CN113232146A - Production method and production line of fiber cement board or calcium silicate board - Google Patents
Production method and production line of fiber cement board or calcium silicate board Download PDFInfo
- Publication number
- CN113232146A CN113232146A CN202110584866.1A CN202110584866A CN113232146A CN 113232146 A CN113232146 A CN 113232146A CN 202110584866 A CN202110584866 A CN 202110584866A CN 113232146 A CN113232146 A CN 113232146A
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- board
- calcium silicate
- fiber cement
- plate blank
- plate
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 71
- 239000004568 cement Substances 0.000 title claims abstract description 55
- 239000000378 calcium silicate Substances 0.000 title claims abstract description 51
- 229910052918 calcium silicate Inorganic materials 0.000 title claims abstract description 51
- OYACROKNLOSFPA-UHFFFAOYSA-N calcium;dioxido(oxo)silane Chemical compound [Ca+2].[O-][Si]([O-])=O OYACROKNLOSFPA-UHFFFAOYSA-N 0.000 title claims abstract description 51
- 239000000835 fiber Substances 0.000 title claims abstract description 51
- 238000001035 drying Methods 0.000 claims abstract description 48
- 229910000831 Steel Inorganic materials 0.000 claims abstract description 39
- 239000010959 steel Substances 0.000 claims abstract description 39
- 238000004537 pulping Methods 0.000 claims abstract description 20
- 238000009966 trimming Methods 0.000 claims abstract description 10
- 238000005096 rolling process Methods 0.000 claims abstract description 8
- 238000013461 design Methods 0.000 claims abstract description 4
- 238000000034 method Methods 0.000 claims description 69
- 230000008569 process Effects 0.000 claims description 60
- 238000003825 pressing Methods 0.000 claims description 35
- 230000006835 compression Effects 0.000 claims description 29
- 238000007906 compression Methods 0.000 claims description 29
- 238000005520 cutting process Methods 0.000 claims description 20
- 239000002994 raw material Substances 0.000 claims description 11
- 238000004321 preservation Methods 0.000 claims description 10
- 229910001220 stainless steel Inorganic materials 0.000 claims description 10
- 239000010935 stainless steel Substances 0.000 claims description 10
- 230000003068 static effect Effects 0.000 claims description 9
- 238000004590 computer program Methods 0.000 claims description 5
- 238000000926 separation method Methods 0.000 claims description 5
- 238000010438 heat treatment Methods 0.000 claims description 3
- 238000005265 energy consumption Methods 0.000 abstract description 5
- XLYOFNOQVPJJNP-UHFFFAOYSA-N water Substances O XLYOFNOQVPJJNP-UHFFFAOYSA-N 0.000 description 15
- 239000002002 slurry Substances 0.000 description 8
- 230000008901 benefit Effects 0.000 description 6
- 230000005540 biological transmission Effects 0.000 description 6
- 230000007246 mechanism Effects 0.000 description 5
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 4
- 239000004570 mortar (masonry) Substances 0.000 description 4
- 235000019353 potassium silicate Nutrition 0.000 description 4
- 238000012545 processing Methods 0.000 description 4
- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 description 4
- 238000003756 stirring Methods 0.000 description 4
- 239000010456 wollastonite Substances 0.000 description 4
- 229910052882 wollastonite Inorganic materials 0.000 description 4
- 229920001131 Pulp (paper) Polymers 0.000 description 3
- 239000013078 crystal Substances 0.000 description 3
- 238000010586 diagram Methods 0.000 description 3
- 230000000694 effects Effects 0.000 description 3
- 239000000463 material Substances 0.000 description 3
- 239000000843 powder Substances 0.000 description 3
- 238000003860 storage Methods 0.000 description 3
- 239000006004 Quartz sand Substances 0.000 description 2
- FFBHFFJDDLITSX-UHFFFAOYSA-N benzyl N-[2-hydroxy-4-(3-oxomorpholin-4-yl)phenyl]carbamate Chemical compound OC1=C(NC(=O)OCC2=CC=CC=C2)C=CC(=C1)N1CCOCC1=O FFBHFFJDDLITSX-UHFFFAOYSA-N 0.000 description 2
- 230000002860 competitive effect Effects 0.000 description 2
- 238000007688 edging Methods 0.000 description 2
- 238000000227 grinding Methods 0.000 description 2
- 238000012423 maintenance Methods 0.000 description 2
- 230000036961 partial effect Effects 0.000 description 2
- 239000010453 quartz Substances 0.000 description 2
- 238000004064 recycling Methods 0.000 description 2
- 238000007789 sealing Methods 0.000 description 2
- 239000000126 substance Substances 0.000 description 2
- 238000013519 translation Methods 0.000 description 2
- 238000005406 washing Methods 0.000 description 2
- 230000004075 alteration Effects 0.000 description 1
- 238000010009 beating Methods 0.000 description 1
- 230000001680 brushing effect Effects 0.000 description 1
- 239000004566 building material Substances 0.000 description 1
- AXCZMVOFGPJBDE-UHFFFAOYSA-L calcium dihydroxide Chemical compound [OH-].[OH-].[Ca+2] AXCZMVOFGPJBDE-UHFFFAOYSA-L 0.000 description 1
- 239000000920 calcium hydroxide Substances 0.000 description 1
- 229910001861 calcium hydroxide Inorganic materials 0.000 description 1
- 235000011116 calcium hydroxide Nutrition 0.000 description 1
- 239000004567 concrete Substances 0.000 description 1
- 238000005336 cracking Methods 0.000 description 1
- 238000005034 decoration Methods 0.000 description 1
- 238000011068 loading method Methods 0.000 description 1
- 238000012986 modification Methods 0.000 description 1
- 230000004048 modification Effects 0.000 description 1
- 239000010451 perlite Substances 0.000 description 1
- 235000019362 perlite Nutrition 0.000 description 1
- 238000005498 polishing Methods 0.000 description 1
- 238000007517 polishing process Methods 0.000 description 1
- 238000002360 preparation method Methods 0.000 description 1
- 238000007639 printing Methods 0.000 description 1
