Thesis "OBTAINING BRICKS BASED ON MAN-MADE METALLURGY PRODUCTS"

Contents

Introduction

Chapter 1 Literature and Patent Review on the Problem of Making Bricks Based on Man-Made Metallurgy Products

1.1 General information on the production of decorative slag bricks. Concept of decorative mortars and concrete

1.2 Man-made metallurgy products as raw materials for production of building materials

1.3 Blast furnace slag formation methods

1.4 Bleaching and activation of blast furnace granulated slag

1.5 Basic requirements for decorative slag bricks

Conclusions on Chapter

Chapter 2 Research on the properties of raw materials

2.1 Properties of blast furnace slags of ZSMK

2.1.1 General Information

2.1.2 Chemical composition of blast furnace slags

2.1.3 Investigation of slag for silicate decay

2.1.4 Physical and mechanical characteristics of slags

2.2 Characteristics of spent moulding mixture

2.3 Characteristics of lime gas cleaning dust

2.4 Characteristics of sulfate component

2.5 Surface active additive properties

2.6 Properties of colouring pigment - waste of methysis production

Conclusions on Chapter

Chapter 3 Optimization of slag concrete composition

3.1 Calculation of slag binder composition through basicity factor (two-component charge)

3.2 Calculation of mineralogical composition of solidified lime-slag binder

3.3 Optimization of slag binder composition

3.4 Determination of basic characteristics of slag binder

3.5 Determination of pigment effect on binding agent properties

3.6 Optimization of decorative slag concrete composition

3.7 Process Regulations

Conclusions on Chapter

Chapter 4 Process Part

4.1 Production program and product range

4.2 Shop operation mode

4.3 Calculation of productivity by process limits

4.4 Material Balance

4.5 Selection and justification of production flow chart

4.6 Selection of process equipment

Conclusions on Chapter

Chapter 5 Architectural and construction part

5.1 Justification of construction site selection

5.2 Plot Plan

5.3 Space-planning solution of the workshop

5.3.1 Binding of structural elements to layout axes

5.3.2 Interior layout of the workshop

5.3.3 TEP space planning solution

5.4 Structural solution of the workshop

5.5 Main Frame Elements

5.5.1 Foundations and foundation beams

5.5.2 Columns

5.5.3 Rafters

5.5.4 Crane suspensions

5.5.5 Wall fences

5.5.6 Shop coverings and roof

5.5.7 Floors

5.5.8 Gate

5.5.9 Windows

5.6 Heat Engineering Calculation

Conclusions on Chapter

Chapter 6 Automation of Thermal Moisture Treatment Process

6.1 Main tasks of steaming process control

6.2 Description of steaming automation system

Conclusions on Chapter

Chapter 7 Quality Management

Conclusions on Chapter

Chapter 8 Economic calculations. Safety and environmental protection

8.1 Economic calculations

8.2 Safety and Environmental Protection

8.2.1 Safety precautions

8.2.2 Requirements for workplaces and equipment

8.2.3 Fire Safety

8.2.4 Protection of reservoirs

Conclusions on Chapter

Conclusion

List of sources used

Applications

Summary

Production of bricks based on man-made metallurgy products (P = 15 million units per year): Diploma project with elements of research work in the specialty "Production of building materials, products and structures" (270106). - Novokuznetsk, 2008. - p. 145, 74 tables, 44 figures, 9 drawing sheets, 47 sources.

In the diploma project, an analysis of the literary and patent review on the problem of obtaining bricks based on man-made metallurgy products was carried out. The results of investigation of properties of raw materials are given: blast-furnace granulated slag ZSMK, gas cleaning dust of lime production, spent moulding mixture, pigment - waste of methysis production, additive - LST. Composition and properties of decorative slag cement are developed. The technology of brick production based on man-made metallurgy products has been developed. Architectural and construction solutions of the workshop are described. Heat engineering calculation of wall structure is performed. The issues of quality management and automation of heat-moisture treatment process are considered. The economic calculation of the enterprise was made. Health and safety issues resolved, environmental protection measures envisaged

Introduction

Decorative slag brick is an artificial wall construction material made by pressing from a mixture of binder and aggregate and hardened in the process of thermal moisture treatment.

