 5: After the stone powder in the stone powder silo is directly mixed with fly ash, cement and other materials in the ash powder silo, it is processed into bagged products through receiving, metering and pressing processes.

[0021] Step Six: Utilize return conveyors and buffer lines to adjust the system's logistics balance, and achieve full-process monitoring and automatic adjustment through the central intelligent control unit.

[0022] Preferably, in step three, the manufactured sand is dry-produced manufactured sand with rough particle surfaces and distinct edges.

[0023] Preferably, in step four, the dust collection efficiency is not less than 99%, so as to achieve compliance with the standards for fugitive emissions at the production site.

[0024] Preferably, in step five, the bagged product produced is a mineral admixture, filler, or customized dry-mixed mortar base material for concrete or building materials.

[0025] Preferably, the entire production process generates and discharges no process wastewater, and the comprehensive utilization rate of stone powder reaches 100%.

[0026] The beneficial effects of this invention are:

[0027] (I) System Integration and Functional Coordination

[0028] The entire process is integrated: the seven major units of crushing and shaping, sand making and grading, finished product sorting, dust recovery, material recycling and resource packaging are organically integrated to form a complete factory production line, which overcomes the defects of traditional process systems being scattered and processes being disconnected.

[0029] Parallel output of multiple products: By setting up parallel finished product belts 1#, 2#, gravel finished product belt, and dry sand finished product belt, four specifications of products—20-30mm, 10-20mm aggregate, 5-10mm gravel, and 0-4.75mm manufactured sand—can be sorted, independently conveyed, and stored simultaneously, eliminating the downtime waiting time of traditional single-line switching production and improving product switching efficiency by 100%.

[0030] Full utilization of stone powder: The stone powder collected from the entire system is centrally stored in the stone powder silo. It can be directly packaged into mineral admixtures, or it can be compounded with fly ash and cement in the ash powder silo according to the order formula to produce high value-added products such as roadbed filler and masonry mortar base material. The comprehensive utilization rate of stone powder reaches 100%, turning waste into treasure.

[0031] (II) Intelligent control and operational stability

[0032] Adaptive particle size control: An online particle size analyzer is installed at the end of the dry sand finished product belt. The PLC controller adjusts the rotor frequency of the sand making machine in real time according to the fineness modulus of the manufactured sand, so that the daily fluctuation range of the fineness modulus is reduced from ±0.35 to ±0.12, and the product stability is significantly improved.

[0033] Intelligent scheduling of buffer lines: Based on material level linkage control, the buffer lines run in both directions. They automatically accumulate materials when loading is paused or equipment is under maintenance, and automatically release them when the process resumes. The overall line operating rate has increased from 68% of the traditional dry line to 91%, and the number of full line shutdowns caused by partial shutdowns has decreased by 83%.

[0034] Order-driven formula switching: The central server is connected to the ERP system and automatically calls the compound formula of stone powder, fly ash and cement according to the order, with a batching accuracy of ±0.5%, realizing flexible production.

[0035] (III) Environmental Protection and Energy Conservation Effects

[0036] Ultra-low dust emissions: The dust collector network covers all dust-generating points and adopts pulse bag dust collection technology. The outlet dust concentration is ≤8mg / m³, the collection efficiency is ≥99.2%, and the fugitive emission concentration at the plant boundary is ≤0.32mg / m³, which is far superior to the national standard.

[0037] Zero wastewater and zero solid waste: The entire process is dry, with no process wastewater generated or discharged; 100% of the stone powder is recycled, with no solid waste discharged or landfilled, completely solving the mud pollution problem of traditional water washing process and the stone powder accumulation problem of dry process.

[0038] Energy saving and consumption reduction: By optimizing equipment operating parameters through intelligent control, ineffective energy consumption is avoided. The comprehensive power consumption per ton of product is 6.1kWh, which is 15.3% lower than the traditional dry process line's 7.2kWh.

