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dry mortar production line

Dry Mortar Production Line

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Technical Parameters

Dry mortar production line is mainly composed of raw material storage system, sand drying system, batching system, mixing system, finished product silo, conveying and lifting system, packer, dust collecting system, electronic control system. It is suitable for production of regular dry masonry mortar and other special mortars (For example, plastering mortar, insulation mortar, decoration mortar, glass bead mortar etc). The whole production line presents stable performance and balanced mixing, with guaranteed advantages as low energy cost, low investment, fast effect, small scale, simple operation and so on.
Annual production capacity: 200k-450k tons
Structures: Tower type, Stair type, Block type, Flat type

Structure Style Annual Production Model Mixer Specifications Theoretic Productivity
Standard Configuration Minimum Configuration (t/h)
Tower type dry mortar production line 200k Tons HSTL40B LDH2000 WSH6000 40
300k Tons HSTL60B LDH3000 WSH10000 60
400k Tons HSTL80B LDH4500 WSH12000 80
200k+50k Tons HSTL40C LDH2000+LDH600 WSH6000+LDH600 40+10
300k+50k Tons HSTL60C LDH3000+LDH600 WSH10000+LDH600 60+10
400k+50k Tons HSTL80C LDH4500+LDH1600 WSH10000+LDH600 80+10
Stair type dry mortar production line 200k Tons HSTL40B LDH2000 WSH6000 40
300k Tons HSTL60B LDH3000 WSH10000 60
400k Tons HSTL80B LDH4500 WSH12000 80
200k+50k Tons HSJZ40C LDH2000+LDH600 WSH6000+LDH600 40+10
300k+50k Tons HSJZ60C LDH3000+LDH600 WSH10000+LDH600 60+10
400k+50k Tons HSJZ80C LDH4500+LDH1600 WSH10000+LDH600 80+10
Block type dry mortar production line 200k Tons HSLZ40B LDH2000 WSH6000 40
300k Tons HSLZ60B LDH3000 WSH10000 60
400k Tons HSLZ80B LDH4500 WSH12000 80

Flat type dry mortar production line

(No grading of sand)

200k Tons HSZ40B LDH2000 WSH6000 40
300k Tons HSZ60B LDH3000 WSH10000 60
400k Tons HSZ80B LDH4500 WSH12000 80
Note: The annual production in this table refers to ordinary mortar, according to 16 working hours per day, 300 days a year. The standard configuration adopts LDH coulter type mixer as main engine, and the minimum configuration adopts WSH dual shaft agravic paddle mixer.

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Main Features

Tower type dry mortar production line

Production process: After being precast and screened, the sand is lifted to the probability screen on top of the main building by hoister, and then put into different sand silos by sand grades. The sand also can be delivered to the large sand warehouse on the ground for screening in the probability screen on top of the main building. Pneumatically activated butterfly valve of the sand silo makes the dry sands flow on the scales. Powder materials as cement, coal ash and additives are transported to the scales by spiral conveyor. Sand and powder ingredients are put into the mixer after batching. The sufficiently mixed mortar passes the final product transition warehouse and goes directly into the truck, bags or corresponding warehouse for storage by a three-way valve, meanwhile, another round of batching and mixing starts in the scales and mixers above.
Advantages: Multiple sand grades can satisfy more requirements for the mortar. The batching and mixing processes are precise and powered by gravity, which offers high productivity with lower unit energy consumption.

Stair type dry mortar production line

Production process: After being precast and screened, the sand is lifted to the probability screen on top of grounded sand silo by hoister, and then put into different sand silos by sand grades. Pneumatically activated butterfly valve under the sand silo makes the sands flow on the scales. After batching, the ingredients are lifted to the temporary storehouse by bucket elevator for weighing. Powder materials as cement, coal ash and additives are transported to the scales by spiral conveyor. Sand and powder ingredients are put into the mixer after batching. The sufficiently mixed mortar passes the final product transition warehouse and goes directly into the truck, bags or corresponding warehouse for storage. The sand in the grounded sand silo also can be lifted to the special mortar silo in the main building, and packaged after measurement and mixing process through specified scales and mixer.
Advantages: Multiple sand grades can satisfy more requirements for the mortar. Capable for adopting special mortar production line to produce ordinary mortar and special mortar at the same time.

Block type dry mortar production line

Production process: After being dehydrated and screened, the sand is lifted to the single grade probability screen on top of grounded sand silo by hoister, and then temporarily stored in different sand silos as coarse sand and fine sand before sent to two middle sand silos on top the of the building. Control the pneumatically activated butterfly valves in the middle silos to make dry sands fall on the scales. Powder materials as cement, coal ash and additives are transported to the scales by spiral conveyor. Sand and powder ingredients are put into the mixer after batching. The sufficiently mixed mortar passes the final product transition warehouse and goes directly into the truck, bags or corresponding warehouse for storage.
Advantages: Attached single grade probability screen causes less failure rate. The batching and mixing processes are precise and powered by gravity, which offers high productivity with lower unit energy consumption and saves time on batching. Less investment on civil foundation and facilities.

Flat type dry mortar production line

Production process: Purchase sands in different sizes, and lift them to the grounded sand silo by hoister after being dehydrated and screened, and then lift them to the two middle sand silos on top the of the building. Control the pneumatically activated butterfly valves in the middle silos to make dry sands fall on the scales. Powder materials as cement, coal ash and additives are transported to the scales by spiral conveyor. Sand and powder ingredients are put into the mixer after batching. The sufficiently mixed mortar passes the final product transition warehouse and goes directly into the truck, bags or corresponding warehouse for storage.
Advantages: Production process is simple and stable because no probability screen is used. Gravity takes charge in the delivery of sands from batching, mixing to final treatment, which is very accurate and time saving. High productivity with lower unit energy consumption and lower investment on civil foundation and facilities.