- 238000005086 pumping Methods 0.000 description 1
- 238000012797 qualification Methods 0.000 description 1
- 238000011084 recovery Methods 0.000 description 1
- 238000006467 substitution reaction Methods 0.000 description 1
- 230000007306 turnover Effects 0.000 description 1
Images
Classifications
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B15/00—General arrangement or layout of plant ; Industrial outlines or plant installations
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/08—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads
- B28B11/0845—Apparatus or processes for treating or working the shaped or preshaped articles for reshaping the surface, e.g. smoothing, roughening, corrugating, making screw-threads for smoothing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/12—Apparatus or processes for treating or working the shaped or preshaped articles for removing parts of the articles by cutting
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B11/00—Apparatus or processes for treating or working the shaped or preshaped articles
- B28B11/24—Apparatus or processes for treating or working the shaped or preshaped articles for curing, setting or hardening
- B28B11/245—Curing concrete articles
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/12—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material
- B28B3/126—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein one or more rollers exert pressure on the material on material passing directly between the co-operating rollers
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- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Devices For Post-Treatments, Processing, Supply, Discharge, And Other Processes (AREA)
Abstract
The invention discloses a method for producing a fiber cement board or a calcium silicate board, which comprises the following steps: pulping and making a plate to obtain a plate blank; carrying out fixed-thickness and fixed-pressure steel belt rolling treatment on the plate blank by adopting a single tablet press; trimming, namely trimming the edges of the plate blank according to the design requirement; continuously drying the board surface for a short time, and quickly drying the surface of the board blank at the temperature of 80-120 ℃ to ensure that the surface is not bonded; stacking, and keeping the stacked plate blank at the temperature of 50-60 ℃ for standing for 8-12 h; putting the plate blank into a still kettle for steam curing treatment; and (4) separating the boards, drying and sorting to obtain the finished product of the fiber cement board or the calcium silicate board. The production method of the fiber cement board or the calcium silicate board provided by the invention has the characteristics of simple equipment, small occupied area, low energy consumption, low labor consumption, higher automation degree, more stable product quality, higher product percent of pass and the like. The invention also provides a fiber cement board or calcium silicate board production line.
Description
Technical Field
The invention relates to the technical field of building material production, in particular to a production method and a production line of a fiber cement board or a calcium silicate board.
Background
At present, the process for producing fiber cement boards and calcium silicate boards at home and abroad mainly comprises the following processes: 1. a raw material processing and pulping system; 2. a board making system; 3. a stacking system of plate blank trimming and a plate-die; 4. a pallet pressurization system; 5. a stacking plate pre-curing system; 6. a slab demoulding and restacking and template deashing and oil brushing system; 7. a slab steam curing system; 8. a board splitting system; 9. a board drying system; 10. a sanding, edging and chamfering system for subsequent processing of the plate; 11. and classifying and warehousing the qualified products and the unqualified products.
Although the existing production processes of fiber cement boards and calcium silicate boards are mature, the problems of various working procedures, large occupied area, large investment, high energy consumption, high consumable items, high cost, more manpower, high equipment maintenance cost, low automation degree and the like exist.
In view of the above, it is necessary to provide a new process to solve the above technical problems.
Disclosure of Invention
The invention aims to solve the technical problem of providing a production method and a production line of a fiber cement board or a calcium silicate board, and the production method and the production line have the characteristics of simple equipment, small occupied area, low energy consumption, few manpower, higher automation degree, more stable product quality, higher product percent of pass and the like.
In order to solve the problems, the technical scheme of the invention is as follows:
a fiber cement board or calcium silicate board production method comprises the following steps:
step S1, pulping and plate making to obtain a plate blank;
step S2, a single tablet press is adopted to carry out the fixed thickness and fixed pressure steel belt rolling treatment on the plate blank;
step S3, trimming, namely trimming edges of the plate blank according to design requirements;
step S4, continuously drying the board surface for a short time, and quickly drying the surface of the board blank at the temperature of 80-120 ℃ to ensure that the surface is not bonded;
s5, stacking, and keeping the stacked plate blank at the temperature of 50-60 ℃ for 8-12 h;
step S6, putting the plate blank into a still kettle for steam curing treatment;
and step S7, board separation, drying and sorting to obtain the finished product of the fiber cement board or the calcium silicate board.
