Silicate brick production plant with capacity of 30 million units per year - diploma

Contents

INTRODUCTION

1. Construction area justification

1.1 General information about silicate brick

2. PROCESS PART

2.1. Nomenclature of products produced

2.2. Raw materials

2.3. Process Diagram Description

2.3.1 Description of Production Technology

2.4 Variant Part

2.4.1. Process Cycle Calculation

2.4.2 Composition and operation mode

2.4.3 Calculation of enterprise production

2.4.4 Calculation of demand for raw materials for 1000 pieces

2.5 Calculation of Raw Material Requirements

2.6 Equipment List

2.7 Incoming Material Inspection

2.8 Calculation and design of warehouses

2.8.1 Calculation of sand storage

2.8.2 Lime Storage Calculation

2.8.2 Calculation of power demand

2.8.4 Calculation of process water demand

2.9 Company Staff List

3. MECHANICAL PART

3.1 Basic information about the mixture preparation process

4. HEAT ENGINEERING PART

4.1. Justification of selection and description of autoclave unit

5. ARCHITECTURAL AND CONSTRUCTION PART

5.1. Source Data

5.2. Space planning solutions

6. ECONOMIC PART

7. OCCUPATIONAL AND ENVIRONMENTAL PROTECTION

CONCLUSION

LIST OF LITERATURE USED

PATENT RF METHOD OF MAKING SILICATE BRICK

Introduction

In the current tough market conditions, energy savings are becoming increasingly important in the production of construction materials, as the largest item in the cost of finished products. Applied technologies include hydrothermal treatment of articles to ensure calcium hydrosilicate formation reactions. Hydrothermal treatment in the autoclave is an energy-consuming step in the technology of silicate brick. But there are also opinions on the possibility of hardening lime-sand crude without steaming in an autoclave, which is interesting in the field of silicate brick production. To choose the optimal direction of scientific research, we will analyze the known methods for accelerating chemical reactions in lime-silica mixtures. Silicate products are made from the most common material on Earth - silicon dioxide (sand, trepel, etc.) with the addition of small amounts of lime and water. In the process of modern production of silicate bricks, products are formed from a mixture of sand and lime with water, which are subsequently heat treated in an autoclave. If the steam saturated medium is exposed to temperature effects, physicochemical processes will occur between the components entering the mixture, which will result in the formation of calcium hydrosilicates.

The production of silicate bricks is characterized by a relatively simple technological process, a high level of mechanization and partial automation, the completeness of equipment, the possibility of using various raw materials and industrial waste. The duration of the production cycle is 510 times shorter, and the specific capital investments, the consumption of fuel and energy resources, the cost of producing a unit of production is 1.52 times lower compared to similar indicators of work on the manufacture of ceramic bricks.

The improvement of silicate brick production is based on the achievements of domestic scientists who conduct research to identify the essence and regularity of physical and chemical processes to improve technology and improve the quality of silicate brick.

Most building materials have a larger volume and average density. Which causes significant costs for their transportation from the plant or quarry where they are manufactured or mined to the construction site. Production of construction materials, in particular silicate bricks, should increase mainly by further improving production at existing plants, re-equipping plants with new, modern equipment, introducing integrated mechanization and automation of production processes, increasing labor productivity, and using reserves.

Silicate brick factories are highly mechanized enterprises. Increasing the efficiency of silicate plants is ensured on the basis of wide use of scientific and technological achievements and is achieved by reducing the production cycle, reducing labor costs, significantly improving the quality of products and wide best practices.

Silicate brick has a number of advantageous characteristics that provide comfort and comfort. From it, due to its high density, the walls of structures of all classes are built. High heat storage capacity can create a favorable climate in the house - in winter it will provide heat, in summer it gives cool. On a summer day, it absorbs and preserves the heat of the sun until the air temperature drops - only then does the silicate brick give heat to the rooms of the building. Another important advantage should be noted - noise insulation, it does not matter whether sounds come from the street, or are transmitted through the ceiling and walls. The masonry of external walls made of silicate brick increases the useful area by 57%, reducing the thickness of walls and floors, but with an unchanged amount of development.

Currently, the leading positions in the construction industry are mainly occupied by enterprises that are actively introducing new knowledge-intensive technologies. These circumstances are caused by the fact that these developments are developing faster in the framework of search, fundamental, and then applied research in accordance with the predicted and priority problems of the industry. Recently, one of the most acute problems in construction has been the problem of energy conservation.

The main solution to this problem, when making silicate bricks, is to eliminate the negative aspects that autoclave treatment carries, which is the highest item in the cost of the finished product.

Studies aimed at solving this problem have made it possible to obtain a construction material of autoclave hardening, which is not inferior to the characteristics of conventional silicate brick autoclave hardening.

