Concrete batching plant parts name, as crucial information of concrete batching plant, is the important knowledge that can help people do better with concrete batching plant investment, using and maintaining.
The composition of concrete batching plants is different depending on various plants types. According to the production process and system function, the concrete batching plant can usually be divided into several main systems: material storage system, material weighing system, material conveying system, mixing system, control system, pneumatic system, dust removal system, etc.
Next, we will recognize these concrete batching plant parts names according to different fuctional systems.
Concrete Batching Plant Parts Name In Material Storage System
Material storage system is used to store raw materials required in concrete producing process, including four main parts: aggregate storage system, powder storage system, water storage system and additive material storage system.
Storage Bins In Aggregate Batching Machine
Aggregate storage system is a part of aggregate batching plant. Exactly, aggregates are loaded into the storage hoppers for a little while to wait for be weighed and conveyed to the mixer. Not like powder and water system, aggregate materials are usually stored directly on the ground of the concrete batching site.
When needed, they will be loaded into the storage bins of the aggregate batching machine by a loader.
According to the production capacity of the concrete batching plant and different types of aggregate required in concrete production, different numbers of aggregate storage hoppers are available from 2 to 4. (As shown in the following table)
Aggregate Storage Hoppers in Batching Machine
|
Model of Batching Machine |
Number of Storage Bins |
Capacity of Single Storage Bin |
Productivity |
Number of Aggregate Types |
Ingredients Precision |
Capacity of Weighing Hoppers |
|
PLD800 |
2 |
3.2m³ |
48m³/h |
2 |
±2% |
0.8m³ |
|
3 |
3.2m³ |
3 |
±2% |
0.8m³ |
||
|
PLD1200 |
2 |
7.3m³ |
60m³/h |
2 |
±2% |
1.2m³ |
|
3 |
7.3m³ |
3 |
±2% |
1.2m³ |
||
|
4 |
6.6m³ |
4 |
±2% |
1.2m³ |
||
|
PLD1600 |
2 |
6.3m³ |
80m³/h |
2 |
±2% |
1.6m³ |
|
3 |
8.38m³ |
3 |
±2% |
1.6m³ |
||
|
4 |
10m³ |
4 |
±2% |
1.6m³ |
||
|
PLD2400 |
2 |
10m³ |
120m³/h |
2 |
±2% |
2.4m³ |
|
3 |
8.38m³ |
3 |
±2% |
2.4m³ |
||
|
4 |
10.8m³ |
4 |
±2% |
2.4m³ |
||
|
PLD3200 |
4 |
15.6m³ |
160m³/h |
4 |
±2% |
3.2m³ |
|
PLD4800 |
4 |
25m³ |
280m³/h |
4 |
±2% |
25m³ |
Cement Silos In Powder Storage System
Powder storage system, as the name suggesting, is designed for storing powder of cement, mineral powder and fly ash. According to the shape of the silo and the assembly form, cement silo can be classified into four types:
Horizontal Cement Silo
Horizontal Cement silo is installed horizontally. With a large occupation and convenient mobility with wheels, horizontal cement silo is usually free of foundation, lower in height and good in safety performance. The cost is slightly higher than the vertical cement silo. This kind of cement silo is widely used in mobile concrete batching plant and free-foundation concrete batching plant with adequate place.
Vertical Cement Silo
Cement silo is usually a cylindrical structure installed vertically on the ground. With small footprint, tall body, deep foundation, dust-collect device and air-pressure alarming system, vertical cement silo is suitable for stationary concrete batching plant.
Integrated Cement Silo
Integrated cement silo cannot be disassembled, limited by its size and pack(only cement silos below 50tons can be packed and transported), so this kind of integral cement silo is not commonly used.
Assembled Cement Silo
Powder materials, such as bulk cement, mineral powder and fly ash, are blown to powder silos, where they can be stored for a long while to ensuring continuous supply of powder materials. In this process, some excellent related equipment is essential to ensure sturdy warehouse fixing, water-proof storage and environmental protection:
Support Legs
Support legs of the fixed silo is made of strong and durable steel material. Especially in the vertical powder silo system, the outriggers need to be deeply erected on a firm foundation to ensure the stability and reliability of the entire powder storage system.
Platform, Guardrail And Ladder
Inspection platform, guardrails and ladders are set up for the convenience of the maintenance.