Further, the monolithic tablet press includes that the compression roller and lower compression roller, wind on the multiunit go up the last conveying steel band that the compression roller set up, wind the lower conveying steel band that the compression roller set up down, be used for the drive go up the compression roller and down compression roller simultaneous movement's drive arrangement, locate every a set of go up the compression roller be used for adjusting compression roller pressure and the adjusting device in clearance to and go up conveying steel band tensioning deviation adjusting deflector roll and conveying steel band down and adjust the deflector roll, during operation, the slab is compressed through last conveying steel band and lower conveying steel band biography power pressurized under the effect of last compression roller and lower compression roller.
Furthermore, along the direction of the conveying path of the plate blank, the gap adjusting range of the front groups of upper pressing rollers and lower pressing rollers is 3-30 mm; the linear pressure adjusting range of the upper pressing rolls and the lower pressing rolls in the first groups is 60-120kg/cm, the gap adjusting range of the upper pressing rolls and the lower pressing rolls in the last group is adjusted according to the required size of the product, the linear pressure of the upper pressing rolls and the lower pressing rolls in the last group is 1000-2000kg/cm, and the compression amount of each group of pressing rolls is 5-10%.
Further, along the conveying path direction of the plate blank, gaps of each group of upper pressing rolls and lower pressing rolls are arranged from large to small at equal ratio, and linear pressures of each group of upper pressing rolls and lower pressing rolls are arranged from small to large at equal ratio.
Furthermore, the continuous short-time plate surface drying process adopts a tunnel type dryer driven by a stainless steel mesh belt, and the tunnel type dryer comprises a rack, the stainless steel mesh belt arranged on the rack, a sealed heat shield arranged on the rack, and a heating device arranged on the sealed heat shield.
Further, the linear speed of the tunnel dryer is 20-28m/min, the surface moisture of the surface-dried plate blank is controlled at 18-25%, and the internal moisture of the plate blank is controlled at 36-42%.
Furthermore, the plate drying process after the plate separation of the autoclave adopts a comb dryer, the comb dryer comprises a chain track, a chain with a fixed plate, a product fixing frame, a top cover, a heat preservation layer, a heat source fixing frame, a heat source and a fan, the chain is arranged on the chain track, the product fixing frame is arranged on the chain with the fixed plate, the top cover is arranged above the product fixing frame, the heat preservation layer is arranged on the inner side of the top cover, the heat source fixing frame is fixed on the top cover, the heat source is arranged on the heat source fixing frame, the fan is fixed on the top cover and used for providing circulating hot air, the product fixing frame comprises a plurality of fixing plates which are arranged obliquely at intervals, and the plate blank is supported on the fixing plates during operation.
Further, the fan comprises a motor, blades and a rotating shaft connected with the blades, the motor is in transmission connection with the rotating shaft through a triangular belt, and the drying temperature of the comb type dryer is 100-140 ℃.
Further, the whole production process of the fiber cement board or calcium silicate board finished product is controlled by a computer program.
The invention also provides a fiber cement board or calcium silicate board production line, which comprises a raw material treatment and pulping process, a board making process, a slab thickness setting process, a constant-pressure single-piece tabletting process, an edge cutting process, a continuous short-time board surface drying process, a pre-kettle heat preservation and static stopping process, an autoclave steam curing process, a board dividing process, a drying process and an automatic classification, stacking and warehousing process which are sequentially arranged.
Compared with the prior art, the production method and the production line of the fiber cement board or the calcium silicate board have the advantages that:
the invention provides a fiber cement board or calcium silicate board production method and a production line, wherein a board blank after board manufacturing is sequentially subjected to fixed thickness, fixed-pressure steel belt rolling treatment, edge cutting treatment, continuous surface drying treatment of the board blank, static treatment before stacking and kettle entering, autoclave steam curing treatment, board separating treatment and drying treatment. The fixed-thickness and fixed-pressure steel belt is subjected to rolling treatment to ensure that the plate blank is equal in thickness and density, the upper surface is compact and smooth, and blanket printing on the lower surface is reduced or eliminated, so that the product quality can be improved, and subsequent processes such as surface grinding and polishing can be omitted; the plate blanks after edge cutting are subjected to continuous surface drying, so that most of water on the surface is lost, and a state that the surface is dry and non-sticky is formed, therefore, the plate blanks after surface drying can be directly stacked and then subjected to pre-curing standing and steam curing treatment, and compared with a one-plate one-die process mode in the prior art, the method not only saves equipment cost, but also can save the process time of multiple stacking and demolding in the prior art, and improves the working efficiency; because the invention adopts the mode of combining single-piece drying and heat preservation standing, the drying time and the temperature of each part of each plate blank are constant, the moisture content of each part of each plate blank can be ensured to be consistent, the effective crystal substances generated by each part of the plate blank after the plate blank is put into the autoclave can be consistent, the generation of cracked plates can be completely avoided, the quality consistency of each plate blank is ensured, and the product quality is more stable. Therefore, compared with the prior art, the production method and the production line for the fiber cement board or the calcium silicate board provided by the invention can reduce a plurality of working procedures, and have the characteristics of high production efficiency, high automation degree, less manpower, low energy consumption, low production cost and the like, and meanwhile, the used equipment is simple, and has the advantages of low equipment investment cost, small occupied area and the like, and the obtained product has stable quality.