At present, perhaps there is not a single country in the world that does not produce or use bricks based on industrial waste in construction. The use of such raw materials contributes to such tasks as, for example, ensuring environmental protection, rational use of raw materials, reducing the energy intensity of construction and increasing labor productivity.

NKMK and ZSMK annually produce about 5 million tons of blast furnace slags, the targeted technological implementation of which will reduce the shortage of raw materials and the cost of construction materials in particular in Kuzbass.

The purpose of this work is to develop compositions and methods for producing bricks based on technogenic metallurgy products.

Tasks of work:

To conduct a literary and patent review on the production of decorative slag bricks and the use of metallurgical waste for its production;

Investigate and describe the main properties of raw materials;

Develop the composition of decorative slag bricks and study the factors affecting its properties;

Design a brick shop based on man-made metallurgy products with a capacity of 15 million units per year;

Perform process calculations and select equipment;

Describe the architectural and construction part of the enterprise;

Perform economic calculations;

Describe environmental and safety measures.

Literature and patent review on the problem of brick production based on man-made metallurgy products

1.3 Blast furnace slag formation methods

Blast furnace slag is obtained by smelting cast iron. From 1.72 tons of iron ore and melts, 1.3 tons of fuel, 60 tons of water and air, 1 ton of cast iron and 0.60.7 tons of slag are obtained, which are recommended and used for the production of building materials [2325]. Since glassy slags have increased hydraulic activity, blast furnace slags intended for the manufacture of binders are granulated, that is, quickly cooled with water, steam or air.

Currently, three methods of granulating slags are used: wet, semi-dry and dry [26]. The wet method is most widespread. It is based on the property of hot slags to crack under the influence of thermal stresses, as well as to spray due to micro-explosions when the melt contacts water to form slag granules. However, wet granulated slag, when drained from a ladle into a water-filled pool, contains up to 2530% moisture, which during storage and transportation in winter makes loading and unloading difficult and more expensive, causes mass loss. The water consumption of such granulation is about 3 m3/t, and dry granulation of slag is required to dry the product before grinding.

The semi-dry granulation method is more effective. It is carried out in drum, hydraulic percussion, hydraulic and other installations. Hydroelectric installations are most effective. At the same time, the melt from the slag ladle is drained into a bath, then it enters the granulation trough, where it is picked up by a bunch of strong water jets ejected from the nozzle holes or slot-like holes, cooled, broken into granules and delivered to the receiving site. From here the slag is taken with a grapple crane .

Dry granulation of slag according to the scheme proposed by N.A. Semenenko takes place inside a large hopper in the opposite flow of cold air blown from below. Granular slag is supplied from lower part of hopper chamber. At the reference temperature of slag 12001300oC cold air in the course of the movement heats up to 800900oC up, and then is used in a copper utilizer.

With the rapid cooling of slags, a predominantly vitreous (amorphous) structure is formed and granules with a size of up to 0.51 cm are formed. It has been found that the activity of metallurgical slag depends on the melt temperature at the time of granulation, which is influenced by the residence time in ladles of fiery-liquid slag before granulation. Thus, at relatively liquid temperatures of the melt (13801420oC), slags with reduced activity are obtained, the hydraulic activity of which increases sharply at the temperatures of the melt 14201480oC, reaching a maximum in the temperature range of the beginning of the formation of the crystalline phase. Reducing the slag melt temperature from 1538 to 1479oC also reduces the slag activity to 40%. Granulation at high melt temperatures (1600oC and higher), on the contrary, helps to reduce slag activity [26]. Thus, at a granulation temperature of less than 1300oC, the activity of the blast furnace slag is relatively low.