Dust Filter
Cement, mineral powder and fly ash produces dust during working procession, which leads to atmosphere pollution. The dust filter device is specially designed to collect dust in the air.
Pneumatic Vibrator
Pneumatic vibrator is used to shake off the dust particles attached to the dust filter bag to prevent the bag from being blocked and bursting.
Level Gauge And Siren
Material level gauge is used to measure the height of the powder in the bin. When the maximum value is reached, the alarm will sound an alarm. At this time, stop adding powder into the bin.
Safety Valve
When the pressure on the top of the warehouse exceeds the safety value, the pressure valve will be open to release the pressure in the cabin and prevent explosion accident due to excessive pressure in the silo.
Manual Butterfly Valve
The switch action of manual butterfly valve is driven manually. Manual cement butterfly valve is mainly used for opening and closing material boxes, hoppers and silos with powdery or granular materials. It can be used for the treatment of all powdery and granular materials.
The number of powder silos is determined by the types of powder, while the capacity of the powder silos is determined by the production capacity of the whole concrete batching plant. In addition, it is also necessary to consider that the powder storage capacity should meet the requirement of concrete continuous production.
Water Storage Tank
Water tank is for storing water required in concrete production. The volume of water tank is determined by the production capacity of the concrete batching plant. It also can be customized according to actual needs of buyers.
Additive Storage Tank
External additive tank is used to store additive liquid.
When choosing the configuration, it should be noticed that some concrete, in the production and mixing process, need more than one additive storage tank.
The number of additive storage tank is determined by the number of additive types needed in concrete producing process.
The discharge gates of various material storage hoppers should neither be too small to avoid excessive material loss, nor too large for considering the measurement accuracy.
All discharging gates are driven by pneumatic system according to the instructions from controlling system.
Material Weighing System Parts Name
According to different types of raw materials, material weighing system is consisted with of aggregate weighing system, powder weighing system, water weighing system, additive weighing system, etc.
The four major systems are responsible for the precise weighing of aggregates, powders, water and additive materials. To complete this process, three types of components are the key parts: weighing hoppers, load cells and pneumatic valves.
The materials are concentrated in their respective weighing hoppers, and after being precisely weighed by load cells they are transported to the main mixer.
Material Weighing hoppers
Material weighing hoppers are the measurement places of various materials needed in concrete production. Cooperating with the load cells installed on the weighing hoppers, precise weighing process is finally completed.
Aggregate Weighing Hopper
According to different weighing methods, aggregate weighing systems are divided into accumulative weighing system and individual weighing system. Both aggregate weighing systems are located below the aggregate batching bin, the differences are:
In the accumulative weighing system, various materials are accumulated and weighed sequentially in the same aggregate weighing hopper. Just one weighing hopper can complete the weighing task of all aggregates. The accumulative weighing system is simple structure and low-cost.
In the separate weighing system, there is a weighing hopper under each storage batching hopper, and each aggregate is weighed separately. With higher weighing accuracy, the cost of separate weighing system is slightly higher.
The volume options of the weighing hopper, ranging from 3.2m3 to 25m3, are related to the production capacity of concrete batching plant, types of required aggregates, the number and volume of the aggregate batching hoppers, etc.. The specific configuration parameters are available in the following table:
Actually, aggregate storage bins and weighing hoppers are integrated in the aggregate batching machine systems. From top to bottom, the aggregate batching machine is consisted of storage bins, weighing hoppers and the next step is the conveyor machine. Provided here are the main parameters of the most common PLD series aggregate batching machine.
Powder Weighing Hopper
The powder weighing hopper is the main component of the powder weighing system. Cement, mineral powder, fly ash and other kinds of powder materials are collected here for a short stay, waiting for being measured and then conveyed to the mixing host.
Water and additive weighing hopper
Usually, the water and additive weighing hopper in the concrete batching plant is located directly above the mixing host. Water and additives are pumped separately from the water storage tank and the additive tank to the weighing hopper.
Load Cells In Material Weighing System
Load cells are key parts to ensure the accuracy of concrete material proportion. Various material weighing systems measure the weight of materials by electronic load cells, which are controlled by computers to achieve accurate mixing ratios of concrete.