Drawings
In order to more clearly illustrate the technical solutions in the embodiments of the present invention, the drawings needed to be used in the description of the embodiments will be briefly introduced below, and it is obvious that the drawings in the following description are only some embodiments of the present invention, and it is obvious for those skilled in the art to obtain other drawings based on these drawings without creative efforts.
FIG. 1 is a schematic view of a fiber cement board or calcium silicate board production line provided by the present invention;
FIG. 2 is a schematic view of a single sheet press in the fiber cement board or calcium silicate board production line of FIG. 1;
FIG. 3 is a schematic view of another angle configuration of the single sheet press of FIG. 2;
FIG. 4 is a schematic view of a tunnel dryer in the production line of the fiber cement board or calcium silicate board shown in FIG. 1;
FIG. 5 is a schematic view of a comb dryer in the production line of the fiber cement board or calcium silicate board shown in FIG. 1;
FIG. 6 is a schematic view of a portion of the comb dryer of FIG. 5;
FIG. 7 is a schematic flow chart of the method for producing fiber cement board or calcium silicate board provided by the present invention.
Detailed Description
In order to make the technical solutions in the embodiments of the present invention better understood and make the above objects, features, and advantages of the present invention more comprehensible, specific embodiments of the present invention are described below with reference to the accompanying drawings.
It should be noted that the description of the embodiments is provided to help understanding of the present invention, but the present invention is not limited thereto. In addition, the technical features involved in the embodiments of the present invention described below may be combined with each other as long as they do not conflict with each other.
Referring to fig. 1, a schematic diagram of a fiber cement board or calcium silicate board production line provided by the present invention is shown. The production line of the fiber cement board or the calcium silicate board comprises a raw material processing and pulping process 1, a board making process 2, a board blank thickness setting, a constant-pressure single-piece tabletting process 3, an edge cutting process 4, a continuous short-time board surface drying process 5, a pre-kettle heat preservation and static stopping process 6, an autoclave steam curing process 7, a board dividing process 8, a drying process 9 and an automatic classification, stacking and warehousing process 10.
The process of the raw material treatment and pulping process 1 and the plate making process 2 refers to the prior art, and the process flow is as follows:
raw material treatment and pulping process: inputting raw material data into a computer of a raw material processing and pulping system, controlling by a computer program, feeding pulp board paper into a paper shredder through a belt conveyor to prepare pulp, achieving the requirements of resolution and wet weight through a pulp grinder, feeding the pulp board paper into a pulp making machine through a metering tank, feeding the pulp board paper into the pulp making machine, feeding cement in a cement tank into the metering tank through a screw conveyor and then into the pulp making machine, feeding quartz sand into a hopper through a loading vehicle, feeding the quartz sand and water into a ball mill through a belt conveyor to be ground into mortar, feeding the mortar into a stirring tank, pumping the mortar into a mortar stirring storage tank, the method comprises the following steps that wollastonite in a wollastonite pot is conveyed into a metering tank and a pulping machine by a pump, enters the metering tank and then enters the pulping machine, water glass in the water glass pot enters the pulping machine again by a flow meter through a pipeline pump, the pulping machine prepares raw materials and mixed water in a water return large tank into slurry with a certain concentration within a set time according to set process requirements, and the slurry is pumped into a slurry storage tank, and then the slurry is pumped into a pre-stirring tank of a plate making system by the slurry storage tank;
the plate making process includes forming homogeneous thin material layer on the blanket with the pre-stirring tank slurry in the plate making machine via the net wheel cage blanket feeding mechanism or the head box blanket feeding mechanism, vacuum dewatering, rolling into plate blank in the forming cylinder, inserting the plate blank in the blank accepting machine in the linear speed 15-30% higher than that of the forming cylinder, and conveying the plate blank to the constant thickness and constant pressure steel belt rolling and trimming system with the blank accepting belt; water and vacuum dewatering pump of the blanket washing machine are pumped into a backwater large tank to separate clear water and mixed water, the clear water is used for washing the blanket and making paper pulp, the mixed water is used for pulping, and water circulation is not discharged.
Referring to fig. 2 and 3, fig. 2 is a schematic structural view of a single-piece sheet press in the fiber cement board or calcium silicate board production line shown in fig. 1; fig. 3 is a schematic view of another angle configuration of the single sheet press of fig. 2. In the invention, the equipment used in the plate blank thickness-fixing and pressure-fixing single-piece tabletting process 3 is a single-piece tabletting machine, also called a steel belt roller press. The single-chip tablet press comprises a plurality of groups of upper press rollers 31, lower press rollers 32, upper conveying steel belts 33 arranged around the upper press rollers 31, lower conveying steel belts 34 arranged around the lower press rollers 32, a driving device 35 for driving the upper press rollers and the lower press rollers to move synchronously, an adjusting device 36 arranged on each group of upper press rollers for adjusting the pressure and the gap of the press rollers, an upper conveying steel belt tensioning deviation adjusting guide roller 37 and a lower conveying steel belt adjusting guide roller 38.