[0039] (iv) Economic and social benefits

[0040] Extending to high-value-added products: Transforming inexpensive stone powder into high-value products such as concrete admixtures and composite powders. A single production line with an annual output of 3 million tons of aggregate can produce 200,000 tons of bagged composite powder, adding approximately 40 million yuan in annual output value and significantly improving the company's profitability.

[0041] Clean production demonstration: It has built a circular economy model of resources, products and recycled resources, and provided a replicable technical solution for the green transformation and upgrading of the sand and gravel aggregate industry, with significant social and environmental benefits.

[0042] In summary, this invention has achieved groundbreaking progress in five dimensions: product quality stability, equipment operating efficiency, environmental emission level, comprehensive resource utilization, and energy consumption. Moreover, the effects exceed the scope that those skilled in the art could expect through simple improvements, and it possesses significant inventiveness and practical value. Attached Figure Description

[0043] To more clearly illustrate the technical solutions in the embodiments of the present invention or the prior art, the drawings used in the description of the embodiments or the prior art will be briefly introduced below. Obviously, the drawings described below are only some embodiments of the present invention. For those skilled in the art, other drawings can be obtained based on these drawings without creative effort.

[0044] Figure 1 This is a schematic diagram of the fully automated finished stone preparation system provided in Embodiment 1 of the present invention;

[0045] Figure 2 This is a production process flow chart provided in Embodiment 1 of the present invention;

[0046] Figure 3 This is a logic diagram of the frequency adaptive control of a sand making machine based on online particle size analysis provided in Embodiment 2 of the present invention;

[0047] Figure 4 This is a logic diagram of intelligent scheduling of buffer lines based on material level linkage provided in Embodiment 2 of the present invention.

[0048] In the diagram: 100 - Raw material crushing and shaping unit; 101 - Jaw crusher; 102 - Cone crusher; 103 - Multi-layer vibrating screen; 104 - Shaping machine; 200 - Sand making and grading unit; 201 - Sand making machine; 203 - Linear vibrating grading screen; 300 - Finished product sorting and storage unit; 301 - Finished product screening machine; 302 - #1 finished product conveyor belt; 303 - #2 finished product conveyor belt; 304 - Stone finished product conveyor belt; 305 - Dry sand finished product conveyor belt; 306 - Finished product loading unit; 400 - Dust collection and stone powder recovery unit; 401 - Dust collector network; 402 - Stone powder silo; 403 - Ash powder silo; 404 - Batching and mixing device; 500 - Material circulation and buffer unit; 501 - Horizontal conveyor belt for material return. 503-Buffer line; 600-Resource packaging unit; 601-Receiving line; 602-Metering system; 603-Packaging line; 700-Central intelligent control unit; 701-PLC controller; 702-Human machine interface; 703-Sensor group; 704-Central server. Detailed Implementation

[0049] The technical solution of the present invention will now be clearly and completely described with reference to the accompanying drawings. Obviously, the described embodiments are only some embodiments of the present invention, and not all embodiments. Based on the embodiments of the present invention, all other embodiments obtained by those skilled in the art without creative effort are within the scope of protection of the present invention.

[0050] Example 1

[0051] This embodiment provides a fully automated finished stone preparation system, which adopts a factory-style assembly line layout and is designed to process 3 million tons of finished aggregate and 200,000 tons of bagged composite powder materials per year.

[0052] I. System Composition and Connections

[0053] like Figure 1 The system structure diagram shown below includes, along the material flow direction, the following components in sequence:

[0054] 1. Raw material crushing and shaping unit 100

[0055] It includes a jaw crusher 101, a cone crusher 102, a multi-layer vibrating screen 103, and a shaping machine 104.

[0056] The jaw crusher 101 has a feed opening width of 1200mm and is used to process raw stone with a particle size ≤800mm;

[0057] The cone crusher 102 adopts a single-cylinder hydraulic cone crusher with a discharge port adjustment range of 10-30mm;

[0058] The multi-layer vibrating screen 103 has 3 layers of screen mesh: the upper layer has a screen hole size of 30mm, the middle layer has a screen hole size of 15mm, and the lower layer has a screen hole size of 5mm.

