Autoclave and production method for aerated concrete blocks

Abstract

This invention relates to the field of aerated concrete block production, specifically to an autoclave and production method for aerated concrete block production. The autoclave for aerated concrete block production includes a tank body, a supporting moving body, a water-collecting plate, and a steam-generating mechanism. One end of the tank body is configured to be openable. The tank body is equipped with a vacuum extraction assembly, a polyvinyl alcohol solution spraying assembly, and a steam spraying assembly. The supporting moving body is disposed within the tank body to support and move the aerated concrete blocks within the tank body. The water-collecting plate is disposed within the tank body and located below the supporting moving body. The water-collecting plate is higher at the periphery and lower in the middle, with a water tank in the center, which is in close contact with the tank body. The steam-generating mechanism is installed outside the tank body for heating the water tank. This invention can significantly suppress the escape of moisture from the material, prolong the hydration time to enhance the material strength, and also significantly reduce the amount of aluminum powder used.

Description

Technical Field

[0001] This invention relates to the field of aerated concrete block production, specifically to an autoclave and production method for aerated concrete blocks. Background Technology

[0002] Aerated concrete blocks possess advantages such as light weight, sound insulation, good thermal insulation, and high temperature resistance. These advantages are all achieved through an autoclave during the production process. Through high-temperature and high-pressure curing, the strength and performance of the aerated concrete blocks are guaranteed, while their aesthetic appearance is not easily damaged. The working principle of the autoclave during production mainly involves curing within the vessel, including three stages: heating, maintaining a constant temperature, and cooling. The quality of various properties of the aerated concrete blocks is primarily determined by the curing temperature (pressure) and the length of the curing time. Higher temperature (pressure) ensures a more complete reaction, resulting in better performance. Furthermore, a higher curing temperature allows for a shorter curing time to achieve the same strength.

[0003] However, the inventors of this patent discovered that higher temperatures are not necessarily better during the curing process; rather, maintaining sufficient moisture at high temperatures is crucial for the reaction to continue. Once the moisture in the material has evaporated, the strength will not continue to increase. Therefore, the purpose of switching to moist heat curing after the green body has hardened to a certain extent is to inhibit moisture evaporation, ensure the hydrothermal process continues, and allow the hydrothermal reaction to be completed as thoroughly as possible.

[0004] Furthermore, the bubble generation process of aerated concrete blocks mainly relies on the addition of aluminum powder. Aluminum powder typically accounts for more than half of the gas-generating material by weight, resulting in high consumption and a significant cost component. Therefore, to reduce the cost of aerated concrete blocks, it is essential to reduce the amount of aluminum powder used. Summary of the Invention

[0005] The technical problem to be solved by the present invention is to overcome the defects of the prior art and provide an autoclave for the production of aerated bricks, which can greatly suppress the escape of moisture from the material, prolong the hydration time to enhance the strength of the material, and also greatly reduce the amount of aluminum powder used.

[0006] To solve the above-mentioned technical problems, the technical solution of the present invention is: an autoclave for producing aerated bricks, comprising:

[0007] The tank body, one end of which is configured to be openable, is equipped with a vacuum pumping assembly, a polyvinyl alcohol solution spraying assembly, and a steam spraying assembly;

[0008] A carrier is disposed inside the tank to carry the aerated concrete blocks and to move the aerated concrete blocks inside the tank.

[0009] A water-gathering plate is installed inside the tank and located below the carrier moving body. The water-gathering plate is high around the perimeter and low in the middle, with a water trough in the middle. The water trough is in close contact with the tank body.

[0010] A steam generating mechanism, installed outside the tank, is used to heat the water tank.

[0011] Furthermore, the vacuum pumping assembly and the polyvinyl alcohol solution spraying assembly are disposed at the top of the tank; the steam spraying assembly is disposed at the bottom of the tank and located around the water tank.

[0012] Furthermore, to minimize heat loss, the outer wall of the tank is provided with an insulation layer.

[0013] A specific structure for a steam forming mechanism is further provided, wherein the steam forming mechanism is an electric heating component.

[0014] A further specific structure for carrying a mobile body is provided, the mobile body including a track and a mobile platform, the track being installed inside the tank, and the mobile platform being rolled on the track by its wheels.

