VU120 Maschinegemachte Sandproduktionslinie in Shijiazhuang
Entwickelt, hergestellt und installiert von SBM, wurde diese VU120 Maschinegemachte Sandproduktionslinie in Shijiazhuang im Februar 2015 in Betrieb genommen. Its establishment plays an important role in relieving the shortage of natural sand, protecting the environment and developing green building materials and green mines.
The use of highly-intensive fully-closed tower-like layout integrates the high-efficiency sand-making system, particle shape optimization, stone powder control, grading adjustment, water content control and environmental protection, which can optimize and adjust the indexes like the particle shape, grading, powder content and fineness modulus so that machine-made sand can completely replace natural sand in concrete and mortar preparation. The performance of machine-made sand is improved, and a large amount of cement and additives can be saved.
Politik Faktor
Seit der Einführung der Technischen Vorschriften für mit Maschinen hergestellten Sand durch das Ministerium für Wohnungsbau und Stadt-Land-Bau Chinas (MHURC) im Jahr 1973 wurde maschinell hergestellter Sand umfassend entwickelt. Darüber hinaus wird die Entwicklung von maschinell hergestelltem Sand stark von der makroökonomischen Steuerungspolitik, der Industrialisierung, der B&R-Initiative, der Urbanisierung und dem ökologischen Management beeinflusst.
Umwelt Faktor
The cost for quarrying natural sand gets higher and higher while the amount gets less and less because of excessive quarrying. Natürlicher Sand is a non-renewable resource, so to preserve natural terrain, protect riverbanks, and maintain ecological balance, natural sand quarrying has been prohibited in some regions.
Unter dem Einfluss von Politik und Umwelt werden einige relevante Unternehmen ermutigt, die Produktion von maschinell hergestellten Sand zu entwickeln, um die ökologische Umwelt in Shijiazhuang, Hebei, zu schützen.
The sand produced by VU meets the standards of GB/T14684 and JGJ52. The sand can be adjusted according to the practical requirements. The fineness modulus can be controlled within 2.0-3.5; the powder is content 3-15%.
| Siebgröße | Betonsand 1 | Betonsand 2 | Mörtelsand 1 | Internationale Grenze von Betonsand | ||||
|---|---|---|---|---|---|---|---|---|
| Einheit Siebwurfquote | Akumulierter Siebwurfquote | Einheit Siebwurfquote | Akumulierter Siebwurfquote | Einheit Siebwurfquote | Akumulierter Siebwurfquote | Einheit Siebwurfquote | Akumulierter Siebwurfquote | |
| 4.75 | 0 | 0 | 0 | 0 | 0 | 0 | 10% | 0% |
| 2.36 | 9.5% | 9.5% | 5.3% | 5.3% | 3.5% | 3.5% | 25% | 0% |
| 1.18 | 26.8% | 36.3% | 27.6% | 32.9% | 22.0% | 25.5% | 50% | 10% |
| 0.6 | 22.9% | 59.3% | 23.7% | 56.6% | 24.5% | 50.0% | 70% | 41% |
| 0.3 | 17.8% | 77.1% | 19.2% | 75.8% | 18.5% | 68.5% | 92% | 70% |
| 0.15 | 14.6% | 91.7% | 15.5% | 91.3% | 17.5% | 86.0% | 94% | 80% |
| 0.075 | 3.9% | 95.6% | 4.5% | 95.8% | 9.3% | 95.3% | -- | -- |
| Chassis | 4.4% | 100% | 4.2% | 100% | 4.7% | 100% | -- | -- |
| Feinheitsmodul | 2.74 | 2.61 | 2.33 | |||||
In order to satisfy the increasing demand for high quality sand and the performance requirement of concrete and mortar, SBM spent 5 years developing VU System at the specialized aggregate optimization test site with over 30-year experience in this industry.
The VU Aggregat Optimization System is a system designed to produce high-quality machine-made sand, which overcomes the problems in sand-making technology, including crushing, grinding and separating.
In diesem Projekt erfüllte das VU Aggregat-Optimierungssystem perfekt alle Produktionsstandards für maschinell hergestellten Sand für den Kunden.
------Hohe Effizienz der Sandherstellung
The new generation of VU Sandproduktion Maschine firstly realizes the grinding technologies including high-frequency "stone hitting stone" and "material cloud". Compared to VSI Sand Making Machine, the VU system increases the sand rate and fine sand rate by over 10%.
-----Hohe Effizienz
The combination of crushing, screening and powder separating, the screen can finish material screening and stone dust removing at the same time because of its full closure, dust removal using negative pressure and uniform screening.
-----Einstellbar und kontrollierbar
Wind volume and flow duct can achieve continuously online precise adjustment without replacing the screen mesh and other parts. The fineness of final sand is controllable within 2.5-3.2; the powder content within 3-15%.