[0059] The shaping machine 104 uses a vertical shaft impact crusher to improve the aggregate particle shape.

[0060] 2. Sand making and classification unit 200

[0061] It includes a sand making machine 201, a sand making machine dust collector, and a linear vibrating classifying screen 203.

[0062] The sand making machine 201 adopts a centrifugal impact sand making machine with a power of 315kW and a processing capacity of 150t / h;

[0063] The dust collector for the sand making machine is an offline pulse bag dust collector with a filtration area of ​​1200㎡;

[0064] The linear vibrating grading screen 203 is a double-layer screen, with an upper screen aperture of 4.75mm and a lower screen aperture of 2.36mm.

[0065] 3. Finished product sorting and storage unit 300

[0066] It includes a finished product screening machine 301, a parallel set of finished product belts 1# 302, 2# 303, 304, 305, and a finished product loading unit 306.

[0067] #1 Finished product belt, made of 302 stainless steel, 1200mm wide, used for conveying 20-30mm aggregate;

[0068] #2 Finished product belt, made of 303 stainless steel, 1000mm wide, used for conveying 10-20mm aggregate;

[0069] The finished belt for conveying 5-10mm granulated stones is made of 304 stainless steel with a width of 800mm.

[0070] The dry sand finished belt is made of 305 stainless steel with a width of 800mm, and is used to transport 0-4.75mm manufactured sand.

[0071] The finished product loading unit 306 is equipped with four bulk material unloading ports, a weighbridge, and an automatic loading control system.

[0072] 4. Dust collection and stone powder recovery unit 400

[0073] It includes a dust collector network 401, a stone powder silo 402, a dust powder hopper 403, and a batching and mixing device 404.

[0074] The dust collector network 401 consists of 16 pulse bag dust collectors, which are arranged at all dust-generating points such as crushing, screening, sand making, and transfer points, with a total filtration area of ​​8,500 square meters.

[0075] Stone powder silo 402 consists of two steel silos, each with a volume of 800m³, and is equipped with a pneumatic conveying system;

[0076] There are four fly ash silos, each with a volume of 300 m³. Two silos are used to store purchased fly ash and two are used to store purchased cement.

[0077] The batching and mixing device 404 is a twin-shaft paddle mixer with a single batch mixing capacity of 3 tons and a mixing uniformity variation coefficient of ≤5%.

[0078] 5. Material circulation and buffer unit 500

[0079] This includes the wrong material return conveyor 501, the shaping line 502, and the buffer line 503.

[0080] The return conveyor belt 501, with a width of 800mm and a horizontal arrangement, is used to return the material on the vibrating screen and the unqualified finished product to the cone crusher 102 for further processing.

[0081] The shaping line 502 is an independently set vertical shaft impact crusher, specifically used for secondary shaping of some 10-20mm aggregates;

[0082] The buffer line 503 consists of three reversible belt conveyors arranged between key processes, with a single buffer capacity of 500 tons.

[0083] 6. Resource-based packaging unit 600

[0084] It includes a receiving line 601, a metering system 602, and a pressing line 603.

[0085] The receiving line 601 is a combination of a screw conveyor and a bucket elevator, which transports the powder in the stone powder silo 402 or the ash powder hopper 403 to the metering system 602.

[0086] The 602 metering system is an electronic packaging scale with a single bag weighing range of 20-50 kg and a dynamic accuracy of ±0.2%.

[0087] The 603 packing line includes an automatic bagging machine, a sealing machine, a bag-turning machine, and a palletizing robot, with a packaging speed of ≥600 bags / hour.

[0088] 7. Central Intelligent Control Unit 700

[0089] It includes a PLC controller 701, an industrial-grade human-machine interface 702, a sensor group 703, and a central server 704.

[0090] The PLC controller 701 adopts a redundant architecture with a master-slave switching time of ≤50ms.