Slag glass differs significantly in chemical and physical properties from crystallized slags. Depending on the content of calcium oxide in the slag, they are divided into "basic" (Mo > 1) and "acidic" (Mo < 1). Ground high-calcium granular (vitreous) slag, when interacting with water, is able to harden, forming a strong stone, like cement. Hardening processes can take place at a temperature of 1820oC, but are more intense at an elevated temperature and in the presence of hardening activators such as lime, gypsum, etc .

Acid slags exhibit latent binding properties, therefore, to increase the activity of slags used to make binder, all fire-liquid slags are abruptly cooled and various activation methods are used to use them in the production of building materials [14,27,28].

Thus, semi-dry slag granulation is a more progressive method of blast furnace slag formation, due to lower water consumption and high productivity.

The active component of blast furnace slags is two-calcium silicate. But the activity of the slag depends on the temperature of the melt at the time of granulation. At low temperatures (about 1300 ° C), slag is obtained with reduced activity, it is necessary to use measures to activate the slag system.

The solution of the task of preliminary bleaching, activation of slag and development of parameters for obtaining decorative fine-grained concrete based on it is relevant.

1.4 Bleaching and activation of blast furnace granulated slag

The decoration of mortars and concretes is ensured more often by the use of colored cement. The most effective method of its production is the use of a white clinker, in which the number of coloring oxides is limited: Fe2O3, MnO, Cr2O3. In metallurgical slags, these oxides are part of metal inclusions, which in slag melt belong to heavy fractions. Thus, the degree of whiteness of slag depends on the content of dye elements in them, called chromophores. Chromophores are Fe, Ni, Mn, Cr, Ti, Cu and others. The first place among chromophores is iron in the form of Fe2O3. It gives an intense color - red, brown, yellow. Iron oxide FeO gives greenish and bluish colors [3]. The melt, being in a certain thermodynamic state, being abruptly cooled by water during granulation, hopefully causes an energy change in the system. Slag bleaching is due to a change in the coordination of coloring oxides and a decrease in the oxidation state of iron, the formation of colorless crystals. When analyzing the chemical composition of blast furnace granulated slags of two metallurgical plants of Kuzbass, NKMK and ZSMK plants, it was found that the content of ferrous impurities Fe2O3 reaches 3.7%. It is hypothesized that when holding molten slag in buckets, heavier fractions will precipitate.

To improve the quality of concrete products, many methods have been developed to control the mechanical and physicochemical properties of disperse systems. Directional structuring processes in such systems are possible only in the condition of continuous destruction of structures with reversible contacts between particles of the dispersed phase. The change in the energy state of the substance is usually called activation. The most famous methods of activation are: mechanical, chemical and thermal .

A promising method is mechanical activation of slag. To destroy the natural structure and improve the properties of raw materials and additives, the following grinding methods are used: "free" impact (disintegrator, hammer crusher, mine mill); "constrained" impact (ball and rod mills); shear compression (runners) [28]. The work of disintegrators, hammer crushers leads to large dust formation. A mine hammer mill leads to a high power consumption.

One of the main and most common methods of controlling the structural and mechanical properties of mineral dispersions is the chemical activation of slag, which consists in the fact that surfactants, electrolytes or water-soluble polymers are introduced into the dispersion medium - universal regulators of the properties of technical dispersions.

For example, Avtonomov I.V., Zaitsev A.G. and Riches A.V. from OJSC "Search" patented (Patent No. 2131856) a method of preparing a concrete mixture, characterized in that 520% of the PC of its total mass is previously introduced into powdered bentonite and mixed, after which a concentrated solution of superplasticizer C-3 is introduced and mixed until the mixture is uniform, after which crushed stone and sand are introduced, held for 510 minutes and final mixing is carried out until the mixture is uniform. Babaev Sh. T., Lyskov L.I., Bashlykov N.F. and others from the military unit No. 89515 invented (patent No. 2042653) a method for preparing a concrete mixture involving pre-treatment of cement with a superplasticizer in an amount of 2,520% weight of cement with mechanical impact of 30120 W on 1 kg of the treated mixture during 2.03, 6· 104 with subsequent mixing with filler and water .