[0015] Furthermore, the autoclave for producing aerated concrete blocks also includes a support frame, which is located at the bottom of the tank and is used to support the tank.

[0016] To further prevent the tank from deforming and breaking due to thermal expansion and contraction, the support frame is an elastic telescopic structure.

[0017] Furthermore, the openable end of the tank is equipped with a movable end cap, and the other end is equipped with a fixed end cap.

[0018] This invention also relates to a method for producing aerated concrete blocks, comprising:

[0019] Step S1: The slurry with aluminum as foaming agent is poured into the aerated brick mold frame. Before it is fully hardened, the aerated brick mold frame enters the tank from the open end of the tank and is placed on the carrier moving body. The carrier moving body moves the aerated brick mold frame to the appropriate position in the tank and closes the end of the tank.

[0020] Step S2: Open the vacuum pumping assembly and perform a vacuuming operation inside the tank. While vacuuming, use the polyvinyl alcohol solution spraying assembly to spray a polyvinyl alcohol solution with a mass concentration of 0.4% to 1% into the tank 1. Maintain the air pressure inside the tank at 4000Pa to 6000Pa for 4-8 hours.

[0021] Step S3: Pull the aerated concrete block mold frame along with the shaped aerated concrete block out of the tank, remove the aerated concrete block mold frame, and put the aerated concrete block back into the carrier moving body.

[0022] Step S4: Start the steam forming mechanism, while the polyvinyl alcohol solution spraying component continues to spray polyvinyl alcohol solution, and the steam spraying component injects steam into the tank to maintain the temperature inside the tank at 120-200 degrees Celsius and the pressure at 1.2-1.4 MPa. Curing is carried out for 3-5 hours, then the pressure and temperature are reduced, and the aerated brick is removed.

[0023] By adopting the above technical solution, the present invention has the following beneficial effects:

[0024] 1. By using the autoclave of the present invention, the amount of aluminum powder used can be greatly reduced. While maintaining the original porosity, the amount of aluminum powder used can be reduced by 1 / 4 to 1 / 2.

[0025] 2. The autoclave of this invention has strong water (steam) retention performance, which can greatly inhibit the escape of moisture from the material, allowing the hydration reaction to continue, prolonging the hydration time and enhancing the strength of the material.

[0026] 3. The autoclave in this invention, through its spraying action on the material surface, can make the material surface relatively smooth;

[0027] 4. This invention recovers and heats condensate in a timely manner, which can save thermal energy and reduce pollution. Attached Figure Description

[0028] Figure 1 This is a schematic diagram of the autoclave used for producing aerated bricks according to the present invention;

[0029] Figure 2 This is a schematic diagram of the autoclave for producing aerated concrete blocks (with an aerated concrete block mold frame) according to the present invention.

[0030] Figure 3 This is a schematic diagram of the autoclave for producing aerated concrete blocks (without the mold frame) according to the present invention.

[0031] Figure 4 This is a schematic diagram of the structure of the mobile platform carrying aerated concrete blocks (with aerated concrete block mold frame) according to the present invention;

[0032] In the diagram, 1 is the tank body; 11 is the movable head; 12 is the fixed head; 2 is the vacuum pumping assembly; 3 is the polyvinyl alcohol solution spraying assembly; 4 is the steam spraying assembly; 5 is the carrier moving body; 51 is the track; 52 is the moving platform; 6 is the support frame; 7 is the water collection plate; 8 is the water tank; 9 is the steam forming mechanism; 10 is the insulation layer; 100 is the aerated concrete block; and 200 is the aerated concrete block mold frame. Detailed Implementation

[0033] To make the content of this invention easier to understand, the invention will be further described in detail below with reference to specific embodiments and accompanying drawings.

[0034] like Figures 1 to 4 As shown, an autoclave for producing aerated concrete blocks includes:

[0035] Tank 1, one end of which is configured to be openable, and tank 1 is equipped with a vacuum pumping assembly 2, a polyvinyl alcohol solution spraying assembly 3 and a steam spraying assembly 4;

[0036] The carrier 5 is installed inside the tank 1 to carry the aerated concrete block 100 and drive the aerated concrete block 100 to move inside the tank 1.

