Continuous ball mill, intelligent spray, 33,000-ton ultra-large tonnage press, 7-layer drying, intelligent glaze line, carbon-neutral energy efficiency benchmark new energy-saving kiln, rock slab/large slab double-layer kiln, intelligent whole-line central control system , automatic conveying and packaging system after the kiln...
In 2021, under the background that rock slabs/large slabs continue to be hot, the production capacity expansion of leading companies continues to accelerate, energy prices continue to rise, the national carbon peak carbon neutrality policy has been implemented, and labor costs continue to rise, super large Concepts such as tonnage presses, energy conservation and emission reduction, and digital intelligence have become the common focus of the Foshan Tanzhou Ceramics Exhibition and the 2021 Guangzhou Ceramics Industry Exhibition in late July.
Especially as industry leading companies such as Marco Polo, New Pearl, Mona Lisa, Hongyu, Oceano, and Nobel have increasingly stringent requirements for production equipment and the recognition of green intelligent entire lines continues to increase, Under the industry trend of green, intelligent and returning to the "original intention" of manufacturing, intelligent complete lines that are "small but refined" for a single machine and "big and powerful" for the entire line have also become the choice of the times.
Continuous ball milling, intelligent spray
Make the entire production line more environmentally friendly, stable and efficient
Affected by the epidemic in 2020, almost all global ceramic equipment exhibitions were suspended. The Tanzhou Ceramics Exhibition in late July 2021 has also become the main battlefield for global ceramic people to learn about the industry's most cutting-edge innovative technologies.
Under the trend of rock slabs, what are the highlights of the green intelligent complete line equipment technology and innovation that is currently hot in the world?
At this exhibition, Litai brand gave its own answer.
The newly upgraded Henlitai automated raw material preparation system has greatly met the industry's demand for green products and services, especially the technological upgrades of continuous ball mill pulping systems, spray tower powdering and other systems, which have not only greatly improved The single-line production capacity of raw materials also has the characteristics of energy saving, high efficiency, and high degree of automation, which can provide a strong guarantee for the normal and stable operation of subsequent equipment and the smooth completion of mass production of the entire plant.
Teng County Mona Lisa Continuous Ball Mill
Continuous ball mill pulping is quite mature both in terms of equipment and production technology. It can not only be seamlessly connected with automation and intelligent technology, but also improve the management of enterprises, reduce labor intensity, and solve problems such as labor difficulties.All will bring revolutionary changes, with the characteristics of high degree of intelligence, high precision, stable operation, and significant energy saving effect.
With the technological upgrading of the spray tower milling system, the single-line production capacity of raw materials can be greatly increased. Among them, the ST2000 spray tower settled in Jiangxi Zhibo is one of the largest, most energy-saving spray towers with the highest output and the latest automated control system in the global industry. The daily output can exceed 2,000 tons. It is known as the "spray tower in the industry". big mac".
Jiangxi Zhibo ST2000 spray tower< /p>
33,000-ton ultra-large tonnage press
3-20mm large slate plate taking into consideration both thickness and thickness
Henglitai's ultra-large size ceramic plate press HB33000 adopts the "belt + mold frame + square cylinder" molding process, with the square oil cylinder applying pressure and the belt cloth process. The equipment has strong adaptability, good brick quality, can achieve full-body pattern texture, less powder loss, fast pressing speed, and low comprehensive use cost.
The entire set of molding equipment adopts intelligent centralized control and management, has data networking functions, can be connected to factory production management systems such as MES and ERP, and can press large/rock plate products with a thickness of 3-20mm.
The YP90 series automatic hydraulic press is Henlitai's innovative fruit guided by intelligent development. It is an environmentally friendly equipment with high standards and strict requirements, which optimizes the performance of the press and meets the operational requirements of large production capacity, low loss and high yield. , is the crystallization of wisdom that adapts to the new normal development trend of the industry.
HB33000 Extra Large Size Ceramic Plate Press
At the same time, Henlitai's new large-sized intelligent ceramic plate press series has outstanding and excellent pressing technology, with a maximum pressing force of 168000-250000kN. It can optimize the performance of the press and has high comprehensive performance and reliability. It can make the molded body denser, have lower water absorption and higher added value, and can meet the requirements of large production capacity and low cost.Operational requirements with high losses and yields.