-----Partikelformoptimierung
Imitating the formation principle of natural sand, the machine adopts globally pioneering technologies of "low energy crushing and dressing" and "self-grinding via falling mode", which can effectively remove edges on the surface of final products and increase the volume of fine sand to about 0.6mm. The voidage is reduced by 1–2%, and the flow time by 5%.
------Niedrige Kosten
The new and targeted dressing technology reduces the energy consumption and extends the life span of vulnerable parts (under the same conditions, the life span is over ten times of impact crushers).
Automated control design guarantees stable water adding to keep the eligible water content of final sand and uniformity, and to avoid segregation.
------Greener
The use of negative pressure dust collector and the closed operation boasts less dust and pollution, fully in line with national standards of "green" construction.
------Intelligenter
The design of automatic monitoring and material discharging of fine ore bin makes the fine material storage and transportation possible by pressing a button. It greatly reduces labor intensity and operation cost.
------Stabil und bequem
Die Kontroll- und Überwachungsaufgaben aller Maschinen sind in das zentrale Kontrollsystem integriert, was den Betriebsprozess erheblich vereinfacht und eine sichere, kontinuierliche und stabile Produktion gewährleistet.
------Hohe Effizienz
Setting and keeping the optimal operating parameters is available. And the quality of products is stable. This system can maximize productivity and keep the overall efficiency at the highest level.
After being crushed and shaped by the VU Sand-making Crusher, the tailings below 10mm as raw materials are divided into three components under the action of FM Control Screen and Dust Collector--- stone powder, reverting material and finished sand product. Stone powder is collected by Dust Collector and stored at the fine ore bin while the finished sand product enters the Particle Shape Optimization Machine for further dressing and then is taken the last processing step--- mixing in a humid environment. Processed by VU Aggregat Optimization System, raw materials can be turned into high-quality sand with reasonable grading, smooth shape and controllable powder content, and dry, clean, recycled and high-quality stone powder (Application fields depend on raw materials).
The VU Aggregat Optimization System---- a world-leading dry-type sand-making system designed by SBM for machine-made sand production of Shijiazhuang Hengxin Jinshuo Construction Material Company was upgraded fully on the basis of the existing dry-type sand-making system. The use of highly-intensive fully-closed tower-like layout integrates the high-efficiency sand-making system, particle shape optimization, stone powder control, grading adjustment, water content control and environmental protection. Not only does the productivity increase a lot, but also all standards including particle shape, grading and powder content improves so that the performance of machine-made sand can be compared with natural sand and new chances and value in the development of the sandstone, cement and concrete industries.
Hoher Umweltschutz
A. Umwelttechnologie: The fully closed transportation and production and the negative pressure dust removal design avoid raising dust in production sites. The dry-type production and screening technology avoids the emission of waste water and slush.
B. Umweltbetrieb: Feuchtigkeitskontrollmaschine（optional）keeps the water content of finished sand products qualified and avoids raising dust. The powder storehouse monitoring and automatic telescopic material discharging design prevent the stone powder from spilling in transit. Besides, the dry-type dust removing and separating technology keeps the dryness and cleanness of stone powder, making the treatment and overall utilization easier.
Hohe Effizienz
A. Effiziente Produktion: The all-around innovation of crushing and grinding technologies increases the sand production rate by over 10%. The integrated dry-type screening technology elevates the screening efficiency obviously, and the screen area can be reduced by over 50% compared with that of traditional technology. The performance improvement of single machine and the reasonable use of technologies reduce the electricity consumption a lot and increase the processing volume by 5-10%.
B. Effizienter Betrieb: The intensive tower-like design occupies smaller floor area. For example, an area of 7.5m×24m can place the body part of VU70. The new anti-abrasive design and the upgrading of materials prolong the lifespan of wear-resistant parts and reduce the maintenance downtime a lot. The integrated control system and online adjustment design can adjust the system settings during operation, improving the quality and yield of finished sand products and reducing labor.
Hohe Qualität
A. Angemessene Bewertung: Integrated crushing & grinding functions and flexible screening design make the grading of finished sand product continuous, adjustable and controllable. The fine sand within 0.15-0.6mm increases sharply while the coarse sand with fineness within 2.36-4.75mm reduces relatively. The grading meets the American standard ASTMC33, the secondary level of Chinese standard JGJ52 and Indian standard IS383.
B. Gleichmäßige Partikelform: Completely original grinding and material falling shaping technologies mainly produce square and spherical sand. The edges on the sand surface are reduced to the extreme. Meanwhile, the superficial area and voidage decrease obviously and the fluidity is therefore increased.
C. Kontrollierbarer Pulvergehalt: dry-type powder removing technology keeps the powder content of finished sand products (0-0.15mm) stable and controllable within 3-15%. The dry and clean stone powder got by dry-type separation method can be recycled.
Hoher Gewinn
Highly-efficient system design reduces electricity consumption by 5-10% and labor cost by 40%. The one-time investment can save costs over 30% in comparison with similar products.