[0037] The water collection plate 7 is installed inside the tank 1 and located below the carrier moving body 5. The water collection plate 7 is high around the perimeter and low in the middle, which can collect the condensate in the tank 1 in one place. A water tank 8 is set in the middle, and the water tank 8 is close to the tank 1.

[0038] The steam generating mechanism 9 is installed outside the tank 1, directly opposite the water tank 8, to heat the water tank 8 and ensure the amount of water vapor inside the tank 1.

[0039] A method for producing aerated concrete blocks based on an autoclave for aerated concrete block production includes:

[0040] Step S1: The slurry using aluminum as a foaming agent is poured into the aerated concrete block mold frame 200. While it is not yet fully hardened, the aerated concrete block mold frame 200 enters the tank 1 from the open end and is placed on the supporting moving body 5. The supporting moving body 5 moves the aerated concrete block mold frame 200 to a suitable position inside the tank 1, and then the end of the tank 1 is closed. Figure 2 As shown;

[0041] Step S2: Open the vacuum pumping component 2 to perform a vacuuming operation inside the tank 1, gradually reducing the air pressure inside the tank 1 until it approaches a vacuum. Maintain the air pressure at 4000Pa to 6000Pa for 4-8 hours, making the aluminum bubbles in the slurry larger and the aerated concrete block 100 lighter; that is, while obtaining the same amount of bubbles, the amount of aluminum used can be reduced. At the same time as vacuuming, use the polyvinyl alcohol solution spraying component 3 to spray a polyvinyl alcohol solution with a mass concentration of 0.4% to 1% into the tank 1, which maintains humidity and keeps the surface of the aerated concrete block 100 relatively smooth, preventing it from becoming rough due to the rupture of surface bubbles. Polyvinyl alcohol can also be used to form a polymer film on the surface of the aerated concrete block 100, controlling the evaporation of moisture on the surface of the aerated concrete block 100. After vacuuming and maintaining it for 4-8 hours, the bubbles are basically fixed.

[0042] Step S3: Pull the aerated concrete block mold frame 200 along with the shaped aerated concrete block 100 out of the tank body 1, remove the aerated concrete block mold frame 200, and put the aerated concrete block 100 back into the supporting moving body 5, as shown. Figure 3 As shown;

[0043] Step S4: Start the steam forming mechanism 9, and at the same time, the polyvinyl alcohol solution spraying component 3 continues to spray polyvinyl alcohol solution to increase the humidity inside the tank; the steam spraying component 4 sprays steam into the tank 1 to increase the temperature inside the tank 1, maintain the temperature inside the tank 1 at 120-200 degrees Celsius and the pressure at 1.2-1.4 MPa, and cure for 3-5 hours. After completion, reduce the pressure and temperature, and take out the aerated brick 100.

[0044] Using the autoclave in this embodiment can significantly reduce the amount of aluminum powder used. While maintaining the original porosity, the amount of aluminum powder used can be reduced by 1 / 4 to 1 / 2. Furthermore, the autoclave in this embodiment has strong water (vapor) retention performance, which can greatly inhibit the escape of moisture from the material, allowing the hydration reaction to continue, prolonging the hydration time and enhancing the strength of the material. The spraying effect on the material surface can make the material surface relatively smooth. The recovery and timely heating of condensate can save heat energy and reduce the generation of pollution.

[0045] In one embodiment, such as Figure 1 , Figure 2 and Figure 3 As shown, the vacuum pumping assembly 2 and the polyvinyl alcohol solution spraying assembly 3 are located at the top of the tank 1; the steam spraying assembly 4 is located at the bottom of the tank 1 and around the water tank 8.

[0046] In one embodiment, such as Figure 1 , Figure 2 and Figure 3 As shown, the outer wall of tank 1 is provided with a heat insulation layer 10.

[0047] Specifically, the insulation layer 10 can play a role in heat preservation, minimizing heat loss inside the tank 1.

[0048] In one embodiment, such as Figure 1 , Figure 2 and Figure 3 As shown, the steam forming mechanism 9 is an electric heating component, which can be an electric heating tube or an electromagnetic heater. The one shown in the figure is an electric heating tube.

[0049] In one embodiment, such as Figure 1 , Figure 2 and Figure 3 As shown, a movable end cap 11 is installed at the openable end of the tank body 1, and a fixed end cap 12 is provided at the other end.

