Two Components Fireproof Materials Production Line

Project Background

As the world's largest "Dark Laboratory" that is truly operational, Shenyun Intelligence Technology Innovation Industrial Park has successfully developed a series of new silicon-based materials, including ultra-thin fireproof and heat-insulating coatings, high-performance anti-corrosion coatings, high-performance thermal insulation coatings, and silicone flame retardant synergists. Inner Mongolia Shenyun Intelligent Manufacturing Co., Ltd. undertakes the task of transforming research and development results into industrial applications. Moving from "laboratory" to "application field", requires large-scale production line construction, and the introduction of efficient and intelligent production equipment is an important part of this.

Project Overview

Location: Inner Mongolia Autonomous Region, Baotou

Material: Fireproof coating

Viscosity: 500,000cps

Temperature: 60℃

Production: 5000Tons/Year

Process Flow

Based on the customer's material and production process requirements, we recommended the double planetary dispersing and mixing process to the customer. The two-component fireproof material production line designed for the customer mainly includes: Powder Unpacking and Feeding System, Powder Batching System, Liquid Feeding System, Liquid Batching System, Double Planetary Mixing Unit, Supporting Unit, Control System, etc.

 1) Powder Unpacking and Feeding System

There are 4 kinds of powders, which are unpacking and unloading step by step through the unpacking station for both small bags and ton bags. The iris valve controls the flow rate to effectively prevent dust leakage. With three-port valve control, the vacuum feeder transports the powder to each storage silo through hard pipe. The dust collector is configured to capture dust and purify the air. The Screw Conveyor transports the powder from the storage silo to the batching hopper, and the inverter controls the screw speed to improve the batching speed and accuracy.

2) Liquid Feeding System

The liquid feeding system is divided into a high-viscosity feeding pump group and a low-viscosity feeding diaphragm pump group.

The dumping station is connected to the high-viscosity pump feed port, and the high-viscosity pump is connected to the corresponding metering tank for feeding; the low-viscosity material is connected to each raw material storage tank through the diaphragm pump group.

 3) Liquid Batching System

Liquids are batched by weighing. A/B components are each equipped with a set of 600L liquid measuring tanks, which are connected to the liquid inlets of the Double Planetary Mixers of A/B components respectively. High-viscosity materials are batched by reduction method, and each raw material tank is equipped with a weighing scale to achieve simultaneous batching of multiple materials; low-viscosity materials are batched successively by increment method.

4) Double Planetary Dispersing Mixer Unit

The mixing area is divided into A/B components Double Planetary Dispersing Mixers. The planetary structure adopts tank lifting method, which is stable and reliable and suitable for automatic batching of raw materials.

After the powder-liquid batching is completed, the A/B components are dispersing and mixing. The Planetary Mixer and Extrusion Machine are connected by track + turntable, the tank transfer station is convenient, and the mixing and extrusion and filling are carried out at the same time to improve production efficiency.

The steel structure manual operation small platform is convenient for operators to observe the material status and temporarily add materials (fiber materials).

The tank is connected to the semi-automatic Filling Machine to fill the A/B components separately.

5) Supporting Unit

Equipped with water temperature controller, absorb the heat in the heating or cooling medium through circulating water to control the temperature change in the process flow; the compressed air generated by the air compressor unit can be used for automatic valve control, and back blowing of powder dust removal and vacuum conveying.

6) Control System

Control cabinet, PLC control system + SIEMENS touch screen, clear and intuitive, easy to operate.

Highlights

• • The Double Planetary Powerful Dispersing Mixer (Tank Lifting Type) is designed for large models. It is closed with the barrel cover by hydraulic lifting of the tank. Suitable for automatic batching of raw materials. It is equipped with a high-position locking device, which is stable and reliable to prevent the displacement of the barrel during work and cause safety accidents.
  • Modular design to meet the scale of production. The entire production line is divided into multiple modules to efficiently utilize the production space. For example, the tank with a platform in the batching area adopts a building block design, which can be delivered to the customer site as a whole, is easy to install, and can be put into production quickly.

 Conclusion

The layout of this Two-component Fireproof Material Production Line is compact and reasonable, which scientifically reduces the material transportation distance and realizes intensive production.

The project does not produce any production wastewater, and the indicators such as waste gas and noise meet the standard limits and have passed the review of the local ecological environment bureau.

Accurate material ratio, good mixing uniformity, easy operation, high automation, greatly improve the product quality and production efficiency. The two-component fireproof material has multiple characteristics such as flame retardancy, fireproofing, heat insulation, waterproofing, moisture-proofing, dustproofing, and corrosion resistance, and has excellent applications in many industries such as construction, transportation, metallurgy and etc.