Plaster Fiber Sheet Factory - Thesis

Contents

Introduction

1. Process Part

1.1 Justification of selected production method

1.2 Raw Materials

1.3 Process Description

1.4 Nomenclature of products produced

2. Architectural and construction part

2.1 Characteristics of the construction area

2.2 General Plan Description

2.3 Space Planning Solution

2.4 Design Solutions

2.5 Process calculation of enclosing structures

3. Mechanical equipment

3.1 Calculation of gypsum mixer

4. Heat engineering part

5. Process Automation

5.1 Analysis of the process of production of gypsum fiber sheets and its hardware design from the point of view of automation tasks

5.2 Description of Functional Diagram for Automation of Gypsum Fiber Sheet Drying Process in Tunnel Dryer

5.3 Specification of Automation Devices and Tools

6. Safety of life

6.1 Calculation of plenum and exhaust ventilation of the workshop for production of gypsum fiber sheets

6.1.1 Calculation of general ventilation intensity

6.1.2 Plenum ventilation

6.1.2.1 Calculation of air distribution in the room

6.1.2.2 Aerodynamic calculation of air ducts

6.1.2.3 Fan unit

6.1.3 Exhaust ventilation

6.1.3.1 Aerodynamic calculation of air ducts of B1 and V system

6.1.3.2 Dust fan selection

6.2 Calculation of plant waste water treatment

7. Organization and economy of the enterprise

7.1 Justification of construction area

7.2 Plant Production Structure and Management Organizational Structure Diagram

7.2.1 Production structure

7.2.2 Organizational Structure

7.3 Operating time mode of working, main process equipment and enterprise

7.4 Material Balance and Material Flow Diagram

7.5 Selection of main process equipment

7.6 Calculation of the number of workers and payroll

7.7 Determination of electric power consumption for process purposes

7.8 Determination of Planned Cost

7.9 Sizing warehouses

7.10 Object estimate for the construction of the GVL workshop

7.11 Consolidated cost estimate for the construction of the GVL plant

7.12 Technical and Economic Indicators

List of sources used

Conclusion

Graphic part

Sheet 1 - Nomenclature

Sheet 2 - Flow Diagram

Sheet 3 - Job Instruction

Sheet 4 - Production Building Plan

Sheet 5 - Production Building Section

Sheet 6 - GVL Plant Plot Plan

Sheet 7 - Gypsum mixers CM-

Sheet 8 - Tunnel Dryer

Sheet 9 - Drying Automation Diagram

Sheet 10 - Organization and Economics in Production

Sheet 11 - Industrial Building Ventilation System Diagram

Introduction

Building materials played a major role in the development of the culture and technology of all mankind. Without them, it would be impossible to erect residential and public buildings, industrial structures, bridges, tunnels, roads, dams and many other structures. One of the main building materials is occupied by binders, which serve as the basis of modern construction and are used to connect individual components of products, even the building itself, into one monolithic mass. A very large part of the building materials is occupied by finishing materials based on gypsum binder. The main materials based on gypsum binder are gypsum board and gypsum fiber sheets.

In a market economy, there are certain trends in the production and use of building materials.

Firstly, there is a rapid development in the production of materials and is occupied by finishing materials of products that provide a significant reduction in the mass of buildings being built, based on the use of local raw materials.

Secondly, the production of materials, products and structures (primarily enclosing) using energy-saving technologies is significantly increasing.

Thirdly, modern construction is characterized by an increasing share of environmentally friendly materials and products.

In view of these trends, gypsum materials and articles are in a more preferred position than other widely used similar building materials and articles.

This is due to the widespread spread of natural gypsum raw materials and gypsum-containing wastes, the simplicity and environmental friendliness of their processing into gypsum binders, and the latter into gypsum materials with lower, compared to/other mineral binders and products, fuel and energy costs (4 and 5 times less, respectively, than for the production of, for example, cement); low specific investments and metal consumption of equipment of gypsum plants compared to cement plants (2 and 3 times less, respectively), which is especially important when organizing production at medium and small-capacity enterprises.

