As the core protective barrier of industrial kilns, the batching accuracy and stability of the furnace lining directly determine the kiln’s service life, operational safety, and production efficiency. Traditional furnace lining batching relies on manual operation, which often leads to issues like batching deviations, material contamination, and low efficiency—these simply can’t meet the demands of large-scale and refined production in modern industry. With years of deep expertise in the automation sector, Sihyde . has custom-built a full-set automated batching system specifically for furnace lining batching scenarios. By integrating multiple core equipment modules, this system leverages technical excellence and strong practicality to help customers solve batching challenges and achieve an intelligent upgrade of their production processes.
This furnace lining automated batching system covers the entire production chain, including material storage, feeding, conveying, metering, mixing, transportation, and dust removal. All components work in synergy to form a closed-loop automated production line, ensuring batching quality from the source, significantly reducing manual intervention, and boosting production efficiency.
1. Material Storage Core: Stable Supply & Quality Control from the Source
Material storage is the foundation of the batching process. The system is equipped with three core storage devices—powder silos, powder feeding silos, and aggregate silos—paired with dedicated auxiliary components. This setup enables the safe, stable storage and precise discharge of different materials.
Powder silos feature professional silo bodies that provide a sealed, dry environment for powder materials, preventing moisture absorption and caking. Equipped with air knock hammers, they effectively solve common issues like powder adhesion to silo walls and bridging, ensuring smooth material discharge. Built-in level gauges send high/low level alerts for timely material replenishment. Manual butterfly valves work with blowing devices to precisely control powder discharge volume, while the blowing function cleans residual materials to minimize waste.
Powder feeding silos are designed exclusively for powder feeding. They come with bin doors and gas springs for easy operation and excellent sealing, preventing dust leakage during feeding. Built-in filter screens remove impurities from powders to ensure material purity. The dual permanent magnet iron removal bars efficiently absorb ferromagnetic impurities, eliminating their impact on furnace lining quality from the source and further improving batching standards.
Aggregate silos use specialized silo bodies tailored to aggregate storage characteristics. Paired with vibration motors, high-frequency vibration ensures uniform aggregate discharge and prevents blockages from material accumulation. Level gauges provide high/low level alerts to feedback residual aggregate volume in real time, and manual gate valves precisely control discharge—adapting to the storage and discharge needs of different aggregates and ensuring stable supply for subsequent batching steps.
For easy operation and maintenance, the system includes a dedicated silo platform with guardrails and ladders. This balances operational convenience with personnel safety, providing a secure environment for daily inspections and material replenishment in the storage phase.
2. Conveying & Metering Stage: Precise Control to Ensure Batching Accuracy
Conveying and metering are the core links of automated batching, directly determining batching precision. The system achieves efficient material conveying and precise metering through the coordinated operation of key equipment such as screw conveyors, electromagnetic vibrating feeders, and metering trolleys, ensuring all material ratios meet production standards.
Screw conveyors, the core of material conveying, adopt a high-precision conveying structure for stable and efficient material transport. Paired with single-flange pneumatic butterfly valves, they precisely control start/stop and conveying volume to adapt to different material needs. The conveying process is completely leak-free, keeping the production environment clean.
Electromagnetic vibrating feeders realize uniform material feeding through electromagnetic vibration, with feed volume adjustable for materials of different particle sizes and densities. Equipped with pneumatic flap valves, they effectively control the start/stop of feeding to avoid over-supply, further improving feeding accuracy.
Metering trolleys are the core of precise metering, featuring dedicated hoppers and trolley frames for stable structure. Driven by gear motors and assisted by vibration motors for hopper discharge, they ensure smooth and efficient metering. Equipped with high-precision load cells and weighing modules, they collect real-time material weight data, keeping metering errors to a minimum and ensuring accurate material ratios.
Pneumatic wafer valves precisely control material discharge, while dust collectors and sealing mechanisms prevent dust leakage during metering and discharge—balancing precision with a clean production environment. Proximity switches, cable reels, and RFID control enable automated positioning, movement, and operation control of metering trolleys, greatly improving work efficiency. Air compressors and machined accessories ensure stable equipment operation and extend service life.
3. Mixing & Transportation System: Efficient Mixing to Guarantee Material Quality
Mixing and transportation directly affect the mixing uniformity of furnace lining materials and transportation stability. The system is equipped with mixing systems, transport trolleys, lifting platforms, and mixer platforms to achieve efficient material mixing and precise conveying.
The mixing system uses a vertical shaft mixer with high mixing efficiency and excellent uniformity, perfectly suited for furnace lining material mixing. Discharge door guards ensure safe discharge and prevent material splashing.
Lifting Platform 1 comes with a dedicated frame, hydraulic lifting system, and guardrails, enabling easy lifting of the mixing system to adapt to different operation heights. Comprehensive safety protection features ensure stable and safe lifting operations.
Transport trolleys complement the structure of metering trolleys, equipped with hoppers, trolley frames, gear reducers, and vibration motors to ensure uniform material distribution during transportation. Electric wafer valves precisely control discharge, while proximity switches, cable reels, and RFID control enable automated positioning and movement of transport trolleys, boosting transportation efficiency. Machined accessories ensure long-term stable operation.
The mixer platform is fitted with chutes, guardrails, and ladders. Chutes realize precise material diversion, ensuring smooth connection between mixing and transportation stages. Guardrails and ladders protect operators and facilitate daily equipment maintenance and operation.
4. Resin Processing System: Custom Configuration for Special Material Needs
To address the processing requirements of special materials like resin in furnace lining batching, the system is equipped with a dedicated resin storage system and resin metering system, ensuring stable storage and precise metering of resin materials.
The resin storage system uses mixing tanks for resin storage. Paired with heating rods, it can adjust storage temperature according to resin characteristics to prevent solidification due to low temperatures. Manual ball valves work with high-viscosity gear pumps for stable resin conveying, and pneumatic ball valves precisely control start/stop—adapting to the storage and conveying needs of high-viscosity materials like resin.
The resin metering system includes a metering hopper with heating tapes to maintain optimal resin viscosity during metering and prevent solidification that could affect accuracy. A support frame ensures stable equipment installation, and high-precision load cells collect real-time metering data for accurate resin measurement. Conveying pipelines and pipe fittings use specialized materials tailored to resin characteristics, preventing material contamination and pipeline blockages.
Lifting Platform 2 has the same structure as Lifting Platform 1, providing convenient height adjustment for the resin metering system to ensure operational convenience and safety.
5. Auxiliary Support System: Comprehensive Protection to Enhance Production Safety
The system is equipped with auxiliary equipment such as surge silos, material distribution belt conveyors, and a main dust removal system, fully ensuring the smoothness, safety, and environmental friendliness of the production process.
Surge silos are paired with belt conveyors and frames for temporary material storage. This prevents front-end production halts caused by subsequent process failures, improving production flexibility.
Material distribution belt conveyors adopt a high-precision structural design, paired with load cells and weighing modules to real-time monitor the weight of conveyed materials and achieve precise control of material distribution volume. The belt conveyors run stably and adapt to different material distribution scenarios.
As the core of environmental and safety protection, the main dust removal system builds a comprehensive dust collection network through dust removal pipelines and supports. Paired with dedicated dust collectors and hoses, it efficiently captures dust generated during production. Pneumatic air volume control valves precisely adjust dust removal air volume, ensuring dust removal effectiveness while reducing energy consumption. This prevents dust pollution of the production environment, protects operator health, and complies with modern industrial environmental protection standards.