[0091] The sensor group 703 includes a total of 280 monitoring points, such as belt scales, level gauges, vibration monitors, online particle size analyzers, and dust concentration detectors.

[0092] The central server 704 is equipped with a material balance algorithm and equipment health management system, which supports remote monitoring and fault early warning.

[0093] II. System Working Principle

[0094] During operation, the raw stone is coarsely crushed by jaw crusher 101 and medium crushed by cone crusher 102 before entering multi-layer vibrating screen 103 for grading. The material on the screen with a diameter >30mm is returned to cone crusher 102 for further crushing, while the material under the screen with a diameter <5mm enters the stone powder collection system. The intermediate material with a diameter of 5-30mm enters shaping machine 104 to improve the particle shape before entering finished product screening machine 301, and a portion enters sand making machine 201 for sand making.

[0095] The material produced by the sand making machine 201 is classified by the linear vibrating classifier 203. The material above 4.75mm is returned to the sand making machine 201 for further processing. The material between 2.36-4.75mm is used as gravel and is output by the gravel finished product belt 304. The material between 0-2.36mm is used as manufactured sand and is output by the sand finished product belt 305.

[0096] The finished product screening machine 301 divides 5-30mm aggregate into three grades: 20-30mm, 10-20mm, and 5-10mm. These grades are then output to the finished product loading unit 306 or the finished product storage yard via the No. 1 finished product belt 302, the No. 2 finished product belt 303, and the granulated stone finished product belt 304, respectively.

[0097] Dust-laden gas from all dust-generating points in the entire system is purified by the dust collector network 401. After being captured, the dust is pneumatically conveyed to the stone powder silo 402. The stone powder in the stone powder silo 402 can be directly processed into bagged products by the resource-based packaging unit 600, or mixed with fly ash and cement in the ash powder silo 403 according to the set formula in the batching and mixing device 404 to form composite powder, which is then processed into bagged products by the receiving line 601, the metering system 602, and the pressing line 603.

[0098] The wrong return conveyor belt 501 continuously returns unqualified materials to the crushing system; the buffer line 503 automatically accumulates materials when the main production equipment is under maintenance or finished product loading is suspended, and automatically releases them when the process resumes, ensuring continuous operation of the entire line; the central intelligent control unit 700 automatically adjusts the operating parameters of each device based on real-time data from the sensor group 703.

[0099] Example 2

[0100] This embodiment is basically the same as Embodiment 1, except that the control strategy of the central intelligent control unit 700 has been specifically optimized to reflect the level of intelligence of the present invention, such as... Figure 3 , Figure 4 As shown.

[0101] I. Adaptive Frequency Control of Sand Making Machine Based on Online Particle Size Analysis

[0102] An online laser particle size analyzer, one of the sensor groups 703, is installed at the end of the dry sand finished product belt 305 to monitor the fineness modulus and gradation curve of the manufactured sand in real time. The PLC controller 701 has a built-in fineness modulus target range, namely 2.6-3.0. When the measured value deviates from the target range, the system automatically adjusts according to the following rules:

[0103] If the fineness modulus is >3.0, which is too coarse, increase the rotor frequency of the sand making machine 201 by 2Hz to increase the number of crushing cycles;

[0104] If the fineness modulus is less than 2.6, which is considered too fine, the rotor frequency of the sand making machine 201 should be reduced by 2Hz to decrease the number of crushing cycles.

[0105] The adjustment step size is executed every 30 seconds until the fineness modulus returns to the target range.

[0106] Field operation data shows that this strategy reduced the daily fluctuation range of the fineness modulus of manufactured sand from ±0.35 to ±0.12, significantly improving product stability.

[0107] II. Intelligent Scheduling of Buffer Lines Based on Material Level Linkage

[0108] Radar level gauges, i.e., one of the sensor groups 703, are installed at the beginning and end of each belt conveyor in buffer line 503. The central server 704 runs the material balance algorithm.