Hoher Umweltschutz
Hohe Effizienz
Hohe Qualität
Hoher Gewinn
The raw materials are relatively clean low-value stone chips with fineness within 0-5mm and 5-10mm. The 0–5mm stone powder before processing costs 4 yuan per ton, while the processed high-quality machine-made sand is 45 yuan per ton, with the value of tailings increased by 40 yuan per ton.
Die Anwendungseffekte des von VU120 Aggregat Optimization System produzierten maschinell hergestellten Sands sind deutlich besser als die von natürlichem Sand.
Der von VU-System produzierten Sand kann natürlichen Sand vollständig ersetzen, um C20-C60 Beton und andere spezielle Arten von Beton herzustellen. Der maschinell hergestellte Sand hat hohe Festigkeit, breite Anwendbarkeit und kann den Einsatz von Zement und Zusatzstoffen sparen.
| Sand | Verhältnis | Setzmaß | Mischsituation | Intensität | |||
|---|---|---|---|---|---|---|---|
| Wasser-Zement-Verhältnis | Wasserreduzierer | Initial T/K | T/K 1 Stunde später | Situationsbeschreibung | 7d | 28d | |
| Natürlicher Sand | 0.38 | 1.42% | 235/490 | 185/390 | Gute Beschaffenheit und Fließfähigkeit | 24.9 | 42.3 |
| VU-Sand | 0.38 | 1.42% | 240/495 | 180/385 | Gute Beschaffenheit und Fließfähigkeit | 25.8 | 44.5 |
Fertigprodukt-Sand
Bild 01 der Leistungsevaluierung
Bild 02 der Leistungsevaluierung
Feedback des Projektmanagers zur Installation
1. The whole VU system is over 25 meters high. It is a heavy engineering project which must strictly observe the national safety regulations and be finished by following the drawing requirements.
2. Bei Erhalt der relevanten Daten des VU-Systems muss der Installationsplan im Voraus erstellt werden. Je nach Größe jedes Teils ist es notwendig zu planen, was wir in jedem Installationsprozess benötigen, wie Ersatzteile, Materialien, Werkzeuge, Kräne, Personal und Zeit, um die Installationszeit und -kosten erheblich zu reduzieren und den Abschluss des Projekts rechtzeitig zu gewährleisten.
3. 10-20 workers are required to form an installation team. And they must have over 2-year experience in machinery and steel industry. Besides, after safety training, they have a strong awareness of self-protection. Moreover, related skills must be grasped well. Before working, they must wear all protective equipment such as work clothes, safety helmets, safety shoes and gloves. Meetings about safety and quality requirements are held in advance and each individual’s working responsibility is assigned. The progress of project and related problems would be taken down every day and regular project meetings are held.
Kundenfeedback
The project using sand and gravel tailings to make high-quality sand was offered by SBM. SBM offered both equipment and installation service. The whole process of installation was successful and VU120 system was put into operation on schedule. The operation was stable with little noise and no dust. The most important thing was that using the wastes produced by previous production to make valuable products brought us great economic profits.
Seit der Einführung der Technischen Vorschriften für mit Maschinen hergestellten Sand von Chinas Ministerium für Wohnungswesen und ländliche Entwicklung (MHURC) im Jahr 1973, wurde Maschinen-Sand umfassend entwickelt. Vom Bauwesen über Straßen, Eisenbahnen, Wasser & Strom, Metallurgie-Systeme, von Blockierungs- und Schutzprojekten bis zu Brücken, Tunneln und Wasserwerken, von Mauerwerk-Mörtel bis hin zu normalem Beton, Stahlbeton, vorgespannter Beton, Pumpenbeton, luftdichtem Beton und kombiniertem Bolzen und Spritzbeton ist Maschinen-Sand überall zu sehen.
In light of the protection to natural resources and the increase in construction quality, machine-made sand gradually becomes the key to dry-mixed mortar. Machine-made sand as the new construction sand for dry-mixed mortar has a significant impact on the integrated use of resources.
Niedrige Qualität:Bearbeitet von billigen Brechern werden grobe Aggregat einfach zerkleinert und gesiebt, so dass die elongated und schuppigen Partikel entstehen und große Hohlräume und ungleichmäßige Qualität auftreten.
Hohe Kosten:Because of the continuous quarrying, the sand resources get fewer and fewer. The demand exceeds the supply so that the price increases sharply. Furthermore, because the supply and quality of sand cannot be guaranteed, the laboratory has to adjust the mix proportion frequently, which usually gives rise to the overuse of cement. And then production cost rises.
Technische Mängel:Because the technologies like crushing, screening, dust-removing by rinsing are too simple, the quality of finished sand products fail to pass standards on the one hand and how to treat sewage and sludge is a problem on the other hand.
Schwere Verschmutzung
Beratung