Along with a number of positive technical properties of gypsum and products based on it, it has a significant fragility, especially this property affects the use of thin-walled sheet materials and products (gypsum dry plaster). Therefore, artificial hardening is carried out by using reinforcing materials (fibrous) introduced into the molding mass or being parts of the structure of the product itself. So, in gypsum fiber sheets, the role of reinforcement is performed by finely ground paper fiber. Gypsum fiber sheets are a sufficiently strong material that can be used in rooms with 75% humidity.

Gypsum fiber sheets have both general and special applications defined by their basic properties. Structures using gypsum fiber sheets can be used in the construction and repair of residential, public and industrial buildings for various purposes; different fire resistance system and functional fire hazard class; Any number of floors and any structural systems constructed in all climatic areas, including seismic and other specific areas.

Gypsum fiber sheets are far from a new type of product in the domestic construction materials market. This type of production was widely used in construction in the USSR. But in modern Russia there is not a single Russian plant. The main European manufacturer of GVL is the German company KNAUF.

KNAUF is one of the world leaders in the production of gypsum and gypsum products, including gypsum fiber sheets

In terms of physical and hygienic properties, plaster fiber sheets are ideal for residential premises. It is environmentally friendly, free of toxic components and has no adverse effects on the environment, as evidenced by hygienic and radiological certificates.

Gypsum fiber sheet is a homogeneous, environmentally friendly building material obtained by semi-dry pressing from a mixture of gypsum binder and fluffed cellulose waste paper in accordance with the requirements of Specification 57420040351537797. The gypsum fiber sheet has a certificate of compliance of the Gosstroy of Russia, a fire safety certificate and a hygienic certificate.

Having high strength, hardness, as well as high fire characteristics, a gypsum fiber sheet is recommended for use in the construction of a prefabricated floor base and for lining wooden structures in order to increase their fire resistance (for example, when finishing mansards). Depending on the properties and application, sheets are divided into conventional gypsum fiber sheets (GVL) and moisture resistant (GVL). Gypsum fiber sheets are used in residential, civil and industrial buildings with dry and normal temperature-moisture conditions according to SNiP II379. Moisture-resistant gypsum fiber sheets have a special hydrophobic impregnation and therefore can be used in rooms with high humidity (for example, in bathrooms, bathrooms and kitchens of residential buildings).

Like all gypsum based materials, gypsum fiber sheets have:

- the ability to maintain optimal indoor air humidity due to absorption of excess moisture, and in case of disadvantage - its release into the environment;

- low coefficient of heat absorption, which makes them warm to the touch;

- high fire safety indicators.

Structures of prefabricated floor bases using GVL are used both in reinforced concrete and in wooden floors. Such designs are suitable for any type of modern finishing coating (linoleum, parquet, ceramic tiles, etc.). Prefabricated floor bases using GVL allow:

- reduce labour intensity and significantly reduce the duration of finishing works;

- avoid "wet" processes and reduce technological breaks accordingly;

- save funds due to minimal waste during installation;

- avoid increasing static loads due to the low weight of the structure, which is especially important in the reconstruction of old buildings and in cases of limiting loads on load-bearing structures;

- increase heat and sound insulation parameters of the floor;

- use them in rooms with complex configuration.

2. Architectural and construction part.

2.1. Characteristics of the construction area.

Now gypsum-based finishing materials, in particular gypsum fiber sheets, are very popular, because they are beautiful and easy to install and do not require special skills. The construction area is the city of Ufa. Ufa has roads and railways that provide the delivery of raw materials. Power supply of the plant due to the city network. Ufa is characterized by the presence of large labor resources.

Climate data:

- air temperature of the coldest five-day period -35C0;

- air temperature of the coldest days -35C0;

- average monthly outside air temperature in July + 19C0;

- average wind speed in January 5.7m/s;

- average wind speed in July 3.6m/s.

2.2.Plan General Plan Description

The general plan was developed on the basis of valid construction and sanitary and fire safety standards.

When designing the plot plan, the process diagram of the sequence of production processes is taken as the basis, which ensures the flow and elimination of counter process flows. The production process begins in the production building and ends with the export of finished products to the facilities.

