Production of waterproofing membrane PE 5mln/year

Contents

1. Introduction

2. Nomenclature of products produced

3. Characteristics of raw materials

4. Process Part

4.1 Selection and justification of technological method of production

4.2 Shop operation mode

4.3 Manufacturing Process

4.3.1 Methods of waterproofing membrane production

4.3.2 Production Process Options

4.3.3 Physicochemical processes during production

4.3.4 Calculation and selection of main process equipment

5. Quality Control

List of literature

Introduction

Waterproofing, including roofing and sealing materials and products, are designed to isolate building structures of buildings and structures from the effects of aggressive environment, especially water and wet air. Therefore, the materials of this group must be waterproof and meet the required indicators of strength, elasticity, heat resistance, durability, firmly adhere to the base. Waterproofing materials are used: for external and internal protection of underground structures (pits, foundations, pipelines, collectors, tunnels, etc.) from the influence of groundwater, with aggressive salts, acids and alkalis dissolved in them, as well as other chemical reagents; - to isolate reservoirs, basins, reservoirs, etc.; - to protect bridges (roadway structures, supports, etc.); - at arrangement of anti-filtration shields and reinforcement coverings in hydraulic engineering construction; - for filling cavities in rocks, at arrangement of bases and foundations; - at protection of interstage floors in production rooms and bathrooms; - at arrangement of roof and roof coverings of buildings; - for sealing of joints, temperature joints, holes in large-panel house building. Waterproofing not only protects the protected surface from contact with the aqueous medium, but also contributes to steam and gas insulation, and increases the corrosion resistance of structural materials.

The most common products for waterproofing and roofing are materials that are in an elastic or elastic state during their use. In most cases, these materials are the most complete factory readiness, so quality control, mechanization and automation of production can be carried out. They are convenient when transporting, performing roofing and waterproofing operations. Waterproofing materials of this group are divided into the following subgroups: roll, film, piece.

In recent years, film waterproofing materials have become increasingly common in construction. They have high strength, waterproof, heat resistance, durability, low labor input, are applied in one layer. They can be attributed to materials of the XXI century, materials of the "fourth generation." Polymeric waterproofing roll materials are commonly called roofing membranes, their materials are divided into films (membranes) based on thermoplastics and elastomers (soft rubbers). Thermoplasts are polymeric materials that can reversibly transition when heated to a highly elastic or viscous-flowing state.

Characteristics of raw materials

Polyethylene enters the enterprise by road in bags. Bags are located on pallets and wrapped with film; each bag contains 25 kg of polymer, 12 bags are placed on the pallet. The company has a raw material warehouse, which is a site with rows of racks. Based on the amount of raw materials consumed per day and the need to have 10 daily stock of raw materials in stock, there should be at least 170 pallets in stock. In the cold season, the polymer supplied to the warehouse before processing must be kept at the workshop temperature for at least 12 hours.

The polymer entering the warehouse is subjected to input control, during which a number of process parameters of polyethylene, such as PTP and density, are examined and compared with passport data, and the homogeneity of the polymer in the batch is checked.

Granulated polyethylene from storage tanks is supplied by centralized pneumatic transport to intermediate tanks with volume of 3.5 m3, installed on process platforms above bins of extrusion units. From these containers, feed is fed in portions through a metering device and a magnetic collector of metal particles to an extruder hopper.

Intermediate containers of about 0.5 m3 are provided at the same site for the introduction of various additives into the feedstock. The specific grade of raw materials, supercentrate and additives for each type of film is determined by the shop service and indicated in the shift task daily, for each shift separately.

Raw materials used for the manufacture of geomembranes must comply with the requirements of existing regulatory documents and have quality certificates of the manufacturer.

For the manufacture of geomembrane, granular polyethylene is used with the addition of antioxidants and carbon black, which should be at least 2%.

The use of secondary polyethylene in the production of geomembranes is not allowed. It is allowed to apply not more than 10% of geomembrane production wastes in the form of cutouts from rolls accepted by the quality control service. [GOST R 56586-2015]

The polyethylene from which the geomembranes are made should have a melt index of 1.0 g/10 min .

The main element in the geomembrane is polyethylene. To improve the properties, high temperature stabilizers and antioxidants are added to the main component. The technical characteristics of the geomembrane depend on which type of raw material is used.

Geomembrane also includes special stabilizing additives to increase the resistance of geomembrane to chemicals and UV radiation. The most widespread stabilizer - technical carbon (soot) up to 3%.

The raw material used for smooth geomembrane is PPE, surface density is 0.95 kg/m3, density is 0.95 g/cm3, breaking load is 2077 kN/m, elongation at break is 700%.