Aggregate Load Cell
The aggregate weighing load cell is installed under the aggregate weighing hopper, including pressure sensors, tension sensors and so on. Tension sensor is more commonly used. The number of sensors installed in each aggregate weighing bin is generally 3 to 4 aiming to higher accuracy. The measurement accuracy of the aggregate weighing sensor is ≤2%. The measuring range is usually optional between 500kg-2000kg according to the production output (30m3/h – 240m3/h) of the concrete batching plant.
Powder Weighing Sensor
In order to ensure accurate weighing of the powder, each silo is usually equipped with 3-4 load cells, the accuracy can reach ±1%, and the measuring range can be selected between 300kg and 2000kg according to the producing output.
Water And Additive Load Cells
The water and additive weighing sensors are installed on the water weighing hopper and additive weighing hopper. Each weighing hopper is equipped with a sensor, and the measurement accuracy can reach ±1%. For concrete mixing plants with a production capacity of 30m3/h-240m3/h, water and additive measuring range of the sensors is generally 100kg-1000kg.
Material Conveying System
Material conveying system of concrete batching plant is also consisted of four parts: aggregate conveying system, powder conveying system, water conveying system and additive conveying system.
Aggregate Conveying System
According to two different aggregate conveying methods, the main components of the aggregate conveying system are divided into two categories: belt conveyor and hopper elevator.
Belt Conveyor
As the aggregate conveying device of the commercial concrete batching plant, the belt conveyor’s working efficiency affects the running speed of the whole plant.
The belt conveyor of the large scale commercial concrete bathing plant uses a flat belt, and the inclination angle is generally from 18° to 20°. Small and medium-sized commercial batching plants generally use herringbone shallow pattern belts, and the inclination angle is generally from 24° to 30°.
There are many types of driving devices for belt conveyors, such as electric rollers, shaft-mounted gearboxes and JZQ gearboxes, each with its own advantages and disadvantages. The electric drum and the shaft-mounted reducer occupy less space, but are difficult to maintain, which is not as convenient as the JZQ reducer.
The conveying speed of the belt conveyor is generally 1.6m/s or 2.0m/s. The width of the conveyor belt are 650mm, 800mm, 1000mm, 1200mm. The conveying capacity of the inclined belt conveyor should be able to meet the actual output flow requirements of the horizontal belt conveyor of the aggregate batching machine.
In addition, in order to protect the environment, an outer cover can also be installed on the belt conveyor to prevent the dust generation from scattering into the air and polluting the environment.
Hopper Elevator
In small-scale mobile and portable concrete batching plants, hopper elevators are usually used as aggregate lifting tools. The hopper elevator has simple structure, small footprint, large conveying capacity, high lifting height (generally 30-40 meters, up to 80 meters), good sealing, and convenient management. It is an ideal aggregate conveying equipment of small and medium-sized concrete batching plants.
The main components of the hopper elevator are:
1. The traction member is divided into a belt bucket elevator and a plate chain bucket elevator.
2. The hopper is made of 2-6mm steel plate, stamped and welded.
3. The driving device
The driving device is divided into two types: HL and PL. The HL type is driven by friction between the sprocket and the endless chain, and the driving wheel has grooves but no teeth. The PL type driving sprocket and the plate chain are meshing transmission, and the number of sprocket teeth is 6-20, and an even number is appropriate.
4. Tension device
There are screw type, heavy hammer type and spring type. The stroke of the tension device is within the range of 0.2-0.5 meters.
5. Chassis
Powder Conveying System
Powder conveying system usually refers to screw conveyor, which is mainly consisted of screw shaft, screw blades, power source (eletric motor or internal conbustion engine), reducer (also called gearbox), screw rod, spiral groove and machine base.
Screw conveyor is the main powder conveying equipment in the concrete batching plant. It drives the screw to rotate through the motor to push the material to achieve the purpose of horizontal or vertical transmission. It has simple structure, small cross-sectional area, good sealing performance, convenient operation, easy maintenance and convenient closed transportation. Usually divided into shaft screw conveyor and shaftless screw conveyor.
Shafted screw conveyors are suitable for dry powder materials and small particle materials (such as cement, fly ash, lime, etc.), and shaftless screw conveyors are suitable for conveying viscous materials (such as sludge, biomass, garbage, etc.).
In common concrete batching plant with producing capacity from 30m3/h to 240m3/h, the screw conveyor is usually driven by a motor with the power of 11kW or 15kW. And the diameter of the delivery pipe of the screw conveyor is 129mm or 273mm.
