Recipe is nothing but knowing the dry weight (batch
weight) of one batch or one cake.
To find out dry weight, we should know the desired
dry density of final block.
Let us work on the density of 600 kg/m³.
Batch Weight = Density x Mould volume
Density = 600 kg/m3
Dimensions of the mould :
Length = 4840 mm = 4.84 M
Width = 1250 mm = 1.25 M
Height = 670 mm = 0.67 M
Volume of the mould: 4.84 M x 1.25 M x 0.67 M = 4.0535
M³
Batch Weight = 600 x 4.0535 = 2432 kg
(We have taken mould height 670 mm, which is
actually depth of the mould. Generally we maintain the cake height equal to
mould level. But in some AAC factories, cake height may be 650 mm or 680 mm
depending on the parameters like quantity of returns required, sinking of cake,
uneven surface of the cake, etc., In this case cake height should be taken to
calculate the volume.)
Batch weight or Dry weight consists of binders (Cement
and Quicklime), Fly ash or Sand, returns and anhydrite.
Usually the amount of binders is in the range of 25
to 30 %.
The ratio quicklime/cement often is in the range of
1/2 to 1/2.5.
The ratio anhydrite/solids should be in very low
quantities at about 1 or 2% due to scaling or jamming of pipelines.
The ratio of returns/solids is about 20 %.
Recipe:
Lime - 7 to 9 %
Cement - 17 to 20 %
Returns - 15 to 20 %
Anhydrite - 1
to 2 %
Fly ash - 55 to 60 %
Solid/water ratio is about 40%.
The amount of aluminium is in the range of 0.05 to
0.08%, depending on the usage of powder or paste, fineness and quality of the
aluminium.
Most of the plants follow the above range and the
recipe will differ from plant to plant.
For example, let us take the case of AAC Division
of a Large Cement Company.
They have two AAC plants in India. One Plant (North India) is closed and other plant (South India) is struggling at present. When
both the plants were running at best during 2013-2016, recipes of the both the
plants were different though the machinery of the both the plants were of same size
and of same capacity.
So, one cannot copy the recipe of the plant and
apply in other plant. Unfortunately, we had great consultants (at least in
India) who had no hands-on experience. Those who had the experience of more
than twenty years are employed by the best brands in the Industry like Ascolite,
Ecolite, Shreeshakthi, etc.
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