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WHY?
The product properties will be the result of the used raw materials and the way they are prepared and put together.
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Mixtures
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Definition
A mixture can be defined as being the list of individual ingredients, expressed in weight %, used to manufacture the end product. The different ingredients are known as raw materials. From the type, quality and quantity of the RM used, will depend the final characteristics of the product.
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Binders
Process Reinforcement
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Process parameters:
As process fiber: to allow sheet formation on the machine, for which we need interlayer bonding, fiber flexibility, a fine fiber mesh on the sieves to reduce sieve losses As reinforcement fiber for the final product for which we need fiber length, fiber strength (zero span), fiber bonding with the matrix (fibrillation), fiber spreading in the matrix, fiber flexibility Refined > 50 SR for process fibre Slightly refined 22 < SR < 27 for Ca-Si products
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Process parameters:
Mixing time: mixing energy is to be controlled in order to avoid fibre damages Fibre orientation factor
Kinking due to raw materials preparation in FC plant (long/harsch mixing)
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Reactivity
Mechanical Data
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Composition
Volume-% particles smaller
70 60 50 40 30 20 10 0 0 1 10 100 1000
Particle size [ m ]
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Raw Material Calcium Carbonate Amorphous silica Aluminium Hydroxide Lime Perlite Vermiculite Wollastonite Mica Kaolin Bentonite Pigments
Product Performance
Matrix stability Frost resistance Dimensional stability
Process
Cost
Low Blaine
Layer Homogeneity Low density, Fire resistance Low density, Fire resistance Fire resistance, Dimensional stability Dimensional stability, Fire resistance Impermeability Layer adhesion
Visual aspect
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Other
Composition
CaCO3 SiO2 Al(OH)3 Ca(OH)2
Other
PSD D50
Loose bulk density Loose bulk density Aspect ratio Buoyancy test Aspect ratio Buoyancy test
Asbestos free
Iron oxides
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Mixture
How to put all of them together?
According to the product: Fibres
Auxiliary Materials
Application Characteristics
Manufacturing
Process Technology
Binders
Air-cured Autoclaved
Others:
Availability Cost Health
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Pictura Natura
Slates
1.80 0.60
Textura
Promatect-L
0.65
1.60
Glasal/Eflex/Tunnel Etercolor
1.60 0.80
1.60
1.55
Eterboard HD
Promatect-H Supalux
1.40 1.35 1.00 0.95
Eterspan
Cedral
Sidings Multiboard Coated 1.25
Operal
LD MD
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Low density
Eterboard MD (Superboard)
:
1.20
Hydropanel/ Bluclad
Eterbacker MD
~ 1.18
Density in g/cm
21
HD
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The matrix, containing cement, silica (optionally lime) is cured at high temperature (up to 180C) and pressure
Quartz + Lime + Water Mix of fully and partially crystalline CaSilicate Hydrates* + residual quartz
No
Ventilated faade Ceilings Multi-purpose Wet cells Render substrate Tile substrate Fire protection
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Mixture
Autoclaved Raw Material
Fibres Synthetic Cellulose (SUKP, HWP, CPB) Cellulose (WPK) Binders Cement (Cem I) Cement (Cem II) Silica Auxiliary Materials Calcium Carbonate Amorphous Silica Aluminium Hydroxide Lime Perlite Vermiculite Wollastonite Mica Kaolin Bentonite Pigments
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Air Cured
High density Faacde (outdoor application)
NO Process + Reinforcement NO Yes, low amount NO Yes, high amount NO NO Yes Yes NO NO Yes Yes Yes Yes Reinforcement Process Process Yes, high amount Yes, high amount NO Yes Yes NO NO NO NO NO NO Yes (IBM) Yes (IBM) Yes
Roofing
Typical Mixtures
TYPICAL MIXTURE FOR CORRUGATED SHEETS (air-cured process) Raw Material (in wt.%) EBMO Synthetic fibre Refined Cellulose Cement Microsilica (CSF) Limestone Kaolin Bentonite Pigments Hardwaste
Thickness Density Breaking Load
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Quality results for Profile 7 mm 6.5 - 6.7 gr/cm 1.50-1.55 requir. class C1-X average N/m 4400 - 4900
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Typical Mixtures
TYPICAL MIXTURE FOR SLATES (air-cured process) Raw Material (in wt.%) EBMO Synthetic fibre Refined Cellulose Cement Microsilica (CSF) Limestone Pigments
Thickness Density Strenght
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Typical Mixtures
TYPICAL MIXTURE for Medium Density Flat Sheets (IBM Division) Raw Material (in wt.%) High Quality SUKP SUKP + WPK (blend) PVA Cement OPC Quartz Limestone Al-Hydroxyde Na-Bentonite HGW Autoclaved
indoor/outdoor
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Typical Mixtures
Autoclaved Flat Sheet - KOB
Raw Material / Product Cellulose Cement Silica Perlite Vermiculite Mica Lime Wollastonite Pigments Alum. Hydroxide