[0109] When the downstream loading of the finished product loading unit 306 is suspended and the finished product bin material level is >85%, the buffer line 503 automatically starts forward operation and introduces the qualified aggregate produced by the finished product screening machine 301 into the buffer stockpile.

[0110] When the finished product loading unit 306 resumes loading and the finished product warehouse material level is <30%, the buffer line 503 automatically starts to run in reverse to return the buffer stockpile material to the finished product warehouse.

[0111] When the sand making machine 201 is under maintenance, the buffer line 503 automatically switches to a temporary storage channel for gravel and dry sand.

[0112] This strategy increased the overall system uptime from 72% to 91% for traditional dry line systems, and reduced outages caused by partial equipment shutdowns by 83%.

[0113] III. Order-driven automatic switching of ash powder jar formulations

[0114] The central server 704 interfaces with the enterprise's ERP system to receive daily production orders. When the ordered product is a composite mineral admixture for roadbed, the system automatically calls formula A: 70% stone powder and 30% fly ash; when the ordered product is a composite cementitious material for blocks, the system automatically calls formula B: 80% stone powder and 20% cement.

[0115] The batching and mixing device 404 automatically controls the opening degree and opening time of the unloading valve of the stone powder silo 402 and the unloading valve of the ash powder silo 403 according to the formula. The metering system 602 provides real-time feedback of the weighing signal to form a closed-loop control, and the batching accuracy reaches ±0.5%.

[0116] Example 3

[0117] This embodiment is basically the same as Embodiment 1, except that the layout and operating parameters of the dust collector network 401 are specifically limited to prove the feasibility of "dust collection efficiency not less than 99%".

[0118] I. Dust Collector Selection and Layout

[0119] The entire system is equipped with 16 pulse bag filters, with the following specific configuration:

[0120]

[0121] II. Operating Parameters and Measured Data

[0122] The dust collector network 401 is uniformly managed by the central intelligent control unit 700. The dust cleaning method is offline pulse jet cleaning, with a jet pressure of 0.5-0.6MPa and an adjustable jet interval of 60 seconds by default.

[0123] According to continuous 72-hour monitoring by a third-party testing agency, the maximum dust concentration at the outlet of each dust collector was 7.2 mg / m³. 3 Minimum value 3.1 mg / m³ 3 The average value was 4.8 mg / m³. 3 The maximum concentration of fugitive dust emissions at the factory boundary was 0.32 mg / m³. 3 It is far below the national standard of 1.0 mg / m³. 3 The dust collector's collection efficiency is calculated based on the inlet and outlet concentrations, with a minimum of 99.2% and a maximum of 99.7%.

[0124] III. Dust Conveying and Storage

[0125] Each dust collector's hopper is equipped with a pneumatic discharge valve. After discharge, the material is centrally fed into stone powder silo 402 via an air chute, bucket elevator, and pneumatic conveying system. The conveying system uses low-pressure dilute phase conveying with a conveying velocity of 18-22 m / s, a solid-to-air ratio of 8-12 kg / kg, and a maximum conveying distance of 180 m. A silo top dust collector is installed at the top of stone powder silo 402, which is activated during discharge to ensure no dust spillage during the feeding process.

[0126] Example 4

[0127] This embodiment is basically the same as Embodiment 1, except that the product type and application scenario of the resource packaging unit 600 are specifically described to prove the feasibility of "the comprehensive utilization rate of stone powder reaches 100%".

[0128] I. Direct Utilization Path of Stone Powder

[0129] When the stone powder fineness in stone powder silo 402 meets the requirement of ≤15% residue on a 0.075mm square-hole sieve, it directly enters the pressing line 603 via receiving line 601 to produce 25kg / bag mineral admixtures for concrete. This product has been tested by the National Building Materials Product Quality Supervision and Inspection Center.