[0050] In one embodiment, such as Figures 1 to 4As shown, the mobile carrier 5 includes a track 51 and a mobile platform 52. The track 51 is installed inside the tank 1, and the mobile platform 52 is mounted on the track 51 by its wheels. The track 51 extends from the end where the movable end cap 11 is located to the end where the fixed end cap 12 is located. The mobile platform 52 moves along the track 51, allowing the aerated concrete blocks 100 to be transported in and out.

[0051] The mobile platform 52 can be a platform with its own power mechanism. The mobile platform 52 is equipped with a motor, which drives the wheels of the mobile platform 52 to rotate, thereby enabling the mobile platform 52 to move along the track 51.

[0052] Of course, the mobile platform 52 can also be a platform without a power mechanism, which can be moved along the track 51 by pushing and pulling by manpower using tools. It can also be equipped with a mobile drive mechanism such as an electric push rod, hydraulic cylinder, or pneumatic cylinder, which can drive the mobile platform to move along the track 51.

[0053] In addition, such as Figures 1 to 4 As shown, the plane of the mobile platform 52 for placing the aerated concrete block 100 or aerated concrete block module 200 is provided with multiple drainage holes. The aerated concrete block 100 or aerated concrete block module 200 are placed at intervals on this plane, so that some of the drainage holes are exposed, which makes it convenient for the sprayed liquid to leak down from the drainage holes; during vacuuming, it also plays a role in air permeability, so that the vacuuming operation of the entire autoclave can be performed more quickly.

[0054] In one embodiment, such as Figure 1 , Figure 2 and Figure 3 As shown, the autoclave for producing aerated concrete blocks also includes a support frame 6, which is located at the bottom of the tank body 1 and is used to support the tank body 1. The support frame 6 can be an elastic telescopic structure.

[0055] Specifically, the support frame 6 allows the tank 1 to expand and contract freely during thermal expansion and contraction, preventing damage to the tank 1 due to temperature changes.

[0056] The following is about Figure 1 , Figure 2 and Figure 3 The working process of the autoclave for producing aerated bricks (a preferred embodiment of the present invention) is described in detail.

[0057] During operation, a slurry containing aluminum as a foaming agent is poured into the aerated concrete block mold frame 200. Before it is fully hardened, the mold frame 200 containing the slurry is pushed into the tank 1 using the track 51. The movable end cap 11 is closed, and the vacuum pumping component 2 at the top of the tank 1 is opened, gradually reducing the air pressure inside the tank 1 until it approaches a vacuum. The air pressure is maintained at 4000Pa to 6000Pa for 4-8 hours, which makes the aluminum bubbles in the slurry larger, making the aerated concrete block 100 lighter. That is, while obtaining the same amount of bubbles, the amount of aluminum used can be reduced. The volume is as follows: While vacuuming, the polyvinyl alcohol solution spraying component 3 at the top of the tank 1 sprays a polyvinyl alcohol solution with a mass concentration of 0.4% to 1% into the tank 1. This maintains humidity and keeps the surface of the aerated brick 100 relatively smooth, preventing it from becoming rough due to the rupture of surface bubbles. Polyvinyl alcohol can also form a polymer film on the surface of the aerated brick 100 to control the evaporation of moisture on the surface of the aerated brick 100. After vacuuming and maintaining the vacuum for 4-8 hours, the bubbles are basically fixed. Then, the tank 1 is pulled out and the aerated brick mold frame 200 is removed.

[0058] After removing the aerated concrete block mold frame 200, the aerated concrete block 100 is placed back into the tank 1. The electric heating tube at the bottom of the tank 1 is activated to continuously heat the water inside, ensuring sufficient water vapor. Simultaneously, the polyvinyl alcohol solution spraying assembly 3 continues to spray the polyvinyl alcohol solution, increasing the humidity inside the tank 1. Steam is injected into the tank 1 through the steam spraying assembly 4 at the bottom of the tank 1, raising the temperature inside the tank 1 and maintaining it at 120-200 degrees Celsius. The insulation layer 10 provides insulation, minimizing heat loss from the tank 1. The pressure inside the tank 1 is maintained at 1.2-1.4 MPa for 3-5 hours. After curing, the pressure and temperature are reduced, and the aerated concrete block 100 is removed. Throughout the process, the support frame 6 can freely expand and contract with the thermal expansion and contraction of the tank 1, preventing damage to the tank 1 due to temperature changes. During the cooling and depressurization stage, the water collection plate 7 is high around the perimeter and low in the middle, which can collect the condensate in the tank 1 into the water tank 8 at the bottom center of the water collection plate 7, thereby realizing the recovery of condensate and reducing the generation of pollution.