Low Density
X X X X1 X2 X2 X X X
1: Promatect-H 1: New Promina 2: Masterboard 2: Supalux 0.90 - 0.95 1.20
Eterbacker-HD 1.60
Mica Mix
X X X
Lime Mix
X X X
Siding
X X X
Eflex
X X X
X X X X
Eterbacker-MD
X X X3 X
Eterboard-MD
X X
Siding Cedral Multiboard
non-pressed
Density (in gr/cm)
1.20
Eterboard-HD 3: Etercolor 1.60
1.25 - 1.30
Glasal 1.60
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pressed
Density (in gr/cm)
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1.7
Fillers
Cement
fibre mixer cement mixer
main mixer
Silica grinding
slurry chest
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to machine feeding
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Treatment required
YES NO Better if
Dispersed
Expansion Exfoliation
Swelling
Dispersed Dispersed
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Cellulose treatment
PULPING PROCESS
cellulose bales pulper Storage tank
Transport conveyor
pump
1.7
pump
Refiner
pump
Storage tanks
REFINING PROCESS
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Cellulose treatment
Process fibre & reinforcement fibre
Different qualities (HQ-SUKP SUKP CPK WPK) Dosing in bales (dry): check water content ~ 15%
Pulping process
Water dosing
Pulp feeding
Clear process water for pulp preparation: - Consistency : 4% (40 g/l) - Pulping time: 20 30 min - Total cycle time: 30 40 min
to sock chest
Pulping process
LH1
FL1 - flowmeter
6"
6"
VM1 P0 - M0 Flow: +/- 180 m3/h Head: +/- 1.2..1.4 bars Power: 15 kW
4" VM2
6" VM4
6"
FL2 - flowmeter
2"
4"
VM5
HELICO PULPER
Vp2
VM3
Vp5
DUMPING POIRE
DUMPING POIRE M11- 30kW
Vp3
Vp6
16"
6"
6"
10"
Vp8
Contaminants
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Turbine
Pulper feeding
Cellulose bales
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Refining process
What is refining?
Is the mechanical alteration of fibres which is obtained by forcing a flow of pulp through grooved rotating discs.
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Refining process
Evolution of the fibre through refining
unrefined rigid fibres flexible fibre
Refining process
Why to refine the cellulose?
To obtain the most suitable fibre morphology for the Hatschek process (sieve retention):
Increase the specific surface of the fibre Ensure a proper distribution of the fibre in the matrix Maintain a compromise between degree of fibrillation (SR) and fibre length (L-AVG)
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Refining process
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Refining process
Variables affecting refining:
Type of pulp Rotational & peripheral speed: hydration/fibrillation mode Consistency: around 40 g/l No-load power Net specific energy Refining intensity: Specific Edge Load (SEL) Flow through the refiner inlet & outlet pressure Refiner plate pattern:
Pumping vs retention mode
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Bar size: groove depth, bar width, groove width Bar angle
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V3
from pulper Recycling tank Flowmeter
V2
V1
4"
Refiner
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Flowmeter F1
VM30
VM33
4"
Refiner
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Filler 2
No special treatment is required in the factory since the fibre is received ready for use. Supplied in bales (compacted) or in bags. -Accurate weighing is required -Mix with filler (or cellulose) to disperse and pump -Mixing energy has to be limited in order not to damage the fibre: special impeller to reduce shear forces. -Use antistatic material to avoid sticking
Caution: once de-compacted, the fibres can occupy up to 10 times their volume
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Filler plant
Fillers are generally handled in bulk or in bags (or big bags).
Filler 1
Filler 2 Filler 3
RM in powder can behave in different way according to their morphology and physical characteristics: - Ground sand (silica) will flow like water, - Humidity content may change totally the handling conditions (> 2% H20 for CaCO3) - Needle-shaped powder (Wollastonite) or fibrous material (HGW) will bridge in the silos or hoppers. - Some fillers tends to agglomerates and need special intensive mixer to disperse properly (Kaolin, amorphous silica, pigments) - High shear mixers may be requested for process reasons (Bentonite)
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Mixing process
Obtain an homogeneous mixture of the different RM within a certain accuracy and time (min > 10% machine max. output)
Mixing process
Ekato mixer design
shaft baffles
s1 s2
traditional turbines
h1
h 2 d 2 d1
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Ekato turbine
Mixing process
Mixing sequence: Fibre mixer: water + filler (CSF Kaolin - ) + PVA (reduce mixing speed) Cement mixer: water + cement Final mixer
note: cement mixer not always needed
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PVA Debaler
Fill er 1
Cement Mixer
Fill er 2
Fiber Mixer
Main Mixer
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MP1
MP2
MP3
MP3
MP2
MP1
Main Mixer n1
Main Mixer n2
Slurry chest
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RM 1 Vol 4m
RM 2 Vol 2,1m
RM 3 Vol ,25m
RM 4 Vol 1m
RM 5 Vol ,25m
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