Water Conveying System
In concrete batching plant, water is conveyed by pump machine.
There are two pumps used as water conveying tools. One is water supply pump, which take charge of feeding water from the storage tank into the weighing hopper. This process is controlled by computer and PLC. When the data measured by load cell is up to the preset value, water supply pump will stop.
And the other one is water unloading pump. When concrete mixing process is started, the water unloading pump is started first, then the water is unloaded into the mixer.
Additive Conveying System
Additive material is also conveyed by pumps. The same as water conveying system, additive conveying of concrete batching plant also requires two set of pumps.
The brands of water pump and additive pump are various. For the details about them, you can contact us to get more information.
Mixing System
When it comes to the mixing system, the core component of the concrete mixing plant, we have to mention one of the most important parts name, the mixer. There are many types of mixing hosts used in concrete mixing plants. It is divided into two categories: forced stirring type and continuous drum type. At present, the mainstream of mixing hosts in domestic and foreign mixing plants is forced mixer.
Compulsory mixers are divided into vertical-shaft planetary mixers, single-shaft horizontal mixers and twin-shaft horizontal mixers according to their structure. Among them, twin-shaft horizontal mixers performs especially perfectly.
Twin-shaft Horizontal Mixer Machine
JS series forced horizontal twin-shaft mixer (parameters see the table below) has a compact structure and is composed of a transmission system, a mixing tank, a stirring device, and shaft end seals.
It can mix dry hard concrete, semi-dry hard concrete, lightweight aggregate concrete and various mortars. The output capacity is from 350L to 9000L.
The inside of the mixing cylinder is equipped with two horizontally arranged stirring shafts. Each shaft is equipped with mixing arms, and the mixing arms are equipped with stirring blades, which are arranged in a non-continuous spiral. Generally in the form of an octagonal shaft, a hexagonal shaft and a square shaft. The adjacent angles of arms are 45°, 60°, 90°, 120°, 135°, 180°, which can be selected and designed according to the working conditions. For large-scale engineering mixing plants, the hosts are mostly 45° and 60° spirals. This structure is conducive to the better circulation of large aggregates in the interior, and the concrete mixing performance of large aggregates is better.
Main Parameters of JS Series Horizontal Twin-shaft Forced Concrete Mixer Machine
|
Model |
JS500 |
JS750 |
JS1000 |
JS1500 |
JS2000 |
JS3000 |
|
Discharging capacity |
500L |
750L |
1000L |
1500L |
2000L |
3000L |
|
Feeding capacity |
800L |
1200L |
1600L |
2400L |
3200L |
4800L |
|
Mixing time |
72s |
72s |
60s |
60s |
60s |
60s |
|
Discharge height |
3800 |
3800mm |
4100mm |
4100mm |
4100mm |
4100mm |
|
Quantity of blade (unit) |
2X7 |
2X7 |
2X8 |
2X10 |
2X9 |
2X10 |
Twin-shaft concrete mixer has compact structure, high mixing efficiency, excellent mixing performance, perfect stability and durability, and is environmentally friendly. It is the most commonly used mixing equipment for concrete mixing plants of various sizes.
Vertical-shaft Planetary Concrete Mixer Machine
Vertical shaft planetary concrete mixer is mainly composed of transmission device, mixing device, unloading device, hydraulic pump station and other detailed devices.
This kind of mixer has several mixing blades combinations, and the rotation center of the mixing blade combination does not coincide with the geometric center of the mixing drum. When working, the stirring blade group can not only rotate around the axis of its own stirring shaft, but also revolve around the central axis of the disc. It’s like the way the planets move in the universe.
Because the rotation diameter of the stirring blade is generally greater than the radius of the mixing drum, the range of motion of the stirring blade can involve any position on the bottom surface of the entire disc-shaped mixing drum without leaving a dead zone. Vertical shaft planetary mixer can be divided into two structures: fixed plate type and rotary plate type.
Since the mixing blades of the planetary mixer have both revolution and rotation, the movement track is relatively complicated, the mixer is with high quality and efficiency.