Main Components

Three-cylinder Drying Machine

The three cylinder drying machine absorb the latest energy-saving technology in Europe—embedded structure. Inner cylinder, middle cylinder and outer cylinder forms a self-thermal insulation structure. To further decrease heat loss, we add thermal insulation material and stainless steel plate surrounding the cylinder. Special thermo technical concept eliminates the heat loss in wind tunnel. The machine enlarges the heat-exchange surface and evaporation intensity per unit volume. It significantly enhances the thermal energy efficiency by 40% and saves energy twice as normal drying machine. The customers can cut down the infrastructure investment due to the small size of this machine, and can choose coal, oil and gas as fuel freely.

Characteristic:

a. It employs abrasion resistant manganese plate, which is 3-4 times abrasion resistant as normal steel plate, and the equipment investment is only 20% of the imported equipments; b. The initial moisture index of material is about 15%, and the final moisture index is ensured under 0.5-1%, which is the first choice for all kinds of drying processes as slag powder of cement factory, wet and dry mortar production line and so on; c. 40% higher thermal energy efficiency than traditional single-tube rotary dryer; d. Anthracite, soft coal, coal gangue, oil and gas are optional for heating; e. It can dehydrate blocks, aggregates, and powders under 20-40mm diameters; f. Covers 60% less place than single-tube rotary dryer, which reduces the infrastructure investment by 60%; g. Perfected sealing technique ensures no air leakage; h. Discharged material is less than 60 degree. It can be transport to warehouse without cooling; i. The outer cylinder is about 60 degree, and the waste gas is less than 120 degree, which increases the service life of baghouse twice more than usual; j. Saves 2/3 of the coal fuel, and 40% of electricity. Coal consumption is less than 9kg/ton.

Parameters

properties /specifications 2600×5500 3000×5500 3000×6500 3200×7000
Coal consumption(kg) 7-9 7-9 7-9 7-9
Power(kW) 22 30 30 44
Drying capacity(T/h) 30-35 40-45 45-50 55-60
Note: The capacities mentioned above is under condition that the material initial moisture is less than 8%, and final moisture is less than 1%. The number changes with different initial and final moisture requirements.

Coulter Type Mixer

The mixing system of dry mortar production line is adopting the 3rd generation of coulter type mixer invented by our company. A lot of adjustments have been made on the foundation of traditional mixer, among which, the spindle reaches 90 round/minute rotary speed. With advance of the speed, the mixer improves the mixing efficiency, the mortar quality, and effectively prevents the mortar segregation.
High quality mortar means all sand should be coated by powder materials. Only in this way can we prevent the mortar segregation. The key to control mortar segregation is in mixing process instead of transport. The rotary speed of mixer is the key to enhance the cohesive force between mortar powder and aggregates. If the speed slows down, the stress will be so slight that it can only mix the ingredients seemingly. Segregation happens with a little move.

Parameters:

Model Capacity(t/h) Spindle power (kW) Boundary dimension(m)
Length Width Height
LDH-1.0 8-10 11 2.700 1.584 1.756
LDH-2.0 15-20 18.5 3.300 1.584 1.756
LDH-4.0 35-40 55 4.800 1.700 2.200
LDH-6.0 55-60 75 5.168 2.100 2.398
LDH-8.0 80-90 75 5.340 2.383 2.608

Baghouse Dust Collector

Air Box Pulsed baghouse Dust Collector is the most advanced high-efficiency baghouse dust collector that adopts U.S technology. It absorbs advantages from kinds of dust collectors’ such as anti-draught technique and pulse-jet etc, and also conquers the weakness of anti-draught technique, such as conflict between filtering and deashing, which improves the applicability of baghouse dust collector. The series of products is not only applied to the dust collecting system of crashing machine, packaging process, storaging, clinker cooler and any other milling equipments in cement factory, but also suitable for dust collecting from waste gas in building materials, metallurgy, chemical engineering and boiler industries.

Characteristic:

a. More than 99.9% collection efficiency. Less than 30mg/Nm3 dust emission; b. Can deal with high concentration dust under 100g/Nm3; c. Advanced seal measures with less than 2% of air leakage; d. Advanced structural design with large filter area per unit volume and small equipment volume; e. Specialized effective dust collecting method extends its service life; f. Reliable quality; g. Stable performance; high degree of automation; easy daily maintenance and management.

Electronic Control System

The electronic control system adopts international famous IPC and siemens PLC, automatically controlling batching, mixing and other processes. Dynamic simulation displays on the interface, it’s easy to operate and offers report data for the manufacturing management of dry mortar. The system can make auto correction and failure alarm in advance to control product quality and lower production cost. The network and automatic control platform closely connects the users’ production, sales and management together.

Characteristic:

a. Three-dimensional interface. Dynamic display of working conditions as batching data, measuring data, working frequency and unusual service condition; b. Auto-production according to the batched production and cylinder capacity; c. Fast check with self-diagnostic and hint function, providing online help; d. Superposition measurement of materials can be managed by frequency control system modifiable through internet; e. Automatic adjustment of height and trend judgment. Auto correction of negative value; Tracing zero position; One click peeling etc; f. Auto-scales filling. The measuring allowance range of each material can be adjusted individually.

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