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1. System Overview
The dry mortar production line is designed for ready-mixed mortar for construction, suitable for bridge engineering, railroad infrastructure, municipal maintenance and other scenarios, and can produce ordinary mortar and special mortar (tile adhesive, thermal insulation mortar, etc.), with a production capacity covering 1.9-76 t/h, supporting flexible switching of cement-based/gypsum-based formulas. The production line integrates modules of raw material storage, precise metering, efficient mixing, intelligent packaging, etc. The moisture content of the finished product is ≤0.5%, and the homogeneity is up to CV ≤5%, which meets the GB/T 25181-2019 standard.
2. Core process systems
Raw material handling systems
Aggregate pre-treatment:
Three return dryer (sand moisture content from 15% to 0.5%)
Multi-stage vibrating screen (quartz sand particle size control 0.1-4mm)
Powder storage:
Silo group design (cement/fly ash/additives independent silo, capacity 50-300m³)
Anti - bridging technology (pneumatic arch breaker + silo wall vibrator)
Metering and batching system
| Raw material type | Measuring method | Accuracy control |
|---|---|---|
| Aggregates | Dynamic metering on belt scales | ±0.5% |
| Cementitious materials | Continuous weighing on spiral scales | ±0.3% |
| Additives | Micro loss-in-weight scales | ±0.1% |
Highly efficient mixing systems
Double-shaft zero-gravity mixer:
Mixing time ≤ 90 seconds, uniformity ≥ 98%
Liner wear life ≥ 100,000 tons
Flying knife group: Optimized dispersion of fiber materials (fiber length retention rate > 95%)
Finished product handling system
Valve port packaging machine: ton bag/25kg small bag dual mode, speed 40-60 bags/minute
Bulk system: pneumatic conveying to bulk truck (loading rate ≥50t/h)
3.Equipment configuration and parameters
| System module | Core equipment | Technical parameters |
|---|---|---|
| Raw material storage | steel plate warehouse (with dust broken arch) | capacity 50-300m³, pressure ≥ 10kPa |
| Drying and screening | Three-pass dryer | water volume 1-20t/h, thermal efficiency ≥85% |
| Measuring and batching | Control multi-scale linkage system | Recipe storage ≥200 types, switching time ＜5 seconds |
| Mixing host | Double-axis non-gravity mixer | Single mixing volume 1-10m³, residual rate ＜0.1% |
| Dust removal and environmental protection | Pulse bag dust collector | Filtering wind speed 1.2m/min, emission concentration ≤ 10mg/m³ |
| Intelligent control | Industrial DCS control system | Supports remote monitoring/fault diagnosis/production report generation |
4.Technical Advantages
Energy saving and environmental protection
Heat recovery: utilization rate of waste heat of drying system≥30%.
Dust control: fully enclosed design + centralized dust removal, workshop dust ≤ 1mg/m³
Intelligent operation and maintenance
Automatic calibration: automatic zero calibration of the metering system every 8 hours
Predictive maintenance: real-time monitoring of bearing temperature/vibration, fault warning accuracy >90%.
Flexible expansion
Modular design: supports seamless upgrade from 5t/h small line to 80t/h large line
Quick production change: cleaning time ＜15 minutes (special mortar switching)
5.Typical formula and finished product index
| Mortar type | Cementitious material ratio | Aggregate gradation | Compressive strength (28d) |
|---|---|---|---|
| Ordinary masonry mortar | 15-25% | 0.1-4mm continuous gradation | ≥M5 |
| Tile adhesive | 35-45% | 0.3-1.2mm fine screened sand | ≥C1 |
| Insulation board bonding mortar | 40-50% | 0.1-0.6mm quartz sand | ≥0.6MPa |
6. Selection and service
Capacity matching recommendations
Small projects (1.9-10t/h): Compact tower layout
Large commercial concrete mixing station (30-76t/h): Horizontal modular layout, supporting parallel production of 4 formulations
Value-added services
Formula research and development: Provide laboratory-level mortar performance optimization services
EPC general contracting: covering plant design, equipment installation and personnel training