It is suitable for prefabricated structural parts for high-speed rail, PC prefabricated parts, and civil engineering construction sites. The newly developed multi-motor vertical shaft mixer is suitable for high-speed rail special prefabricated structural parts, pipe piles, sleepers, tiles and other manufacturing enterprises, as well as various civil engineering construction sites and commercial concrete mixing stations.
|
Model |
M1000 |
M1500 |
M2000 |
M3000 |
|
Feed Capacity (L) |
1500 |
2250 |
3000 |
4500 |
|
Output Capacity (L) |
1000 |
1500 |
2000 |
3000 |
|
Number of Planetary |
2 |
2 |
3 |
3 |
|
Main Motor Power (kW) |
2×22 |
2×30 |
3×30 |
3×37 |
|
Unloading Motor Power (kW) |
3 |
3 |
3×2 |
3×2 |
|
Weight (t) |
5.3 |
6.2 |
8.2 |
1.300 |
Control System
Control system of concrete batching plant is called as the brain of the whole concrete batching system.
The names of the main components of the concrete mixing plant include:
Computer (upper computer), programmable logic controller PLC (lower computer), batching instrument, power device (AC contactor, air switch), control room, etc. There are three types of mixing plant control systems.
Distributed Microcomputer Control System
Distributed microcomputer control system. The core of this control system is the programmable controller PLC. The control electrical boxes of the mixer and the batching machine are independent, and the computer does not participate in the system control, and is only responsible for the recording and printing of the work data report.
Centralized Microcomputer Control System
Centralized microcomputer control system. This control form integrates the control electric boxes of the mixer and the batching machine, and concentrates the computer control and management functions on one computer to become a centralized control system. Start the production process by clicking the button, and add the central control meter to realize automatic control. This type of control system does not have a computer monitor, and the computer tasks are relatively heavy, so it cannot perform synchronous data statistics, and the measurement is too much interfered by human factors, commonly known as “semi-automatic control system”.
Centralized Dual Microcomputer Control System
Centralized dual microcomputer control system. This control method concentrates the weighing table, database management, production process, equipment fault on-line diagnosis and concrete slump on-line monitoring on the computer control system, which solves the interference of human factors in measurement, and adopts special batching control instruments , The production control and management functions are divided into two computers, and a computer display and a printer are added. The production screen can be simulated through the computer display, and then the form can be printed out through the printer, so as to realize fully automatic control.
The latter two control systems are used commonly.
Pneumatic System
The pneumatic system of concrete batching plant consists of air compressors, cylinders, solenoid valves, air source processor and pneumatic valves, etc.
The pneumatic system takes charge of the switch actions of all hopper gates, butterfly valves in the whole concrete batching plant, including the gates of aggregate storage hoppers, the arch of the cement silo, the butterfly valves of water, fly ash, additive hoppers etc..
Air Compressor
Air Cylinders
solenoid valves
Pneumatic Butterfly Valve
Pneumatic butterfly valves are mainly used for opening and closing material bins, hoppers and silos containing powdery or granular materials. It can be used to deal with all powder and granular materials, and the valve uses its own gravity for interception and pneumatic transmission. It can be installed under hoppers, bins, silos, screw and other types of conveyors, and connected to pneumatic conveying pipes. The pneumatic butterfly valve is a very economical and efficient switching device. Pneumatic butterfly valve models from DN100, DN150, DN200, DN250, DN300 to DN350 correspond to nominal diameters of 100mm, 150mm, 200mm, 250mm, 300mm, 350mm.
Air Source Processor
The air source processor is also called the air source treatment triple unit, including the pressure reducing valve, filter, and lubricator. The pressure reducing valve can stabilize the pressure of the air source, keep the air source in a stable state, and reduce the damage to hardware such as valves or actuators due to sudden changes in the air pressure of the air source. The filter is used to clean the air source, which can filter the moisture in the air and prevent the moisture from entering the device with the gas. The lubricator can lubricate the moving parts of the body, greatly extending the life of the body.
Dust Removal System
Dust removal system of concrete batching plant usually consists of a dust collector and a dust removal pipe.
The dust removal device is usually set in the main mixer building. The dust generated in the main mixer unit, the storage hopper and the powder measuring hopper can be filtered through the dust collector. The back blowing device vibrates the dust at intervals, and the upper fan directs the clean air to the outside.
Conclusion
Concrete batching plant is a complete system of multifunctional units working together. It contains a lot of parts, large and small, and these parts play their roles in different functional units, so that the entire concrete mixing plant can complete every production task stably and excellently. There are many more things that can be said about the components inside. If you are interested in this content, or have any questions about the concrete mixing plant, please click the button below to contact us.