[0130] Flowability ratio: 98%

[0131] Activity index 7d: 66%

[0132] Activity index 28d: 72%

[0133] Moisture content: 0.3%

[0134] Loss on ignition: 3.2%

[0135] All indicators meet the Class II fly ash technical requirements in GB / T 1596-2017 "Fly Ash for Cement and Concrete", and it can be used as a fly ash substitute for concrete with strength grades of C30 and below.

[0136] II. Utilization Path of Stone Powder

[0137] When an order requires a higher activity index, the stone powder in stone powder silo 402 is mixed with fly ash and cement in ash powder silo 403 in different proportions:

[0138] Formula 1: For roadbed filler: 70% stone powder + 30% fly ash

[0139] 7-day unconfined compressive strength: 2.8 MPa

[0140] Water stability coefficient: 0.92

[0141] It was used in a highway subgrade project, with a single batch supply of 23,000 tons, and all indicators met the requirements of JTG E51-2009 specification.

[0142] Formula 2: Masonry mortar: 80% stone powder + 20% cement

[0143] 28-day compressive strength: 12.6 MPa

[0144] Water retention rate: 91%

[0145] Setting time: 245 min

[0146] It was used in a masonry project in a residential community, with a single batch supply of 18,000 tons, meeting the requirements of GB / T 25181-2019.

[0147] Formula 3: Dry-mix plastering mortar base material: 65% stone powder + 20% fly ash + 15% cement

[0148] 28-day compressive strength: 8.4 MPa

[0149] Tensile bond strength: 0.32 MPa

[0150] Impermeability grade: P6

[0151] It was used in a plastering project for an underground parking garage, with a single batch supply of 12,000 tons, meeting the requirements of JGJ / T 223-2010.

[0152] III. Zero Emission Certificate

[0153] From its commissioning in March 2024 to February 2025, this system processed a total of 3.2 million tons of raw stone, producing 128,000 tons of stone powder, accounting for 4.0% of the raw material. Among them:

[0154] Direct packaging and sales: 53,000 tons

[0155] Sales of composite powders: 75,000 tons

[0156] Internal reuse roadbed backfill: 0 tons

[0157] Stockpiling or landfill: 0 tons

[0158] The stone powder has a 100% comprehensive utilization rate, and the system generates no process wastewater or discharges any solid waste throughout the year.

[0159] Comparative Example 1

[0160] according to Figure 2 As shown, to demonstrate the inventiveness of the present invention, Comparative Example 1 is provided: a production line using a traditional dry process.

[0161] This comparative example also has crushing, screening, and sand-making equipment, but there are the following differences:

[0162] There are no parallel and independent No. 1 / 2# finished product belts, rice stone finished product belts, and dry sand finished product belts. Production is switched using a single belt, and each switch requires a 30-45 minute downtime.

[0163] The dust collected by the dust collector is concentrated only in the stone powder silo. There are no ash powder tanks, batching and mixing devices, or pressing lines. The stone powder is sold to outsiders at a low price of 10 yuan / ton or landfilled for free.

[0164] The line was not equipped with a return conveyor and buffer line for incorrect return materials, and unqualified products had to be transferred by a loader. When a part of the equipment failed, the entire line stopped.

[0165] There is no central intelligent control unit; each device is operated independently and manually.

[0166] Comparison with operating data of Example 1, at the same production capacity:

[0167] Fineness modulus fluctuation range of manufactured sand: ±0.48

[0168] Overall line uptime: 68%

[0169] Dust emission concentration: 18-35 mg / m³ 3

[0170] Stone powder utilization rate: approximately 35%, sold at low price.

[0171] Total power consumption per ton of product: 7.2 kWh

[0172] Operating data of embodiments 1-4 of this invention:

[0173] Fineness modulus fluctuation range of manufactured sand: ±0.12

[0174] Overall line uptime: 91%

[0175] Dust emission concentration: ≤8mg / m³ 3

[0176] Stone powder comprehensive utilization rate: 100%

[0177] Comprehensive power consumption per ton of product: 6.1 kWh

[0178] The comparative data above show that, through system integration and intelligent control, the present invention has achieved significant progress in five dimensions: product quality stability, equipment operating efficiency, environmental protection level, resource utilization rate, and energy consumption level, and the effect exceeds the scope that those skilled in the art could expect through simple improvements.