In addition, the equipment maintenance cost and production cost are low, the comprehensive economic benefits are high, and it also has the advantage of suppressing multiple specifications.
Hongwei Ceramics Large Size Intelligent Ceramic Plate Press< /span>
Energy-saving glaze throwing kiln
Energy consumption as low as 1.57 Nm³ natural gas/m²
The "4.0 Energy Efficiency Benchmarking Digital Intelligence Era" glazed brick kiln combination brings together Delitai's latest and most comprehensive advanced technologies. Whether it is energy saving, waste heat recovery, kiln insulation, or intelligent automation and information-based production, it has demonstrated industry-leading levels.
The specifications that can be produced are 300×600mm, 400×800mm, 600×600mm, 800×800mm, 900×900mm, 1000×1000mm, 1200×1200mm, 600×1200mm, 750×1500mm, 900×1800mm and other high-end full throw Glaze products can meet the design requirements of different customers, with daily output ranging from 15,000 to 45,000 square meters.
4.0 Energy Efficiency Benchmark Digital Intelligence Era Glazed Brick Kiln Combination (Teng County Mona Lisa)
At the beginning of 2019, this group of equipment has successfully achieved a major breakthrough in the comprehensive energy consumption of 1.57 Nm³ natural gas/m² in domestic first-tier brand enterprises such as Mona Lisa, and the energy consumption has stepped from 1.8-2.4 Nm³ natural gas/m² to 1.6 Natural gas below Nm³/m² times.
Chongqing Weimei "4.0 Energy Efficiency Benchmark Digital Intelligence Era" Glazed Tile Production Line< /span>
The whole line of rock slabs is 3-18mm thick and thin
Effectively prevent staining and cutting cracks
The "4.0 Energy Efficiency Benchmarking Digital Intelligence Era" slate/large slab kiln combination is based on the Delitai team's more than 20 years of experience in the international market and the success of more than 10 overseas slate kilns, combined with the Italian sub- The company's Weigao has years of technical achievements in slate kilns and has launched a new special kiln for slate/large slabs.
The specifications that can be produced are 800×2700mm, 1200×2400mm, 1500×3000mm, 1200×2700mm, 1600×3200mm, 1800×3600mm and other full specifications of high-end green large rock slabs. The thickness can also be customized according to 3-18mm, according to different customers According to the demand, the daily output can range from 08,000 to 25,000 square meters.
Shengshi Oriental’s “4.0 Energy Efficiency Benchmark Digital Intelligence Era” Stone Slab Production Line
This equipment not only adopts professional and leading design in terms of fast burning, preheating, cutting and cracking treatment, dirt removal treatment, etc., but also carries out scientific and special design in the fields of energy consumption, brick walking, temperature difference resolution, automation, intelligence and other fields. chemical treatment.
In addition, the fully-automatic control of the air distribution and stirring system can protect the uniform heating requirements of the slate in the pre-heating area under automatic control, and can also effectively prevent the contamination of the kiln.
New Pearl "4.0 Energy Efficiency Benchmark Digital Intelligence Era" Slate Kiln Combination< /span>
Nobel "4.0 Energy Efficiency Benchmark Digital Intelligence Era" Slate Kiln
Water jet grooving cutting is normal< /p>
Carbon-neutral slate double-layer kiln
Comprehensive energy saving exceeds 15%
The carbon neutral (Carboneutral) series of the industrial "4.0 energy efficiency benchmark in the digital age" is based on a full investigation of 9 double-layered rock plate kilns in Asia. There are already 6 double-layered roller conveyors through Delitai This new generation double-layer roller kiln is developed based on the practical experience of the kiln, the advanced design concept of the double-layer kiln of the Italian Wego Company, and the design theory of Carboneutral, which is integrated with the first-hand operation data of domestic slate kilns.