• existing faces do not contain flaws;

• perfectly withstand the influence of atmospheric precipitation, there is no color change on the rays of the sun;

• There is no need for additional service;

• creating a comfortable climate in the house;

• no harmful impurities, environmentally friendly silicate bricks.

Pleasantly pleases the wide range of brick colors, which creates endless possibilities for imagination to decorators and architects who use this material in the construction or reconstruction of the building.

This is an absolutely new building material that meets the requirements for the SC, but has a huge advantage in its manufacture.

The technology of producing silicate bricks consists in increasing the strength of products and saving material and energy resources in the production of pressed non-autoclave silicate bricks by activating a lime-sand mixture with additives, which makes it possible to significantly reduce the cost of the finished product due to reducing labor intensity, production areas, metal consumption, heat energy consumption, reducing the time for producing silicate bricks.

Therefore, this material is very promising due to its both technological and economic indicators, without worthy competitors who can stand with it at the same stage.

Construction area justification

The design and construction of a silicate brick plant is planned by the village of Taskala.

Taskala (ex. Kamenskaya) - a village, the center of the Taskalinsky district of the West Kazakh region of the Republic of Kazakhstan. The population of the village is 8.5 thousand people. The village is located in the North-Western part of the West Kazakhstan region on the Derkul River (a tributary of the Chagan River) at a distance of 80 km from the city of Uralsk and 350 km from the city of Saratov. The nearest settlements: the villages of Kuznetsovo (5 km), Aktau (12 km), Krasnenky (15 km). Excavations carried out on local mounds in 1925 by archaeologist P. S. Rykov (1884-1942) discovered the burials of the nobility with gold jewelry, horse collection. It is assumed that they belonged to the Sarmatians who lived here in the 2nd-4th centuries AD. The concept of Shipov or Late Sarmatian culture has firmly entered archaeological science.

In the XIX century, the village was known as the Cossack village of Kamenskaya. Every year, from October 10 to 17, agricultural fairs were held.

Shipovo railway station is named after Lieutenant General N. N. Shipov, who was the ataman of the Ural Cossack army for eight years (1885-1893). A railway, built in 1894, passes through the village. In the center of the village is the Shipovo railway station of the Kazakhstan Railways. Currently, there is regular passenger traffic by rail with the capital of Kazakhstan - the city of Astana, the capital of Russia - Moscow, the capital of Ukraine - Kiev. In 2005, the railway station building was destroyed by fire and re-commissioned in October 2006.

About 30 km from Taskal on the border line itself is the eponymous road checkpoint across the border (to Russia), operating 24 hours a day and passing citizens of all countries of the world.

Shipovo Station is mentioned in the book of Marshal of the Soviet Union G.K. Zhukov "Memoirs and Reflections." Georgy Zhukov, then a young Red Army soldier, took part in battles with the White Cossacks.

The climate is sharply continental - continental, dry hot summers and snowy cold winters. The village is located in the lowland and is surrounded by the mountains Ichka, Sunduk, Glazistaya.

Basic information about silicate brick.

The brick is an artificial charcoal-free wall building material made by pressing a moistened mixture of sand and other fine aggregates, lime and various binders using additives or without them and hardened under the influence of steam in an autoclave.

By purpose, brick and stones (GOST 37979) are divided into ordinary and front. In addition, they are divided into unpainted and colored - painted in mass or with a surface finish of face faces.

According to the type of manufacture, bricks and stones are divided into hollow, porous (with porous aggregates), porous-hollow and full-white. Single full or porous aggregate bricks are produced with dimensions of 250X120X65 mm. Its mass is not normalized. Practically it does not exceed 3.5... 3.7 kg. Thickened hollow or full-white bricks with porous aggregates are produced with dimensions of 250X120X88 mm, and silicate hollow stones - with dimensions of 250X120X138. Mass of thickened brick in dried condition shall not exceed 4.3 kg.

According to the thermal properties and average density in the dry state, bricks and stones are divided into three groups:

effective, allowing to reduce the thickness of enclosing structures compared to the thickness of walls laid out of full brick; brick with density not more than 1400 kg/m3, stones with density not more than 1450 kg/m3 and thermal conductivity up to 0.46 W/( m x K) are assigned to this group;

conditionally effective, improving heat engineering properties of enclosing structures without reducing their thickness; this group includes bricks with a density of 1401... 1650 kg/m3, stones with a density of 1451... 1650 kg/m3 and thermal conductivity of up to 0.58 W/( m x K);

ordinary brick with a density of more than 1650 kg/m3.

Depending on the compression strength, stones, and bricks during compression and bending (without deducting the area of ​ ​ voids) are divided into grades 300; 250; 200; 150; 125; 100; 75. Face bricks are made with grades of at least 125 and stones of at least 100.

Water absorption of silicate bricks and stones shall be not less than 6%.