[0179] The above description is merely a specific embodiment of the present invention, but the scope of protection of the present invention is not limited thereto. Any variations or substitutions that can be easily conceived by those skilled in the art within the technical scope disclosed in the present invention should be included within the scope of protection of the present invention. Therefore, the scope of protection of the present invention should be determined by the scope of the claims.

Claims

1. A fully automated finished stone material preparation system, characterized in that, Adopting a factory-style assembly line layout, the system includes the following components sequentially along the material flow: The unit includes a raw material crushing and shaping unit, a sand making and grading unit, a finished product sorting and storage unit, a dust collection and stone powder recovery unit, a material circulation and buffering unit, a resource-based packaging unit, and a central intelligent control unit. The finished product sorting and storage unit includes parallel and independently conveying 1# finished product belt, 2# finished product belt, rice stone finished product belt and dry sand finished product belt, which are used to transport products of different specifications to designated areas; The dust collection and stone powder recovery unit includes a dust collector network distributed throughout the system, a stone powder silo for centralized storage of collected dust, and a ash powder hopper for premixing powder materials. The material circulation and buffer unit includes at least a material return conveyor for handling returned materials, a shaping line for aggregate shaping, and a buffer line for balancing the process. The resource-based packaging unit includes a receiving line and a pressing line connected to the discharge port of the stone powder silo or ash powder hopper. The central intelligent control unit communicates with all the above-mentioned units to achieve automated operation of the entire system.

2. The system according to claim 1, characterized in that, The sand making and grading unit includes a sand making machine and a matching sand making dust collector. The sand making machine is used to process some of the aggregate into manufactured sand, which is then graded and output by the dry sand finished product belt.

3. The system according to claim 1, characterized in that, The finished product sorting and storage unit is equipped with a finished product loading unit at the end, which is used for bulk loading of aggregates, gravel, or manufactured sand.

4. The system according to claim 1, characterized in that, The ash powder silo receives stone powder from the stone powder silo and is equipped with an interface and mixing device for adding purchased materials such as fly ash and cement, for the production of composite powder materials.

5. The system according to claim 1, characterized in that, The dust collector network adopts centralized dust removal or distributed bag filter dust removal to ensure that dust from each dust-generating point is captured and transported to the stone powder silo.

6. A production process based on the fully automated finished stone preparation system according to any one of claims 1-5, characterized in that, Includes the following steps: Step 1: After crushing, screening, and shaping, the raw materials are used to obtain multi-grade aggregates; Step 2: Some of the aggregate is fed into a sand making machine for processing, and after grading, it produces manufactured sand and gravel; Step 3: Aggregates, gravel, and manufactured sand are sorted, stored, or loaded onto trucks via independent finished product conveyor belts; Step 4: Dust generated during the entire system's production process is collected and stored in a stone powder silo. Step 5: After the stone powder in the stone powder silo is directly mixed with fly ash, cement and other materials in the ash powder silo, it is processed into bagged products through receiving, metering and pressing processes. Step Six: Utilize return conveyors and buffer lines to adjust the system's logistics balance, and achieve full-process monitoring and automatic adjustment through the central intelligent control unit.

7. The production process according to claim 6, characterized in that, In step three, the manufactured sand is dry-produced manufactured sand with rough particle surfaces and distinct edges.

8. The production process according to claim 6, characterized in that, In step four, the dust collection efficiency shall not be less than 99%, so as to achieve compliance with the standards for fugitive emissions at the production site.

9. The production process according to claim 6, characterized in that, In step five, the bagged products produced are mineral admixtures, fillers, or customized dry-mixed mortar base materials for use in concrete or building materials.

10. The production process according to claim 6, characterized in that, The entire production process generates and discharges no process wastewater, and the comprehensive utilization rate of stone powder reaches 100%.

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