In this embodiment, a plurality of sets of upper press rolls 31 and lower press rolls 32 are arranged at intervals, and the upper and lower conveying steel belts 33 and 34 are annular steel belts and move synchronously with the upper and lower press rolls 31 and 32, respectively. The driving device 35 comprises a power part 351 and a transmission gear 352 driven by the power part 351, and the upper press roller 31 and the lower press roller 32 are respectively connected and driven by gears with the same size, so that the linear speeds of the upper press roller 31 and the lower press roller 32 are consistent, and the linear speeds of the upper conveying steel belt 33 and the lower conveying steel belt 34 are ensured to be consistent.
The adjusting device 36 comprises a spring, a feeler gauge and a pressure adjusting handle, and adjusts the gap between the upper pressing roller 31 and the lower pressing roller 32 by rotating the pressure adjusting handle, and realizes the adjustment of the pressure on the plate blank. It should be noted that the gap and pressure between each set of upper and lower press rolls 31 and 32 can be adjusted individually. The pressure and the clearance of each group of compression rollers are adjusted according to the density requirement and the thickness requirement of a determined product, and the compression amount of each group of compression rollers on the plate blank is adjustable. Specifically, along the direction of a conveying path of the plate blank, the gap adjusting range of the front groups of upper pressing rollers and lower pressing rollers is 3-30 mm; the linear pressure adjusting range of the upper pressing roller and the lower pressing roller of the first groups is 60-120kg/cm, the gap adjusting range of the upper pressing roller and the lower pressing roller of the last group is adjusted according to the required size of the product, the linear pressure of the upper pressing roller and the lower pressing roller of the last group is 1000-2000kg/cm, and the compression amount of each group of pressing rollers is 5-10%; preferably, the gaps between the upper pressing roller and the lower pressing roller of each group are arranged from large to small at an equal ratio, and the linear pressure between the upper pressing roller and the lower pressing roller of each group is arranged from small to large at an equal ratio.
The upper conveying steel belt tensioning and deviation-adjusting guide roller 37 and the lower conveying steel belt adjusting guide roller 38 are used as tensioning rollers, so that the upper conveying steel belt and the lower conveying steel belt are always in a tensioning state.
During operation, go up compression roller 31 and lower compression roller 32 and rotate, it rotates with lower conveying steel band 33 to drive, will connect the qualified slab of base machine conveying to come to carry out the definite thickness pressure roll-in on the steel band, the effect of going up the compression roller is on last transmission steel band, and pass pressure for the slab through last conveying steel band, the lower surface and the contact of lower conveying steel band of slab, the slab passes power through annular steel band under the effect of last compression roller and lower compression roller and receives the pressure compression by the biography, make the flat unanimity and improve the surface density of surface about the slab, can also get rid of partial moisture in the slab. The compression amount of the plate blank is adjusted according to the number of the compression roller sets and the acting force of the compression rollers, the continuous work of the steel belt roller press can ensure that the compression amount of each passing plate blank is consistent, the thickness of the plate blank is consistent, the surface density of the plate blank is increased, the upper surface of the plate blank is smoother, the blanket print on the lower surface of the plate blank is reduced or disappears, and the subsequent sanding and polishing process is not needed any more; meanwhile, the steel belt roller press also has the advantages of leveling the uneven-surface plate blank produced by the pulp flow method and solving the problem of layering of the plate blank produced by the wire wheel copying method.
The length and width dimensions of the slabs are varied after compression by a single tablet press, so that the edge cutting process is performed after compression to ensure that the dimensions of each slab are completely consistent. After the edge cutting process, the sizes of all the plates are consistent, so that the subsequent edge grinding and chamfering process can be omitted.
The edge cutting process 4 comprises a plate blank sequential cutting machine, a plate blank transverse cutting machine and a material returning machine, wherein the plate blank sequential cutting machine and the plate blank transverse cutting machine are used for cutting the remaining edges of the plate blank, the sequential cutting machine is fixed on a conveying rack of the plate blank, the sequential edge cutting of the plate blank can be automatically completed when the plate blank moves, a transverse cutting mechanism is fixed on a walking trolley of a two-station machine for translation of the plate blank, a plate blank sucking disc of the two-station machine is fixed on the walking trolley of the two-station machine, the transverse cutting mechanism can be driven to translate when the plate blank sucking disc of the two-station machine translates, the transverse cutting of the plate blank is also completed, the whole process is controlled by a computer program, and the plate blank is transferred to a stainless steel mesh belt conveyor for quick drying of the surface of the plate blank after translation. And the material returning machine is used for recycling the cut residual edges. Specifically, the residual edge is recycled by a recycling machine and then is subjected to a pulping process, and recycled slurry is mixed into the slurry of the plate making machine in equal ratio to participate in plate making.
The plate blank after edge cutting enters a continuous short-time plate surface drying process 5 for continuous, isochronous, isothermal and surface drying. Please refer to fig. 4, which is a schematic structural diagram of a tunnel dryer in the fiber cement board or calcium silicate board production line shown in fig. 1. The invention relates to a tunnel type dryer which adopts stainless steel mesh belt transmission for continuous short-time plate surface drying, which comprises a frame 51, a stainless steel mesh conveyor belt 52 arranged on the frame 51, a sealing heat shield 53 arranged on the frame 51 and a heating device 54 arranged on the sealing heat shield 53, wherein the plate blank after edge cutting is driven by the stainless steel mesh conveyor belt. In the embodiment, the length of the tunnel type dryer is about 50 meters, the transmission linear speed of a mesh belt of the dryer is 20-28m/min, the drying temperature is 80-120 ℃, the surface moisture of the plate blank after surface drying is controlled to be 18-25%, and the internal moisture of the plate blank is controlled to be 36-42%.