The enterprise roads are adjacent to the public highway. Internal roads are made in accordance with SNiP 2.05.11.83. The width of production roads is 6.5 m with a pavement of asphalt concrete. The road inside the enterprise is circular, which provides convenient access to all industrial buildings and in case of emergency provide access to fire engines from either side of the production building. The road has 2 exits to the main highway. For the convenience of receiving gypsum in the south of the factory territory, a railway track is provided to which warehouses adjoin.

For fire safety, a 250 m ³ water tank, as well as water supply networks and drainage plants in each building, were designed at the plant. In order not to cross roads with human flows along the territory of the enterprise, sidewalks are provided along the roads. The administrative building is designed at such a distance that people can reach it in the meekest way. The administrative building has two floors: on the first sports hall and honey point, and on the second accounting department, personnel department, office, etc. Also for convenience, a dining room is located next to the administrative building.

Buildings of service purpose are located in one zone on the basis of homogeneity.

Warehouses are located in the southeast in accordance with the rose of winds so that toxic substances are carried away from the plant.

Fire and sanitary gaps between buildings are accepted in accordance with SNiP 2.9081. The fuel and lubricants warehouse and garage as fire hazardous objects are located at a distance of 30 m from the nearest buildings.

To landscape the territory of the enterprise, local species of trees and shrubs were used, taking into account sanitary and decorative properties and resistance to harmful substances released by the enterprise.

The factory territory is enclosed by a reinforced concrete fence, and each entrance has a checkpoint.

Technical and economic indicators:

Area Fter = 305 ha;

Building area Fzastre = 5410.7 m2;

Area of paved parts of the territory Fzamosz = 4365 m2;

Greening area Foz = 207.9 ha.

The building factor is calculated by the formula:

K1 = Fsaster/Fter, (2.1)

where K1 is the building factor;

Fzastre - building area, m2;

Fter - area, m2.

K1 = 5410.7/30500 = 0.22

The greening coefficient is calculated by the formula:

K2 = Foz/Fter, (2.2)

where K2 is the greening coefficient;

Foz - landscaping area, m2.

K2 = 20790/30500 = 0.63

2.3. Volume-planning solution

The following factors are taken into account when making the space planning decision of the production building:

- peculiarities of functional-technological process, including prospects of its improvement during reconstruction, expansion, technical re-equipment of production;

- characteristics of lifting and transportation equipment used inside the workshop and for external communications, engineering and technical support systems;

- characteristics of the internal environment in the building, determined by technology and human participation in the production process;

- characteristics of the external environment, determined by natural climatic conditions and artificial sources of dust, gas and heat, noise and other hazards - neighboring production and other facilities;

- technical and economic requirements, including the construction of the building by industrial methods on the basis of unified standard structural and space-planning solutions, saving material, labor and energy resources during the construction and operation of the building.

Production housing has rectangular shape in plan, without height differences with spans of one direction, one width and height.

The production building has dimensions of 138 x 30 meters. The height of the production building is 11.15 m. The building is one-story.

The building consists of one span 30 m wide. The pitch of the columns in the extreme and middle rows is 6 m.

In the main production building there is a production line for the production of gypsum fiber sheets, as well as a waste paper warehouse, a waste paper processing department and a finished product warehouse.

The entire production building has an area of ​ ​ 5400 m2 of them: a waste paper warehouse of 467 m2, a waste paper processing department of 403 m2 and a finished product warehouse of 485 m2.

The building is equipped with plenum ventilation, as well as local exhaust devices.

Fire safety groups of building parts and fire resistance limits, fire wall structures and other fire requirements satisfy the requirements of SNiP 210197 "Fire safety of buildings and structures."

The dimensions of space-planning and structural elements of buildings, as well as the location of modular coordination axes, meet the requirements of the "Basic Provisions for the Unification of Space-Planning and Structural Solutions of Industrial Buildings."

Conclusion

In this diploma project, a plant for the production of gypsum fiber sheets was developed, which is located in the city of Ufa. This production is very promising due to the growth of capital construction and reconstruction of old buildings, in these areas this product is widely used as a finishing material.

The technology of this production is the most modern, and the equipment is the most advanced, so this product is a high-quality finishing material that meets all Russian and international quality standards.