Semi-rigid mineral wool board production shop 125

Contents

INTRODUCTION

1 PRODUCT RANGE

2 CHARACTERISTICS OF RAW MATERIALS

2.1 Calculation of charge composition

3 BINDERS

4 FUEL CHARACTERISTICS

5 METHOD OF FIBRE FORMATION

6 PROCESS DIAGRAM OF PRODUCTION OF SEMI-RIGID MINERAL WOOL BOARDS ON SYNTHETIC BINDER GRADE

7 DESCRIPTION OF PROCESS FLOW DIAGRAM OF P

8 PREPARATION OF SYNTHETIC BINDER AND METHODS OF ITS INTRODUCTION INTO MINERAL FIBRE

8.1 Preparation of binder

8.2 Binder Introduction Method

9 WORKSHOP OPERATION MODE

10 MATERIAL BALANCE

11 LUGGAGE BOX

12 SELECTION OF PROCESS EQUIPMENT

13 WAREHOUSES AND SILOS

14 CALCULATION OF ENERGY RESOURCES

15 QUALITY CONTROL OF RAW MATERIALS, PROCESS AND FINISHED PRODUCTS

16 NUMBER AND COMPOSITION OF PRODUCTION WORKERS

17 SAFETY AND HEALTH

18 PROTECTION OF THE ENVIRONMENT

CONCLUSION

BIBLIOGRAPHIC LIST

Introduction

Thermal insulation materials are a type of building materials that are characterized by high porosity and, as a result, low average density and low coefficient of thermal conductivity. One such heat insulating material is mineral wool and articles thereof.

Mineral wool is a high-void material consisting of thin randomly interwoven flexible vitreous fibers. The thermal insulation properties of mineral wool are due to the content in it of a huge number of air voids (up to 95-96% of the total volume of wool) enclosed between fibers that are located in the wool in various directions.

The main property of mineral wool, which distinguishes it from other heat-insulating materials, is incombustibility in combination with high heat and sound-insulating ability, resistance to temperature deformations, non-hygroscopicity, chemical and biological resistance, environmental friendliness and ease of installation. These qualities of mineral wool, as well as the prevalence of raw materials for production and the ease of technology predetermine the wide prospects for its application in many sectors of the national economy. Its introduction into construction reduces the need for basic building materials, facilitates the construction of buildings and structures, and reduces the cost of construction. [1]

Currently, the most widespread production of mineral wool thermal insulation products is such as heat insulation mineral wool boards on a synthetic binder. They are used for thermal insulation of industrial equipment and various structures, wall panels, pipelines and utilities.

3 binders

Binders for the production of mineral wool products are few. In the production of mineral wool products, mainly organic binders are used. Inorganic binders due to insufficient adhesion to mineral fibers have not been widely used. Their use significantly increases the average density of mineral wool products, which in this case are characterized by increased brittleness and low strength.

The general requirements for all binders used in the production of mineral wool thermal insulation products are:

1. Their high adhesion capacity to mineral wool fibers, which provides for the production of products with strength and elasticity that meet the requirements of technical requirements at small volumes of the introduced binder;

2. Sufficient cohesion of the solidified binder to provide the necessary bonding strength of the cotton fibers to each other at their contact points;

3. The possibility of controlling the content of the binder introduced into the articles by one of the accepted methods, uniform distribution on the cotton fibers, without significantly increasing the bulk mass and the value of its thermal conductivity;

4. Low cost of binders, they should not include deficient components.

Organic binders (synthetic resins, bitumens and their compositions) are the main component in the modern production of mineral wool products, by which a porous fibrous structure is fixed and a predetermined strength of these products is ensured. The most widely used synthetic resins, especially those varieties of them, which are characterized by high adhesion to mineral fibers, good solubility in water or the ability to form stable emulsions, in a cured state - sufficiently high cohesion, water and temperature resistance, elasticity, low shrinkage. In addition, binders should not be deficient or release toxic substances.

Phenol-formaldehyde resins and, first of all, thermosetting phenol alcohols were most widely used in the production of products from mineral wool.

Phenol-formaldehyde resins meet most of the requirements for mineral wool binders. However, they also have a number of significant drawbacks: brittleness of the cured film, toxicity, short-lived. Special additives are added to improve the adhesive and other properties of the binder.

Of the nitrogen-containing resins, carbamide are most widely used, which are the products of the interaction of urea with aldehyde. Carbamide resins are cheaper than phenolospirts. Mineral wool products obtained with their use are characterized by sufficiently high physical-mechanical and heat-insulating properties. However, the water resistance of the articles is lower than with a phenolic binder. The main disadvantage of carbamide resins is the lack of stability due to the release of water and unreacted formaldehyde. This phenomenon imparts hydrophilicity to the resin and results in its cracking after curing.

Improving the operational properties of synthetic binders is one of the main tasks, the successful solution of which will significantly improve the quality of mineral wool products, which are the most widely used heat insulation material. [2]

Emulsifier is a clear uniform liquid from light to dark brown. In addition to the basic value (as a plasticizing additive to synthetic binders), emulsifiers are used independently as a dusting agent. When the emulsion is mixed with water, an emulsion is formed.