This equipment is equipped with the advanced digital intelligent management system DDI4.0-A, which brings together a number of newly developed patented technologies and uses the best and reasonable refractory materials to break the constraints of traditional kilns and achieve a wide cycle range and adaptability. Strong, it can meet all kinds of flexible production under personalized customization.
At the same time, it explains how the double-layer kiln plate kiln solves a series of technical problems such as soiling, thermal stability, cutting cracks, and how to solve the temperature interference between the upper and lower layers.
Effectively improve the synergy between equipment and green production capabilities, the comprehensive energy saving can exceed 15%, achieving carbon emission reduction and actively responding to the social responsibility of the national carbon peak and carbon neutrality strategic goals.
The "4.0 Energy Efficiency Benchmark Digital Intelligence Era" carbon-neutral slate kiln project jointly created by Delitai, Oceano Ceramics and New Pearl is currently under construction.
4.0+ Intelligent Central Control System
Promote intelligentization and line integration of production
The entire line 4.0+ intelligent central control system exhibited by the Litai brand in Tanzhou Exhibition this time is a management system that combines ceramic enterprise management and cloud computing, and has improved the auxiliary glaze line on the original system. The central control system cooperates with the powder making and molding equipment to realize intelligent management of the entire line, which greatly realizes the intelligence and integration of the production line equipment.
This system is divided into a whole-line monitoring system for the operation of ceramic equipment such as slurry preparation, powder preparation, press molding, glaze printing, and firing kilns. It provides a data interface for the MES system and a future intelligent production scheduling system. Provide basic data.
The past qualitative description and experience management have gradually transformed into an intelligent manufacturing enterprise with data management and data production, injecting new vitality into the intelligent management technology of the entire ceramic machine line project; coupled with the on-site mobile APP cloud control system The data collection demonstration breaks through the limitations of time and space, enabling remote monitoring of the production line, understanding the production situation anytime and anywhere, and fully grasping the operating status of the equipment.
This display system is an interception of the 7-layer drying, glaze line, roller table and accessory equipment of the partial equipment in the ceramic production system. Enter the single equipment management system from the friendly screen of the entire production central control system. The local interface can clearly and in detail display the current equipment operating status, SCADA status simulation, control interface operation, production data and alarm status, allowing production managers to have a clear and intuitive experience of equipment operation.
This 4.0+ intelligent central control system has been maturely operated in projects such as the Mona Lisa in Teng County, empowering industrial application scenarios. Its automation, informatization, and intelligent technologies have reached industry-leading levels.
Intelligent packaging after the kiln
Efficiency increased by more than 30%
In terms of post-kiln automation and intelligence, Litai brand focused on displaying three-dimensional storage systems and sorting and packaging systems.
The three-dimensional storage and transportation system includes storage shelves, peripheral logistics equipment, stackers, AGV (automatic guided transport vehicles), etc. Intelligent operation, random storage, first-in-first-out account and real-time synchronization, compared with the concrete warehousing method, the comprehensive investment cost of the same storage volume is reduced by 30%. In the sanitary ware industry, it is mainly used for semi-finished product storage and finished product storage.
AGV is an important link in the three-dimensional storage system. It is widely used in the warehousing industry, manufacturing industry, dangerous places and special industries. Navigation methods include magnetic stripe navigation, QR code navigation, laser navigation, visual navigation, etc.
AGV (Automated Guided Vehicle)
Transportation methods include latent jacking, traction, latent traction, etc. In the sanitary ware industry, it is mainly used to transport semi-finished products and finished products. Through information software control, it can realize fixed-point, quantitative and timed logistics transportation and realize flexible production.
The sorting and packaging system includes sorting stations, leak detection machines, functional testing machines, cartoning machines, carton unpacking machines, baling machines, etc. Through logistics transportation and MS system control, automatic leak detection, automatic packing, Functions such as automatic taping and automatic generation of quality reports deeply integrate automation and informatization, effectively improve packaging efficiency and reduce employee labor intensity.
Inspection and packaging system
The sorting and packaging system can effectively reduce employee labor intensity by 80% based on traditional production processes, increase per capita production capacity by 30%, and shorten the inspection and packaging production cycle to 1 day.
(Article reproduced from Ceramic Information)