In order to solve the problem of increasing the activity of metallurgical slags in the Cherkasy branch of the Kiev Polytechnic Institute, effective methods have been developed to improve their chemical and mineralogical composition and control the physical and chemical processes of hydration and hardening, which prevent the drying of the liquid phase of slag with lime, the formation of screens and films on reactive minerals and intensify the dissolution and assimilation by the solid phase of initial binding substances and mineral formation 29. Optimization of chemical-mineralogical composition of granulated blast furnace slag is achieved by introduction of polymineral additives in required amount, which can be ashes, wastes of ferrous and manganese ores concentration, limestone, loam and burnt rocks of coal terricons. Depending on the physicochemical properties and the nature of the effect on the processes of hydration and hardening of granulated slag, polymineral additives are divided into 3 classes:

1. Active additives are hydraulic (themselves having weakly expressed binding properties) blast furnace slags. Their activation of granular slag is due to the development of binding properties by minerals included in the additives. Selection of optimal chemical-mineralogical composition corresponding to maximum activity of mixed binder is achieved.

2. Active (hydraulic) additives that do not show binding properties: coal burning ashes, burnt carbonaceous rocks, ceramic waste (tile, brick scrap). Partially dissolving in water and adsorbing calcium ions from the liquid phase, the additives intensify the physicochemical processes of hydration and hardening of granulated slag. For example, when 50% of the pellet was replaced with burnt carbonaceous rocks, the strength of the composition increased to 12 MPa over 28 days with a slag activity of 8.2 MPa, and after 90 days it was 21.3 MPa.

3. Additives - adsorbents (activators): limestones, iron and manganese ore enrichment wastes, loams with Wp ≤ 17. By adsorbing calcium ions from the liquid phase, they intensify the dissolution of the starting binders. Limestone, being the substrates and the center of crystallization of slag glass, activates the process of crystallization and formation of the structure of slag stone. With an optimal amount (60%), limestone 2.7 times increases the activity of granulated slag. Activation of the latter by iron ore enrichment wastes containing 52... 70% quartz, unlike pure quartz, occurs as a result of the action on quartz of cations of multivalent metals of minerals contained in the ore phase of the waste. I.e. additives - adsorbents have catalytic effect on processes of granular slag hydration and hardening. For example, when replacing iron ore concentration wastes with 30... 40% granular slag, the strength of samples increases by 1.3... 2 times [28].

Based on ground blast furnace slag and burnt rock with hydrophilicity coefficient 6... 18, the State Road Research Institute patented binder (patent No. 1815255). Ratio of components,% by weight:

Ground blast furnace grunschlak 15... 25

Ground hot rock 20... 25

Cement dust of entrainment... 40 60

Phosphogypsum dihydrate 5... 10

To increase the hydraulic activity and whiteness of slag, the Kazakh Institute of Chemical Technology developed and patented (patent No. 1689317) an installation for treating slag melt with steam.

Also interesting is the method of processing slag (patent No. 1678793), proposed by the State All-Union Design and Research Institute of the Cement Industry. This method proposes the introduction into the jet of fire-liquid melt slag 1... 5% by weight of cement dust with gravitational carbon enrichment waste and melt granulation.

1.5 Basic requirements for decorative slag bricks

In Russia, wall materials are produced at 4731 enterprises. Compared to 1998 in 1999, the production of wall materials increased by 11%. The production of efficient wall products currently accounts for about 18% of the total output [30].

The average design structural and typological heat losses in heated buildings consist of losses: through windows and doors (33%); attic and flooring above the technical floor (22%); walls (45%). [31].

Changes in SNiP II379 "Construction Heat Engineering" from 2000. it is envisaged to increase the thermal resistance of the enclosures by 3... 3.5 times. To fulfill this requirement, the thickness of walls made of ceramic concrete with an average density of 950 kg/m3 should be increased from 390 to 500... 700 mm, and from bricks with an average density of 1500 kg/m3 - from 510... 640 to 1000... 1200 mm, which is unrealistic from the point of view. Therefore, wall structures using highly efficient and durable heat insulation materials are urgently required.