The tunnel dryer takes the stainless steel mesh belt as a conveying belt, the tunnel dryer can dry the moisture on the surface of the plate blank within minutes, and the drying on the surface of the plate blank can solve the problem of bonding between the plate blanks when the plate blanks are stacked in a kettle; when the temperature of each plate blank passing through the tunnel dryer is consistent with the time, the moisture content of each part of each plate blank can be ensured to be consistent, the effective crystal substances generated by each part of the subsequent plate blank after entering the autoclave kettle can be consistent, and the generation of cracked plates can be completely avoided (in the prior art, the corresponding precuring process is adopted, a small vehicle-mounted stacking plate is statically stopped in a drying room, the static stop temperature is increased from normal temperature to about 60 ℃, the static stop time needs more than 8 hours, because of the stacking plate, the temperature difference exists between the inside and the outside and the top and the bottom of the plate blank during static stop, when the static stop time is not enough or the temperature difference between the inlet and the outlet of the drying room and the middle of the drying room is too large, the water content of the plate blank is inconsistent, when the water content of each part of the plate blank is inconsistent, the crystal is generated in the autoclave kettle, the plate cracking phenomenon is easily caused when the water content of the plate is inconsistent, the product quality is ensured to be consistent, the use of a continuous short-time board dryer can make product quality more stable.
The plate blanks after surface drying can be directly stacked without a template because the surfaces of the plate blanks are not bonded. And (3) the stacked plate blanks enter a pre-kettle heat preservation and static stop process 6, and are statically stopped for 8-12h in a heat preservation room at the temperature of 50-60 ℃ to ensure that the moisture of each plate is consistent before the plate blanks enter the autoclave. Specifically, the plate blanks with dry surfaces are stacked on a steam curing trolley and conveyed to a heat preservation room for standing, and the process is to finish stacking and adding a steam curing cushion frame through a three-station machine. The structure and the working principle of the three working machines can refer to the prior art.
And the product plate blank sequentially passes through an autoclave steam curing process 7, a plate separating process 8, a drying process 9 and an automatic classification stacking and warehousing process 10 to obtain a fiber cement plate or calcium silicate plate finished product.
The still kettle steam curing process 7 is to put the product plate blank carried by the steam curing trolley into the kettle, and after the product plate blank is put into the kettle, program control is performed to automatically close a kettle door, automatically heat the product plate blank, automatically preserve heat, automatically cool the product plate blank, automatically guide air, automatically open a door and automatically discharge the product plate blank from the kettle in an array manner, the process is completely automatic so as to reduce human factors, and the steam curing conditions of each plate are consistent so as to ensure the stability of the quality. The prior art is referred to for all equipment and working principles of the steam curing process of the still kettle.
The plate separating process 8 is that a five-station machine is used for placing plates on two steam-curing cars after being taken out of a kettle one by one on a sliding table in front of a dryer, a steam-curing pad frame is placed on an empty steam-curing trolley, and the five-station machine meets the capacity of 10 plates per minute. The prior art is referred to for each device and working principle of the plate dividing process.
Please refer to fig. 5 and fig. 6, wherein fig. 5 is a schematic structural diagram of a comb dryer in the production line of the fiber cement board or the calcium silicate board shown in fig. 1; fig. 6 is a partial structural view of the comb dryer of fig. 5. And the drying process 9 is to send the plates conveyed by the plate separating mechanism into a dryer so that the water content of the plate blank is lower than 10 percent after the plate with the water content of more than 30 percent is dried after the plate is taken out of the kettle. In the present invention, the drying process uses a comb dryer, which includes a chain track 91, a chain 92 with a fixing plate disposed on the chain track 91, a product fixing frame 93 disposed on the chain 92 with the fixing plate, a top cover 94 disposed above the product fixing frame 92, a heat insulating layer 95 disposed inside the top cover 94, a heat source fixing frame 96 fixed to the top cover 94, a heat source (not numbered) disposed on the heat source fixing frame, and a fan 97 fixed to the top cover 94 for providing circulating hot air, wherein the product fixing frame 93 includes a plurality of fixing plates 931 disposed at an interval and inclined, and the plate blanks are supported on the fixing plates during operation. The drying machine can improve the drying efficiency, and the production speed of the finished fiber cement board or calcium silicate board is 5-10 standard boards per minute, and the size of the standard board is 2.44m multiplied by 1.22m multiplied by 6 cm.
The fan 97 includes a motor 971, blades 972, and a rotating shaft 973 connected to the blades, and the motor and the rotating shaft are in transmission connection through a V-belt 974. The fan 97 works to uniformly distribute the heat generated by the heat source in the dryer, the drying temperature in the dryer can reach 100 ℃ and 140 ℃, and the moisture content of the finished product dried by the comb dryer is 5-10%.