When using the emulsion, it is necessary to take into account its instability and after each hour of storage mix for 1-2 minutes with a paddle stirrer or compressed air (it is not recommended to prepare a direct emulsion for more than one shift). To increase the stability of the emulsion, it is recommended to prepare it using softened water (condensate of steam power plants).

During long-term storage, the emulsion delaminates and becomes unsuitable. To avoid delamination during storage, it must be mixed periodically. It is stored at positive temperatures (at negative temperatures, the emulsifier is delaminated without heating).

50% phenol-based composite binder with emulsion addition. The components are loaded into the operating mixer in the following sequence: phenolspirts, water, emulsions. We accept a ratio pitch: water 1:2.2. To obtain 1000 l of composite binder, phenol-formaldehyde resin 290 l, water 650 l and emulsion 60 l are taken.

8.2 Binder Introduction Method

At the mineral wool production facilities, three methods of introducing a binder into the fiber are used: spraying or pulverizing, watering with vacuumizing, preparing a hydromass or pulp. In this course project, we apply the spraying method.

For supply and spraying of solution of phenol sprays there is a system of binder supply, which is a closed tubular collector with 12 nozzles fixed on it. To spray the binder, compressed air is supplied to the system with a pressure of 0.4... 0.6 MPa. The pressure of the compressed air shall be lower than the pressure of the binder solution supplied at 0.3... 0.5 MPa.

18 Environmental Protection

In mineral wool production, process gas emissions containing toxic organic impurities such as phenol and formaldehyde pose the greatest environmental hazards. Only during the operation of one process line for the manufacture of heat insulation plates on a synthetic binder, up to 200 thousand m3/h of process gases containing organic impurities are released into the atmosphere, the total amount of which is up to 100 tons per year.

In industrial production, one of the necessary and important natural resources is clean fresh water, which is widely used as:

- feedstock or direct chemical reagent in feedstock mixtures;

- The environment in which certain chemical reactions occur that determine the processes of structuring materials;

- means for maintaining certain process para-meters;

- coolant in power and cooling systems;

- means for transportation of raw materials, materials, products, waste disposal;

means for washing the raw components, grinding them and homogenizing the mixtures;

- facilities for washing and cleaning of process equipment;

- means for hydro-dusting of air;

- resource required for economic and domestic purposes.

Therefore, it is simply necessary to treat wastewater in plants.

Wastewater treatment is designed in three stages:

- delay of large suspensions on sand heads;

- screening of fine suspensions;

- partial clarification of water in filters.

In this production, a closed water supply system of an industrial enterprise is carried out.

Water is mainly used to reduce the temperature of the equipment.

The availability of a recycled water management system is one of the most important indicators of the technical level of industrial enterprises. The introduction of recirculated water supply systems dramatically reduces the amount of wastewater discharged and reduces the need for fresh water, which gives a great economic and environmental effect.

Pump units, fan cooling towers, dosing devices for water treatment with automated control systems shall be installed in cooling water supply systems. Automatic switching on and off of pumps supplying heated water depending on the water level in the receiving chamber.

The following control shall be provided in the recirculated water supply systems:

- pressure in pressure water ducts and at each pump unit;

- water flow rate on pressure water ducts ;

- flow rate of additional water;

- water levels in heated and cooled water chambers;

- pH values of cooled water;

- concentration of salts in heated water.

Mechanical wastewater treatment is usually a preliminary stage for industrial wastewater treatment. At the same time, a small fraction of suspended substances is released and pollution is reduced.

High efficiency of the process is achieved by intensifying gravitational settling, then passing waste water through a layer of various granular materials or through mesh drum, pressure filters or filters with a floating load and without adding chemical reagents and using filter materials.

There are various versions of designs and modifications of thin-layer settling devices.

In practice, two fundamentally different designs are used: with the cross movement of the flow of water and the isolated sediment and with countercurrent. Cross-circuit block designs have some overrun of filter material. Blocks in countercurrent flow circuits are devoid of this drawback. Therefore, they can be made of almost any thin and film material: aluminum sheets, galvanized iron, dural, polyvinyl chloride, fiberglass, sheet or film polyethylene, lavsan film.

In order to improve working conditions, loading of the cupola and its operation are automated, heat transfer from the cupola walls to the environment is compressed by careful heat insulation so that the temperature on the surface does not exceed 40 ° C, workplaces are equipped with air blows, dust dusting is eliminated by humidification.

Water scrubbers or other filter units are installed from the fiberization chambers and the conveyor dryer to clean the exhaust gases from the cupola and steam-air mixture. In the compartment of cans, bathrooms and other types of melting furnaces, Safety Regulations approved by the chief engineer of the enterprise must be posted, which should contain instructions on burning the cell using oxygen, personnel actions for cooling the cupboard, piping conventions, terms and procedures for periodic cleaning of the water jacket, mandatory under the supervision of the shop manager or duty engineer, on the mandatory wearing of thermal insulation clothing.

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