Newly built buildings in the middle zone of Russia require an average area of ​ ​ about 1 500 for heating kVt⋅ch m2, in Germany - 250, and in Sweden and Finland - 135. For the maintenance of 1 m2 of the total area of ​ ​ a residential building in Russia, 84 kg of conventional fuel per year is spent, and in Sweden, for example, 27 kg [33].

In such large metallurgical centers as the city of Novokuznetsk with a clearly pronounced specialization in the metallurgical industry, the issue of recycling industrial waste (occupied by slag dumps and tailings storage facilities of more than 1097 hectares), including for the needs of the construction industry (production of binding, various wall materials, use as fillers), is acute.

Decorative slag brick is an artificial wall construction material made by vibration pressing from a mixture of binder and aggregate and solidified under the influence of heat and moisture treatment in steaming chambers. The products are classified as non-combustible building materials according to GOST 30244. The charred face and ordinary brick are divided into single and one and a half. Single brick is produced with dimensions of 250 × 120 × 65 mm. Full and hollow single brick is made, unpainted or painted in various colors. According to the texture, the face of the product is made smooth with a decorative coating; by color - unpainted, having the color of the raw materials from which they are made, or painted, - from a painted mixture or with the surface color of the face faces. One and a half bricks are produced with dimensions of 250 × 120 × 88 mm with a brick weight of up to 4.3 kg [1].

According to GOST 379-95, the following grades are made depending on compression strength: 75, 100, 125, 150, 175, 200, 250, 300. The adhesion strength of the decorative coating to the surface of face articles must be at least 0.6 MPa (6 kgf/cm2). According to frost resistance, products are made of grades: F15, F25, F35, F50. According to frost resistance, the number of cycles of alternate freezing and thawing is taken, in which there are no signs of visible damage in the products (peeling, delamination, dyeing, etc.), and the decrease in compression strength does not exceed 25% for ordinary and 20% for face products.

Strength indicators, accuracy of geometric dimensions, clarity of faces, increased frost resistance allows using decorative slag brick as a face for building facades. Items shall be marked in each stack, one in the middle row.

The article is coated with indelible paint using a stencil or stamp trademark of the manufacturer. The symbol of the articles consists of the name, type and purpose, grade in terms of strength and frost resistance, designation of this standard.

Acceptance and periodic tests shall be carried out to verify that the articles meet the requirements of this standard. Acceptance tests are carried out according to the following indicators: appearance (presence of appearance defects), size and correctness of the shape, presence of inclusions in the fracture and on the surface, presence of punctures and defects from the infallible mixture, color (color hue), weight of the article, ultimate strength during compression and bending.

Conclusions on Chapter 1

1. Charcoal-free decorative slag brick is an artificial wall construction material made by vibration pressing from a mixture of binder and aggregate and solidified in the process of thermal moisture treatment in steaming chambers.

2. The production of coal-free bricks in Russia began in the 19th century and has since been constantly improved both in technology and in the use of raw materials.

3. Research has led to the introduction of many types of industrial wastes, such as slags of ferrous and non-ferrous metallurgy, as raw materials for the production of coal-free bricks.

4. NKMK and ZSMK annually produce about 5 million tons of blast furnace slags, the targeted technological implementation of which will reduce the shortage of raw materials and the cost of construction materials in particular in Kuzbass.

5. A more efficient way to create the decoration of mortars and concretes is to use colored cement, since its specific consumption in the texture layer is small and the chromaticity is quite intense.

6. The possibility of varying the color of the clinker is a change in the valence of the coloring oxides from Fe + 3 to colorless Fe + 6 by dramatically one-stage lowering the temperature of the clinker with water.

7. Blast furnace slag is used for production of slag portland cement, mortar, concrete with high corrosion resistance, strength and heat resistance.

8. There are three methods of granulating slags: dry, semi-dry and wet, where semi-dry granulation of slag is a more progressive method of forming blast furnace slag, due to lower water consumption and high productivity.