The automatic sorting, stacking and warehousing process 10 is an automatic plate sorting and stacking machine which consists of a laser thickness gauge, a set of one-way three-automatic sorting machine, three lifting platforms (with air cylinder beating and aligning devices) and three sets of guide roller conveyors, and meets the requirement of 10 mark plates per minute for sorting and stacking. The prior art is referred to for all the equipment and the working principle of the automatic sorting, stacking and warehousing process.
In the invention, the whole production process of the fiber cement board or calcium silicate board finished product is controlled by a computer program, and the operation of less humanization and no humanization is basically realized.
Based on the above description of the production line of the fiber cement board or the calcium silicate board, the invention also provides a production method of the fiber cement board or the calcium silicate board.
Please refer to fig. 7, which is a schematic flow chart of the method for producing fiber cement board or calcium silicate board according to the present invention. A fiber cement board or calcium silicate board production method comprises the following steps:
step S1, pulping and plate making to obtain a plate blank;
specifically, in the process of preparing the fiber cement board, the raw material formula required by the pulping process is as follows in percentage by weight: 6.25% of paper pulp, 38.46% of cement, 45.68% of quartz powder, 7.21% of wollastonite and 2.4% of water glass;
taking the preparation of the calcium silicate interior wall decoration fireproof plate as an example, the raw material formula required by the pulping process is as follows according to the important percentage: 6.69% of paper pulp, 14.88% of cement, 46.13% of quartz powder, 20.83% of slaked lime, 3.72% of wollastonite, 0.06% of water glass, 1.19% of perlite and 6.5% of damaged board powder.
The subsequent pulping, board making processes and techniques are described above with reference to the fiber cement board or calcium silicate board production line.
Step S2, a single tablet press is adopted to carry out the fixed thickness and fixed pressure steel belt rolling treatment on the plate blank;
step S3, trimming, namely trimming edges of the plate blank according to design requirements;
step S4, continuously drying the board surface for a short time, and quickly drying the surface of the board blank at the temperature of 80-120 ℃ to ensure that the surface is not bonded;
s5, stacking, and keeping the stacked plate blank at the temperature of 50-60 ℃ for 8-12 h;
step S6, putting the plate blank into a still kettle for steam curing treatment;
and step S7, board separation, drying and sorting to obtain the finished product of the fiber cement board or the calcium silicate board.
The concrete method and principle of each process step refer to the above description of the production line of the fiber cement board or calcium silicate board.
The production method, namely the production line, of the fiber cement board or the calcium silicate board provided by the invention has the following characteristics:
(1) the single-piece press replaces a stacking press in the prior art, so that the compression conditions of each plate are consistent, the product quality is more stable, the operation is simple, and the equipment investment is less;
(2) the compressed plate blank is trimmed to replace the compressed plate blank in the prior art, so that the product is more stable in size and more attractive in appearance, the subsequent processes of edging and chamfering are eliminated, the use of a template is eliminated, and the investment, the subsequent process equipment maintenance cost and the like can be greatly reduced;
(3) the surface of the plate blank is dried by adopting a tunnel type dryer driven by a stainless steel mesh belt, so that the problem of bonding of the turnover plate after the plate is taken out of the kettle is solved;
(4) the slab heat-preservation and static-stop process replaces the slab pre-curing process before entering the kettle, so that the quality of the slab is improved, the pre-curing process is reduced, the cost is saved, and the automation degree is higher;
(5) by adopting the production process, the product quality is more stable and the qualification rate is high compared with the product quality of the prior art;
(6) by adopting the production process, the power consumption is 60 percent of that of the original production process, the energy consumption is low, and the production cost can be greatly reduced; the production process has high automation degree, the number of people is less than 50% of the original production process, the manual operation errors can be reduced, the quality is more stable, and the cost of people can be greatly reduced;
(7) by adopting the production process, the occupied area of the equipment is 70 percent of that of the original production process equipment, the occupied area is reduced, and the investment can be saved; the equipment investment amount is only 50% of the equipment investment amount of the original production process, the investment is small, the competitive advantage with the original production process is obvious, the investment recovery time is also shortened, and the investment risk can be greatly reduced;
(8) by adopting the production process, the production cost can be greatly reduced, and the competitive advantage of the new production process is obvious in severe market competition.
The embodiments of the present invention are described in detail above with reference to the drawings, but the present invention is not limited to the described embodiments. Various changes, modifications, substitutions and alterations to these embodiments will occur to those skilled in the art without departing from the spirit and scope of the present invention.
Claims (10)
1. A method for producing a fiber cement board or a calcium silicate board is characterized by comprising the following steps:
step S1, pulping and plate making to obtain a plate blank;
step S2, a single tablet press is adopted to carry out the fixed thickness and fixed pressure steel belt rolling treatment on the plate blank;
step S3, trimming, namely trimming edges of the plate blank according to design requirements;
step S4, continuously drying the board surface for a short time, and quickly drying the surface of the board blank at the temperature of 80-120 ℃ to ensure that the surface is not bonded;
s5, stacking, and keeping the stacked plate blank at the temperature of 50-60 ℃ for 8-12 h;
step S6, putting the plate blank into a still kettle for steam curing treatment;
and step S7, board separation, drying and sorting to obtain the finished product of the fiber cement board or the calcium silicate board.