[0059] Based on the above-described preferred embodiments of the present invention, and through the foregoing description, those skilled in the art can make various changes and modifications without departing from the inventive concept. The technical scope of this invention is not limited to the contents of the specification, but must be determined according to the scope of the claims.

Claims

1. A method for producing aerated concrete blocks based on an autoclave for aerated concrete block production, characterized in that, Autoclaves used in the production of aerated concrete blocks include: The tank (1) is configured to be openable at one end and is equipped with a vacuum pumping assembly (2), a polyvinyl alcohol solution spraying assembly (3) and a steam spraying assembly (4). The carrier (5) is disposed inside the tank (1) to carry the aerated concrete block (100) and drive the aerated concrete block (100) to move inside the tank (1); A water-gathering plate (7) is set inside the tank (1) and located below the carrier moving body (5). The water-gathering plate (7) is high around the periphery and low in the middle, and a water trough (8) is set in the middle. The water trough (8) is close to the tank (1). A steam forming mechanism (9) is installed outside the tank (1) for heating the water tank (8); The methods include: Step S1: The slurry with aluminum as foaming agent is poured into the aerated brick mold frame (200). Before it is fully hardened, the aerated brick mold frame (200) enters the tank (1) from the open end and is placed on the carrier moving body (5). The carrier moving body (5) drives the aerated brick mold frame (200) to move to a suitable position in the tank (1) and closes the end of the tank (1). Step S2: Open the vacuum pumping assembly (2) and perform a vacuuming operation inside the tank (1). While vacuuming, use the polyvinyl alcohol solution spraying assembly (3) to spray a polyvinyl alcohol solution with a mass concentration of 0.4%~1% into the tank (1). The air pressure inside the tank (1) is maintained at 4000Pa~6000Pa for 4-8 hours. Step S3: Pull the aerated concrete block mold frame (200) and the shaped aerated concrete block (100) out of the tank body (1), remove the aerated concrete block mold frame (200), and put the aerated concrete block (100) back into the carrier moving body (5). Step S4: Start the steam forming mechanism (9), while the polyvinyl alcohol solution spraying assembly (3) continues to spray polyvinyl alcohol solution, and the steam spraying assembly (4) sprays steam into the tank (1) to maintain the temperature inside the tank (1) at 120~200 degrees and the pressure at 1.2~1.4MPa. After curing for 3~5 hours, reduce the pressure and temperature, and take out the aerated brick (100).

2. The method for producing aerated concrete blocks according to claim 1, characterized in that, The vacuum pumping assembly (2) and the polyvinyl alcohol solution spraying assembly (3) are disposed on the top of the tank (1); The steam injection assembly (4) is located at the bottom of the tank (1) and around the water tank (8).

3. The method for producing aerated concrete blocks according to claim 1, characterized in that, The outer wall of the tank (1) is provided with a heat insulation layer (10).

4. The method for producing aerated concrete blocks according to claim 1, characterized in that, The steam forming mechanism (9) is an electric heating component.

5. The method for producing aerated concrete blocks according to claim 1, characterized in that, The carrier mobile body (5) includes a track (51) and a mobile platform (52). The track (51) is installed inside the tank (1), and the mobile platform (52) is mounted on the track (51) by its wheels.

6. The method for producing aerated concrete blocks according to claim 1, characterized in that, The tank (1) has a movable end cap (11) installed at the openable end and a fixed end cap (12) installed at the other end.

7. The method for producing aerated concrete blocks according to claim 1, characterized in that, It also includes a support frame (6), which is located at the bottom of the tank (1) and is used to support the tank (1).

8. The method for producing aerated concrete blocks according to claim 7, characterized in that, The support frame (6) is an elastic telescopic structure.

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