10. There are three ways to activate slags: mechanical, chemical and thermal.

11. The charred face and ordinary brick are divided into single and one and a half. Complete and hollow single brick is made, unpainted or painted in different colors, smooth with decorative coating. Depending on the tensile strength during compression, a charcoal-free brick is made of the following grades: 75, 100, 125, 150, 175, 200, 250, 300.

Selection and justification of production flow chart

The choice of technological scheme of production depends on physical and chemical properties of raw materials, nomenclature, type and size of produced products, technical conditions for produced products, volume of produced products per year, as well as on technological equipment [41].

The production of wall materials at this Rifey-Universal molding complex can be organized only by semi-dry vibration pressing.

The Rifei-Universal brick production plant provides accurate dimensions, faces, a smooth surface of the molded product, and serves as a perfect formwork for forming bricks.

The use of the Rifey-Universal installation is explained by the possibility of forming other products, such as paving tiles of various sizes and configurations, which can be achieved by changing the die and punch.

Thus, the use of the Riffey-Universal installation allows you to produce products of various nomenclature at a small cost of time and money for the re-installation of equipment.

The pellet is delivered by road to the receiving hopper on which an inclined grid with a cell of 10 mm is installed, from which it is loaded into the consumption hopper by means of a bucket elevator and a belt conveyor. The binder is delivered by air transport from an adjacent workshop for the production of decorative slag cement and is loaded into a hopper from which the pneumatic transporter is loaded into a consumable hopper. Water is supplied via pipeline through metering unit to vibration mixer.

From the receiving hoppers, each material is metered on the weighing dispensers and a vibration mixer is supplied, where all the components are thoroughly mixed to a uniform mass.

After mixing, the semi-dry mass is discharged to the conveyor, which supplies the concrete mixture to the reverse conveyor and then to the flow bins of the Rifey-Universal molding plants.

Molding is carried out at the Rifey-Universal molding complex in several operations carried out from the stationary installation panel:

lowering the die;

filling the die with a semi-dry mixture using a loader;

lowering of punches;

vibration compression;

lifting the die;

raising punches.

The articles are on a metal tray, which is moved by a chain conveyor one step corresponding to the molding rhythm, and the next tray is installed in its place. After forming, the tray with the articles is fed to a vertical multi-storey storey. After filling the stack with pallets with moulded articles, it is transported to the steaming chamber for heat-moisture treatment.

Ground dead end chambers are used for steaming of articles. Molded products are aged for 1... 4 hours, and then subjected to heat treatment for 8...... 12 hours, heating is carried out using electrotenes. To prevent drying of articles, irrigation with water from sprinkling nozzles is used, in accordance with electrical safety standards.

After holding, the frames with the products are delivered to the decompression station, where the products from the metal pallets are removed manually and stacked on wooden pallets. The metal sheets are cleaned and lubricated, after which, using a crane, the beams are transferred to the molding station.

Finished products are removed from the shop areas by loading pallets onto vehicles using a crane beam (Q = 3.2 t).

Conclusions on Chapter 4

1. At the designed enterprise for the production of decorative slag bricks with a capacity of 15 million units per year, it is planned to work the main equipment in two shifts. The operation mode of the heat-moisture treatment compartment is adopted in three shifts. The annual working time fund is 3643 hours.

2. For normal operation of the workshop for the production of decorative slag bricks, the main raw materials are required:

- decorative slag cement - 17488 t/year;

- granular slag ZSMK - 59617 tons/year.

3. The following process equipment was selected: crane, VTS120 dosing unit, J200 dosing unit, belt conveyor, VSML300 vibration mixer, concrete mixture conveyor, RifeUniversal vibration press, TVO ground cameras are designed.

4. Steaming of articles is carried out in ground chambers of dead end type. Due to the lack of steam, thermal moisture treatment is carried out by electrotenes. The entire process of thermal moisture treatment is automated, which increases production efficiency.