2. The method for producing fiber cement boards or calcium silicate boards as claimed in claim 1, wherein the single-piece tablet press comprises a plurality of sets of upper and lower press rolls, an upper steel belt wound around the upper press rolls, a lower steel belt wound around the lower press rolls, a driving device for driving the upper and lower press rolls to move synchronously, an adjusting device for adjusting the press roll pressure and gap provided on each set of upper press rolls, and an upper steel belt tension deviation-adjusting guide roll and a lower steel belt adjustment guide roll, and during operation, the board blank is compressed by the upper and lower steel belts under the action of the upper and lower press rolls.
3. The fiber cement board or calcium silicate board production method according to claim 2, wherein the gap adjustment range of the first sets of upper and lower press rolls is 3-30mm in the direction of the transfer path of the slab; the linear pressure adjusting range of the upper pressing rolls and the lower pressing rolls in the first groups is 60-120kg/cm, the gap adjusting range of the upper pressing rolls and the lower pressing rolls in the last group is adjusted according to the required size of the product, the linear pressure of the upper pressing rolls and the lower pressing rolls in the last group is 1000-2000kg/cm, and the compression amount of each group of pressing rolls is 5-10%.
4. The fiber cement board or calcium silicate board production method according to claim 3, wherein the gaps of each set of the upper and lower rolls are arranged at an equal ratio from large to small and the linear pressures of each set of the upper and lower rolls are arranged at an equal ratio from small to large in the direction of the transport path of the slab.
5. The method for producing fiber cement boards or calcium silicate boards as claimed in claim 1, wherein the continuous short-time board surface drying process adopts a tunnel type dryer driven by a stainless steel mesh belt, and the tunnel type dryer comprises a frame, the stainless steel mesh belt arranged on the frame, a sealed heat shield arranged on the frame, and a heating device arranged on the sealed heat shield.
6. The method for producing fiber cement board or calcium silicate board according to claim 5, wherein the linear speed of the tunnel dryer is 20-28m/min, the surface moisture of the surface-dried board is controlled at 18-25%, and the internal moisture of the board is controlled at 36-42%.
7. The method for producing fiber cement boards or calcium silicate boards as claimed in claim 1, wherein a comb dryer is used in the board drying process after the board separation in the autoclave, the comb dryer comprises a chain track, a chain with a fixing plate arranged on the chain track, a product fixing frame arranged on the chain with the fixing plate, a top cover arranged above the product fixing frame, a heat insulating layer arranged on the inner side of the top cover, a heat source fixing frame fixed on the top cover, a heat source arranged on the heat source fixing frame, and a fan fixed on the top cover and used for providing circulating hot air, the product fixing frame comprises a plurality of fixing plates which are arranged obliquely and at intervals, and the board blank is supported on the fixing plates during operation.
8. The method for producing fiber cement board or calcium silicate board as claimed in claim 7, wherein the fan comprises a motor, a blade, a rotating shaft connected with the blade, the motor is connected with the rotating shaft by a V-belt, the drying temperature of the comb dryer is 100-140 ℃.
9. The method for producing fiber cement board or calcium silicate board according to any one of claims 1 to 8, wherein the whole production process of the fiber cement board or calcium silicate board finished product is controlled by a computer program.
10. The production line of the fiber cement board or the calcium silicate board is characterized by comprising a raw material treatment and pulping process, a board making process, a slab thickness setting process, a constant-pressure single-piece tabletting process, an edge cutting process, a continuous short-time board surface drying process, a pre-kettle heat preservation and static stopping process, an autoclave steam curing process, a board separating process, a drying process and an automatic classification, stacking and warehousing process which are sequentially arranged.
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| DE2658915A1 (en) * | 1976-12-24 | 1978-06-29 | Knauf Westdeutsche Gips | PROCESS FOR THE MANUFACTURING OF Lumpy CALCIUM SULFATE |
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| CN210161370U (en) * | 2019-01-16 | 2020-03-20 | 广东科达洁能股份有限公司 | Production equipment for large-scale ceramic sheets |
| CN212058150U (en) * | 2020-03-11 | 2020-12-01 | 上海筱启新能源科技有限公司 | Comb type dryer for calcium silicate boards |
| CN212603899U (en) * | 2020-06-12 | 2021-02-26 | 国塑机械(上海)有限公司 | Double-steel-belt rolling equipment for continuous fiber reinforced composite board |
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| Publication number | Priority date | Publication date | Assignee | Title |
|---|---|---|---|---|
| DE2658915A1 (en) * | 1976-12-24 | 1978-06-29 | Knauf Westdeutsche Gips | PROCESS FOR THE MANUFACTURING OF Lumpy CALCIUM SULFATE |
| CN1110209A (en) * | 1994-10-22 | 1995-10-18 | 四川省绵竹县石棉水泥制品总厂 | Roller press for producing building and ship plates |
| CN109291218A (en) * | 2018-10-15 | 2019-02-01 | 广东科达洁能股份有限公司 | A kind of full-automatic lifting formula roll squeezer |
| CN210161370U (en) * | 2019-01-16 | 2020-03-20 | 广东科达洁能股份有限公司 | Production equipment for large-scale ceramic sheets |
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| CN212058150U (en) * | 2020-03-11 | 2020-12-01 | 上海筱启新能源科技有限公司 | Comb type dryer for calcium silicate boards |
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