Description of the Technological flow:

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1. Treatment and storage of Raw Materials.

   • FLY ASH will be brought by bulkers and pumped into silo in the batching plant.

   • Burnt lime/Quick Lime: Ground burnt lime in jumbo bags is carried into the plant and is pumped into the lime silo in the material batching and mixing building.

   • Cement: Cement is carried into the plant by the trucks and is dropped into the cement silo in the material batching and mixing building.

   • Gypsum: Gypsum powder is carried into the plant by trucks and stocked in the yard. The gypsum is fed in to slurry mixer in the batching and mixing building and mixed along with  Fly ash to from slurry.

   • Aluminum Powder: Purchased aluminum powder packed in bags/drums is carried into the plant by truck and is stored. The aluminum powder for production is lifted to the third floor in batching and mixing plant by the electric hoist. After weighing by the electric scales, it will fed to the mixture.

   • Waste Mortar: The left over bits and pieces cut from the cutting line are flushed along the slope chute into the mortar pond to be mixed again to a certain concentration (density) by adding water and then pumped into the storage tank for use by the slurry pump.

2. Batching, Mixing and Pouring 

   • The burnt lime and cement are fed respectively by the screwed-pipe feeders under the silos to the electronic powder scales. After weighing by the scales, they  are fed to the mixer by the feeding device under the scale.

   • The mortar is pumped into the transition tank in the material batching and mixing building from the storage tank and after weighing  by the scale is put into the pouring mixer.

   • The aluminum powder is put into the aluminum powder scale and into the aluminum powder mixer after weighing. After through mixing with water, slurry is put into the pouring mixer.

   • The feeding order of various kinds of raw materials as follows: first feed mortar and add the required water, then add cement and lime powder, finally add aluminum powder suspension.

   • After feeding all the materials in the high speed mixer, the materials are thoroughly mixed for 2 to 3 minutes to achieve homogeneous concrete slurry while mixing the mixer will be moved by a crane to the respective mould to be casted. The concrete.

   • slurry, is then unloaded into the moulds through a distributor (pour) by lowering the gate in the bottom of the mixer . After unloading the entire quantity of concrete slurry, then gate will be closed and mixer will go back to its original prefixed position to take the next batch of materials.

   • In the floor of the batching and mixing building there will be a central control room equipped with PLC and Central computer processor along with the display screens, which can control batching of raw materials, feeding and mixing thus making the entire batching & mixing process automatic.

3. The Resting cutting & Grouping 

   • The moulds pouring are kept in the resting position, to rest for initial curing at the temperature of about 50 C for about 2.5 hours. 

   • After the cut strength is reached mould frame will be lifted up with crane, the cakes with bottom of mould are moved by handling Crane where it will be lifted up and placed over by the tilting table and then after lifting it will be shifted onto the cutting plate of cutting line. Green block on the cutting plate is then cut horizontally and vertically to the required sizes by the cutting machine. 

   • The green block after cutting is shifted to tilting table in a vertical position and tilted to horizontal position immediately to avoid sticking of green blocks, then  the green block on the curing frame in horizontal position will be shifted from tilting table to respective station and grouped in two layers by the crane with hosting frame. The grouped curing frames will be moved through handling crane into the Autoclave through push and pull system on transfer car.

4. Autoclaving and Finished Products 

   • After positioning the cakes in the autoclave properly, door of autoclave is closed properly and checked for safety before opening the steam valves. The steam will be continuously fed into the autoclaves and controlled to achieve the targeted temperature profile. After the cycle is completed the autoclave door is opened.

   • The green block are autoclaved for 10-12 hours under a constant pressure of 1.3 MP and after 1.5 hours of stooping the supply steam, the door will be opened after emptying unabsorbed steam by vacuum pump. Autoclaved products are drawn out of the autoclave through push & pull system on transfer car, then hoisted by the handling crane to the prefixed station of the curing frames. Then curing frames will be shifted to stocking yard for unloading of blocks through Fork Lifts. The curing frames will be cleaned and oiled manually after unloading of blocks and shifted back to the plant for circulation. 

 
After few days of drying of blocks, the end products are loaded into trucks for dispatch.