According to frost resistance, bricks and stones are divided into SSE 50, 35, 25 and 15 brands. Frost resistance of face articles must be not lower than SSE 25. In samples of silicate bricks and stones tested for frost resistance, a loss of compression strength of not more than 25% for ordinary products and 20% for face products is allowed.

Silicate bricks and stones are used along with ceramic bricks for masonry of stone and reinforced stone external and internal structures in the ground part of buildings with normal and wet operation modes, for the manufacture of wall panels and blocks in accordance with construction codes and regulations.

Silicate bricks shall not be used to lay foundations and basements of buildings below the waterproofing layer exposed to groundwater and sewage. It is not allowed to use silicate bricks for the walls of buildings with wet operation mode (baths, laundry rooms, steaming compartment) without special measures to protect the walls from humidification. In these structures, silicate bricks can be used only with increased frost resistance from SSE 50. Silicate brick is not used for laying stoves and pipes, as it does not withstand prolonged exposure to high temperature.

Strength indicators, accuracy of geometric dimensions, clarity of faces, increased frost resistance make it possible to use silicate bricks and stones as face materials for building facades.

Raw materials

The production technology and quality of silicate bricks largely depend on the physical and chemical characteristics of the raw materials. Deviation of an indicator inevitably affects product parameters. Therefore, it is necessary to correctly determine the chemical, mineral and grain composition of the raw components, to create optimal molding and autoclave treatment conditions affecting the density and strength of the brick.

On the territory of Kazakhstan there are all types of mineral raw materials necessary for the production of silicate bricks. These are mainly sand, lime and water. In addition, loam, treplets and other silica rocks, ashes and slags from coal combustion at thermal power plants (TPP), bauxite sludges of aluminum plants, metallurgical slags and rocks are used.

Typically, these materials are used as cementitious components or active aggregates under autoclave synthesis conditions or simply as sealing additives.

The main component of silicate brick (85-90% by weight) is sand | therefore, silicate brick plants are located, as a rule, near sand deposits, and sand quarries are part of enterprises. The composition and properties of sand largely determine the nature and features of silicate brick technology.

Sand.

Sand is delivered from the quarry, by road from the mesogeneration of quartz sand "Belaya Gorka."

Silicate bricks and stones consist of 85-90% sand. It is the composition and properties of sand that affect the physical and mechanical properties and operational characteristics of silicate bricks.

The special requirements for sands for the production of silicate products are also reflected in the technical requirements of GOST 21180 "Sand for the production of silicate bricks and autoclave concrete products." The standard specifies the requirements for the content of quartz, alkalis and fine particles in sand and its particle size distribution. The content of quartz in the sand should be at least 50%, alkalis in terms of Na2O - no more than 3.6%, and particles less than 0.05 mm in size (pulverized, silty and clay) - no more than 20%. The content of sulfurous and sulphuric compounds in terms of SO3 should not exceed 2%, mica - 0.5%.

The following varieties of sand are distinguished:

1. Mountainous and ravine, consisting of gerbils of a sharp-angle shape with a rough surface, which contributes to their good adhesion to lime.

2. River and lake, consisting of sandstones of a rolled shape with a smooth surface.

The following types of sands are distinguished by grain size (mm):

Coarse-grained........... up to 2... 2.5;

medium-grained........... from 1... 1.6;

Fine-grained............. .from 0.6 to 0.2;

Very fine-grained...... 0.2 to 0.02.

Sand requirements for brick production.

Sand is tested in three stages:

- analytical studies, including chemical, mechanical and petrographic analyses, to compile the general characteristics of sand;

- laboratory, technological tests with the manufacture of samples, according to which the principal suitability of sand is established;

- semi-factory tests with production of bricks of natural size;

During semi-factory tests, the conclusions made at the laboratory tests are checked and specified, a brick mark is installed.

Sand and lime are subjected to input inspection of products according to GOST 2429788.

For 1000 pieces of brick, 2.4 m3 of sand is mainly consumed, which corresponds to about 85% of the volume of the entire raw material mixture.

Sand is mined in two ways: open in quarries and hydraulic washing.

Preparation of sand for production consists in a number of sequential operations:

- loading of sand into the receiving silos and driers;

- mixing of sands of different grain composition;

- sand cleaning from impurities - screening;

- addition of additives.

Lime.

Lime is delivered by dump trucks of workshop No. 3 of ZKKSM JSC, located in the area of ​ ​ the Cretaceous Mountains.

In the production of silicate bricks, calcium air lime is used that meets the requirements of GOST 9179-79.

By the type of basic oxide (CaO, MgO) contained in air lime, it is divided into calcium (CaO < 5%), magnesia (MgO < 20%), dolomite (MgO < 40%).

According to the fractional composition, comic and powdered lime are distinguished. Powdered lime obtained by grinding or quenching (hydration) of comic lime is divided into lime without additives and with additives.

