Do you know how to buy a suitable concrete batching plant? Do you also want to build a high-quality and reliable concrete mixing plant? Do you have much trouble with how to choose the model? Let’s take a look at this reliable expert guide to help you easily select models and build your plant efficiently!
The concrete mixing plant is a combined device that transports, feeds, measures, stores, batches, weighs, mixes and discharges the raw materials of cement concrete – sand, stone, cement, additives (including fly ash, mineral powder, expansion powder), water, etc. according to the set mix proportion, and produces cement concrete that meets the quality requirements. It is also called the concrete precast plant, which is composed of five systems, including the mixing host, material weighing system, material conveying system, material storage system, control system and other auxiliary facilities.
Guidance on how to Buy a Suitable Concrete Batching Plant
From the Perspective of Installation Form
The concrete mixing plant can be installed and fixed in various forms, including fixed type, mobile type and quick transferring type, and its relocation convenience is from weak to strong in order.
From the Perspective of Production Purpose
According to the purpose of concrete production, common mixing plants can be divided into commercial mixing plants and engineering plants.
Commercial concrete mixing plant: it is used to produce ordinary commercial concrete, which is the most common and widely used mixing equipment.
Engineering concrete mixing plant: it refers to the mixing station temporarily built beside the construction site for a project, such as ordinary roads and bridges, small buildings, etc., to meet the production requirements of the project.
X — specification of mixing plant (i.e. productivity) (m3/h);
M — annual demand for concrete (m3/year);
T — annual working days of mixing plant, usually 300 (days/year);
H — daily working hours of mixing plant, usually 8 (h/day);
K – utilization coefficient, usually 0.8.
If the annual demand for concrete is 200,000m3, then X = M/(T× H × K) =200,000/(300 × 8 × 0.8)=104 m3/h, Therefore, HZS120 is selected.
After the preliminary determination of the specifications, it is appropriate to use two sets of the same model (i.e. double stations) as long as conditions permit from the perspective of capital, site, storage, etc., which can not only fully meet the production requirements, but also prevent the failure of a single equipment and the failure of normal production.
Determination of the Configuration
Mixer: The mixer is the heart of the mixing plant, which determines the efficiency of the mixing plant to the greatest extent. At present, the most commonly used is the double horizontal shaft forced mixer with the best comprehensive performance. Among them, the most advanced is the composite spiral belt mixing host. The outer spiral belt is added to promote the annular flow of materials. At the same time, the blade of the inner ring shears the material flow in a radial direction to achieve three-dimensional mixing of materials and greatly improve the mixing efficiency.
Advanced technology – composite spiral belt high efficiency mixing host. In addition to the core composite spiral belt, the cylinder is designed with large volume to reduce production resistance. At the same time, the super efficient motor is used to reduce the power by more than 15% compared with the host of the same model, which truly achieves high efficiency and energy conservation.
Weighing System: The material metering system is a key system that affects the concrete quality and production cost. It accurately measures various materials according to the mix ratio requirements, so as to ensure that the produced concrete meets the quality requirements.
Luton adopts a three scale structure of powder, and cement, coal ash and mineral powder are measured separately to ensure no material shortage. At the same time, the secondary and primary screw conveying mode is used. Large and small screws operate at the same time in the coarse weighing stage, and only small screws
operate in the fine weighing stage. The feeding is accurate, and the rate of reaching the standard is more than 95%. It is especially suitable for the working conditions that require strict measurement accuracy of fly ash and mineral powder.
Aggregate Storage and Transportation System: The batching machine is an aggregate batching device that integrates the functions of storage, metering and output of sand and gravel. It is divided into two types: steel structure type and silo type. Lutong is equipped with floor bin type batching machine as standard. The aggregate metering is located below the ground to block the sand and gravel noise. The storage bin with full concrete structure can store large quantities of sand and gravel. The batching machine is divided into three, four, five and six bins according to the number of bins. Usually, several bins are required for several aggregates.
Aggregate transportation mainly includes belt conveyor, elevator, lifting bucket, etc., and inclined belt conveyor is usually used. It is worth noting that dust is easily generated during aggregate transportation, which affects the environmental protection index of the equipment. Luton has covered the aggregate with canvas to reduce material scattering and dust pollution.
At the same time, it has installed a pulse type dust remover at the tail receiving point to reduce dust and improve environmental protection performance.
Powder Storage and Conveying System: The powder bin is a powder storage container, which can be welded or disassembled. Generally, it is welded and fabricated on site. If there is no powder bin fabrication site on site or the equipment delivery period is relatively urgent, the disassembly type shall be adopted, which shall be fabricated in the factory and assembled on site.
The quantity of powder silos is determined by the type of powder required for concrete. Generally, several powder silos are required for several kinds of powder. Considering the usage of raw materials and transportation distance, large capacity or multiple powder silos can be selected for materials with large usage.
The powder bin is the place where the dust in the mixing plant is high, and the top of the bin shall be installed for dust removal. According to different working principles, there are two types of dust removal on the top of the bin: vibration type (passive dust removal) and pulse back blowing type (active dust removal). It is recommended to use pulse back blowing bag type dust remover with active dust removal. The dust removal effect is better by cleaning the powder bin through continuous blowing. In addition, Luton’s powder silo structure is made of solid materials to prevent breakage and leakage. The dust remover is equipped with safety barriers to effectively eliminate potential safety hazards.
Liquid Material Storage and Transportation System: Liquid materials include water and additives. Water storage is divided into pool and water tank. The pool is a concrete structure water storage device built near the main building. The size and shape can be determined according to the actual situation of the site. The disadvantage is that the location is fixed and cannot be moved. The water tank is generally of steel structure, which is compact and convenient for transfer and movement, but its capacity is limited and its cost is relatively high.
The additive storage device has two forms: liquid storage tank and liquid storage tank. If liquid storage tank is selected, its volume is generally not less than 10m3.
Unloading Device: The discharging device is divided into two forms: the hopper without storage function and the hopper with storage function. The aggregate hopper plays a temporary role in storing the finished materials and can discharge the finished materials in the mixer as soon as possible. Therefore, the aggregate hopper is usually configured to improve the production efficiency. Luton’s new hydraulic gate type aggregate hopper, which is hydraulically driven, can store one tray of material without leakage or scattering, and has been widely praised by the market.
Air Compressor: There are two types of air compressors commonly used in the mixing plant: piston type and screw type. Piston type is easy to realize large capacity and high pressure output, but it has large vibration and noise, and requires air storage tank. LUTONG is equipped with brand screw air compressor with small volume, low noise, no vulnerable parts, reliable operation, long service life and simple maintenance. It is the first choice for environmental protection stations.
Intelligent configuration: Luton intelligent concrete mixing plant integrates various new technologies and brings more realistic, intelligent, safe, efficient and convenient control experience. The central centralized control room can realize remote operation control, centralized monitoring and centralized dispatching. ERP system integrates sales finance, test proportioning, production scheduling, vehicle monitoring, weighbridge collection, vehicle terminal, equipment maintenance, raw material inventory and other functions to achieve intelligent operation and build smart commercial concrete.
There are many specifications and models of concrete mixing plants, and the layout is different. Whether the selection and use are appropriate directly affects the cost, progress and quality of the project. Therefore, it is necessary to comprehensively consider many factors such as engineering characteristics, concrete output and construction period requirements, site and climate characteristics, environmental protection requirements, etc., to buy a suitable concrete batching plant.