Architectural and construction part

A significant part of industrial buildings and structures is built according to standard designs. Typing consists in the constant selection of the most universal space-planning and structural solutions for a given period, which give the greatest economic effect, in the construction and operation of buildings. Modern typical buildings and structures have a high degree of unification - preparation for construction. Unification is carried out by using the most economical and universal elements of buildings, selected in accordance with the capabilities of factory manufacturers, ease of transportation, installation, etc., criteria.

Designs manufactured by domestic factories, unified products for all parts of buildings are constantly developing and improving. They are made on the basis of a single nomenclature of unified products approved by the construction committee.

5.3 Space-planning solution of the workshop

1. This workshop is a panel one-story single-span building, having a simple rectangular plan shape with dimensions of 24 × 48 m and with the pitch of the main columns in the extreme and middle rows of 6 m. The frame of the building is reinforced concrete. The building in axes A-B is equipped with a crane-beam - 3.2t .

2. The relative elevation is the level of the clean floor of the production building.

3. Metal structures are designed in accordance with the requirements: SNiP 2.01.0785 "Loads and impacts. Design Standards, "SNiP P2381" Steel structures. Design Standards. "

5.3.2 Interior layout of the workshop

According to the type of lifting and transportation equipment, this industrial building refers to a building without supporting cranes.

The dimensions of the building in plan 24 × 48 m. According to the volume-planning solution, the building is a span-type scheme. The pitch of the columns along the outer and inner axes is 6 m. Height from the clean floor to the bottom of the supporting rafters H = 9.6 m.

Internal transport - crane-beam with lifting capacity Q = 3.2 t.

According to the technological scheme, the building provides three gates for wheeled transport of 2.55 tons (dimensions 4 × 3.5 m), equipped with a thermal curtain .

The building is heated, with natural lighting. Sanitary units are installed. The maximum distance from the outermost point of the workshop to the bathrooms is not more than 54 m, which meets sanitary and hygienic requirements.

5.5.8 Gate

There are storm gates of the PR0557 series with dimensions of 4.5 × 3.5 m.

5.5.9 Windows

Steel window panels are adopted for the designed building. Windows 4.5 m wide and 4.2 m high are installed. The glazing is double, the window bindings are made of metal profiles.

Conclusions on Chapter 5

1. The designed production building is one-story, single-span, with a total width of the building of 24 m and a column pitch of 6 m. The height of the building to the bottom of the supporting structures is 9.6 m. The total length of the building is 48 m.

2. On the territory of the master plan there are: a production workshop, a workshop for the production of decorative slag cement, a warehouse of granular slag ZSMK, an administrative building, a dining room, a warehouse of finished products, a garage, a repair and mechanical workshop, a transformer substation.

3. Structural diagram of the designed frame building of span type, made according to the frame-link scheme.

4. The design of the wall with a thickness of 727 mm meets all the requirements of SNiP 23022003 "Thermal protection of buildings" and can be used for the construction of wall structures in the city of Novokuznetsk.

Automating the Heat and Moisture Process

6.1 Main tasks of steaming process control

Thermal moisture treatment is the most effective method of accelerating concrete hardening. It is the most important technological operation in the production of building materials. Of all types of heat-moisture treatment, steaming at atmospheric pressure occupies the main place.

Steaming of products is usually carried out until at least 50... 70% grade strength is obtained. The complete cycle of thermal moisture treatment consists of four periods: preliminary aging until steaming, temperature rise in the chamber, isothermal heating, cooling of products. Steaming is carried out in the temperature range 80... 95 ° С for 8... 12 hours.

At the temperature rise stage, the walls of the steaming chamber, steaming cars (storeys) and the products themselves are intensively heated. At this stage, as a result of significant temperature differences between the medium and the surface of the articles, thermal stresses arise, which, when sharply heated, can cause cracks in the articles. Therefore, both at the stage of temperature rise and at the stage of cooling of products, it is necessary to adhere to strictly defined temperature conditions and the rate of their change.

To ensure efficient and automatic steaming of articles, lines of automation of heat-moisture treatment process are used [44]. The main monitored parameters of the TVO process are:

- temperature in steaming chambers;

- relative humidity in the chambers;

- electric power consumption for heating of tanks;

- water flow rate for humidity change;

- material temperature during steaming.