According to the time of quenching, air quicklime of all varieties is divided into fast-quenching - no more than 8 minutes, medium-quenching - no more than 25 minutes, slow-quenching - more than 25 minutes.

Lime production.

To prepare lime, shaft, rotating and fluidized bed furnaces are used. Mine furnaces account for about 80% of the country's lime production. This is due to the simplicity of their design and operation, low capital costs for construction and high thermal efficiency.

The production of air lime is based on the burning of carbonate mountain

rocks (limestone, chalk, lime tuff, dolomite), consisting mainly of calcium dioxide (theoretical composition - 56% CaO and 44% CO2).

Most often, impurities of carbon dioxide, clay substances, quartz and iron oxide are found in these rocks.

Carbonate rocks must meet the requirements of OSTA 2127 and be supplied to the consumer in the form of fractions 520, 20-40, 4080, 80-120, 120180 mm. If the sizes of the raw material pieces are outside the limits of this fraction, then their content is allowed not more than 5% of the sample weight (according to the lower and upper limits separately).

When determining the properties of limestone for roasting in fluidized bed furnaces, it is necessary to pay attention to its petrographic composition, abrasion strength and the ability to maintain the structure at high temperatures throughout the perimeter of the furnace. This is explained by the large dust discharge of limestone of fractions 0-3 mm, which, when fired in these furnaces, is lime of reduced activity.

During the burning of limestone, decarbonization occurs and its conversion to CaO by reaction

CaCO3 = CaO + SO2↑;

In shaft and rotary furnaces, lime is fired at a temperature of 10001200 ° C, and in fluidized bed furnaces at a temperature of 9501000 ° C. A MgO content of up to 5% does not cause significant lime digestion. At a higher MgO content, lime is quenched more slowly, which is explained by the burning of magnesium oxide, which can be formed from magnesium carbonate already at a temperature of 600650 ° C and which is negatively affected by a higher temperature.

In the production of air lime from dolomites, firing is carried out at a temperature of 750900 ° C, and the resulting dolomite lime is converted to

the powder is ground, since the remaining non-deposited part of calcium carbonate is not quenched, and magnesium oxide formed at this temperature is quenched slowly.

Lime can be powdered not only by grinding, but also by quenching with water, in which lime is sprayed into a thin powder. When calcium oxide reacts with water, the hydration reaction of calcium and magnesium oxides occurs:

CaO + H2O = Ca (OH) 2; MgO + H2O = Mg (OH) 2;

Lime hydration is an exothermic process in which 65· 103 J of heat per 1 gram is released - a molecule or 1160· 103 J of heat per 1 kg of quicklime. This is a reversible reaction, since it is possible to reverse decompose Ca (OH) 2 into CaO and H2O, which proceeds most rapidly at a temperature of 547 ° C. To prevent a reversible reaction, an abundance of moisture and a not too high temperature are needed.

Additives used in the production of silicate bricks.

The most polluting factor of the environment is the various wastes of production, thousands of tons accumulating in various dumps, occupying significant areas of land. One of the industries that can partially solve the problem of recycling these wastes is the construction materials industry, including silicate brick factories.

Currently, in connection with the development of the chemical, mitallurgical and coal mining industries, a significant amount of unclaimed waste has appeared. Therefore, for the construction materials industry of Kazakhstan, the main tasks are the study and technological assessment of the use in the production of these wastes.

According to the classification, by-products of industry are divided into three classes A, B and B, of which class A includes products that have not lost their natural properties (quarry and mine waste, ore dressing tailings); class B - artificial products obtained as a result of deep physicochemical processes, for example, when fired below the melting point, or at high temperatures that cause partial or complete melting, as well as precipitates dropped from the solution; to class B - products formed as a result of processes arising during storage of by-products in dumps (spontaneous combustion, leaching, hardening).

Industrial wastes can be used in production of silicate bricks as components of binder in mixture with lime and dispersed silica or as basic raw material. Disperse and coarsening silica additives can be added to the mixture: ground sand, clay, slags, ashes of thermal power plants, breaking brick screenings of ground limestone. Ground silica additives, being plasticizing materials, improve the forming properties of the mixture, its grain composition, fill voids between sand grains and increase the strength of raw bricks.

The introduction of ground sand makes it possible to reduce the total cycle of brick steaming without reducing its strength. In hydrothermal treatment, the additives react early with lime, bind it faster, forming hydrosilicates in brick. Thus, the addition of 0.25-0.3 tons of pre-dried and ground to dispersion with a residue on sieve No. 008 of no more than 15% belite or nepheline sludge (alumina waste) per 1000 pieces of brick allows to reduce lime consumption by half. At the same time, the strength of raw materials increases, the operation of the equipment stabilizes, and the brick brand increases.

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