Automatic Grouting Station (Grout Mixing Plant)

Automated grouting and mixing system for large-scale cement slurry production

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ZJ-40 Automatic Grouting System

The ZJ-40 automatic grouting station is a grouting system consisting of centralized material feeding, grout mixing, grout storage, metering, pneumatic control, water tank, and a control room. It is designed to provide a continuous supply of slurry for high-pressure grouting pumps.

The automatic mixing plant can be integrated with high-pressure grouting pumps to form a complete grouting plant. Utilizing variable-frequency technology, the grouting station allows for real-time adjustment of the injection volume based on geological conditions. Injection pressure can be managed either by regulating the flow rate to limit pressure or by increasing the volume to boost it.

The core high-pressure grouting pump features independent suction and discharge valve assemblies on the hydraulic end, facilitating easy maintenance. The grouting station includes integrated pressure and flow monitoring functions. The station employs PLC technology, an automatic weighing system, and pneumatic controls. Optimized logic sequences with preset safety limits allow the slurry production to be synchronized with the pump’s flow requirements. The water-cement ratio and per-batch volume can be freely configured to meet various process requirements. Both manual and automatic modes are available to ensure flexibility across different working conditions.

Centralized material feeding: Materials such as cement, bentonite, and fly ash are delivered via screw conveyors.

Grout mixing unit: High-shear mixing is employed to ensure thorough homogenization of materials and water, effectively preventing clumping and agglomeration.

Slurry storage system: A low-speed agitator prevents sedimentation. Grout is supplied to the injection pump through the discharge outlet. When the storage tank reaches its upper level limit, the mixer switches to recirculation mode, maintaining agitation without discharging further grout into the storage tank.

Metering system: Individual materials are weighed, and feeding volumes are regulated based on preset mix designs. Data signals are transmitted to the control console, where the PLC manages the feeding equipment.

Pneumatic control system: The grouting system’s valves are pneumatically driven, supported by solenoid directional valves and a dedicated air compressor.

Control room: Equipped with a PLC system for fully automated sequence control of the mixing process. Manual overrides are provided for emergency or special operations. The air compressor and mixers remain active upon system startup, independent of the automated sequence. During material discharge, silo arch-breakers remain active to ensure consistent flow.

Water tank: Provides water for mixing and serves as a reservoir for cleaning tanks, pumps, and pipelines.

Mixing and storage tank capacities, as well as agitator power ratings, are scalable based on hourly output requirements. Additional auxiliary equipment can be integrated to suit specific project conditions.