Production area must conform to the following demands in order to house an ICF production line:
1. Ceiling height.
We recommend that the height be around 4 m at 50% of the total area and around 3 m at the rest of the area.
We recommend that working space be 90-120 m2 to house a production line with a single ICF blockmold installed. This should include:
- raw material (EPS) storage zone — 10-20 m2. Storage temperature range 10-20 oC;
- preexpansion site — 20-25 m2, depending on the location of the equipment;
- blockmold with an engineering zone — 10m2;
- steam generator and steam accumulators installation zone — 10m2.
3. Power network connection (external networks and internal wiring)
Total equipment capacity should be taken into consideration when connecting the line to power networks.
Total equipment capacity of an ICF production line is 5,1 kW + additional capacity for steam generation.
If a KEP electric steam generator is used total (peak) equipment capacity will be:
N=5,1+160=165,1 kW (with a KEP-160 steam generator; 160 kW; 200 kg of steam per hour)
These data are used to determine a connecting cable section.
The actual power consumption of the line is significantly lower than the estimated total value as steam generator works for the most part to 50% of its capacity when one blockmold is used and to 75% when two blockmolds and a preexpander function simultaneously.
The production line can also function with a gas — or oil-fueled steam generator or with a factory steam supply if their characteristics are compatible with those of the KEP steam generators (steam-generating capacity — 100-200 kg/hour, pressure — 6 atm).
4. Water consumption
including the amount of water used to generate steam is 0,1…0,2 m3/h depending on the number of blockmolds functioning simultaneously. The water flow per each cooling cycle is 60-100 l (a 5m2 return water tank is used for each blockmold).
It is possible to use secondary steam to heat the room. In this case steam is forwarded to the register inclined so that it could divert condensation.
5. Drainage is required. The draining pipe must be connected to the collecting system or be drawn outside of the premises.
We recommend installing a floor-level exhaust ventilation and a forced ventilation above the ceilings in the areas where raw material is stored and near the silo bunkers to avoid the accumulation of pentane in the air. This is required because PENTANE, the blowing agent, is heavier than the air and can yield a deposit on the floor level.