Conclusions on Chapter 6

1. Steaming of articles is carried out in ground chambers of dead end type. Due to the lack of steam, thermal moisture treatment is carried out by electrotenes. The entire process of thermal moisture treatment is automated, which increases production efficiency.

2. According to the conditions of the process mode, the automation system of the steaming chambers should provide: the specified temperature of the steaming chambers with an accuracy of ± 5 ° С and the specified air humidity in the chambers with an accuracy of ± 2%.

Conclusion

1. Charcoal-free decorative slag brick is an artificial wall construction material made by vibration pressing from a mixture of binder and aggregate and solidified in the process of thermal moisture treatment in steaming chambers.

2. Research has led to the introduction of many types of industrial wastes, such as slags of ferrous and non-ferrous metallurgy, as raw materials for the production of coal-free bricks.

3. NKMK and ZSMK annually produce about 5 million tons of blast furnace slags, the targeted technological implementation of which will reduce the shortage of raw materials and the cost of construction materials in particular in Kuzbass.

4. Blast furnace slag is used for production of slag portland cement, mortar, concrete with high corrosion resistance, strength and heat resistance.

5. Granulated blast furnace slag ZSMK is obtained by method of semi-dry granulation at hydroelectric plant. In terms of chemical composition, the granular is between grade I and II (Al2O3 content = 10.36%; MgO=6,55%; TiO2=0,94%; MnO2=0,625%). Granshlak in composition by 90% consists of glass phase. Characteristics determining slag quality are as follows: K = 1.51; Mo = 1; Ma = 0.27; Mk = 0.997. Mineralogical composition of slag: gelenite, okermanite, pseudovollastonite, orthosilicate, etc. Analysis of the chemical composition of granular slag from 1970 to 2001 indicates its stability and resistance to silicate and iron decay. Granular sand refers to sands of increased size (Mkr = 3.39). As raw materials for housing products, slag corresponds to NRB96, Aeff = 168 ± 28 Bq/kg, which is < 370 Bq/kg.

6. Used as silica component is spent moulding mixture (waste of ZSMK foundry) with Mkr = 1.26. OFS consists of quartz sand, clay and liquid glass, the content of quartz - up to 80%. It contains active silicate and aluminate components.

7. As a alkaline component, gas cleaning dust of lime production ZSMK was used. Lime dust has a high specific surface area (the residue on sieve No. 008 is less than 3%) it lacks infallible grains, therefore, the possibility of the appearance of dukes in finished products is excluded. Lime dust has a bulk density of 660 kg/m3, and in a compacted state of 810 kg/m3. The chemical composition includes: CaO, Ca (OH) 2, CaCO3.

8. As a pigment, the waste of methysis production (WMD) of red color is used. The optimal amount of pigment is established - up to 5%, exceeding this amount causes a sharp decrease in strength.

9. The laboratory method of mathematical planning is the optimal composition of slag binder: alkaline activator (lime dust) - 15... 20%; grinding activator (spent moulding mixture) - 3... 6%; sulphate activator (ammonium sulfate) - 3%; granulated slag - the rest.

10. The optimal composition of slag concrete is selected: the ratio of components Binder: Aggregate - 1: 3.5 (product grade 100) and 1:3 (product grade 150).

11. At the designed enterprise for the production of decorative slag bricks with a capacity of 15 million units per year, the main equipment is supposed to be operated in two shifts. The operation mode of the heat-moisture treatment compartment is adopted in three shifts. The annual working time fund is 3643 hours.

12. For normal operation of the workshop for the production of decorative slag bricks, the main raw materials are required:

- decorative slag cement - 17488 t/year;

- granular slag ZSMK - 59617 tons/year.

13. The following process equipment was selected: crane, VTS120 dosing unit, J200 dosing unit, belt conveyor, VSML300 vibration mixer, concrete mixture conveyor, RifeyUniversal vibration press, TVO chambers.

14. Steaming of articles is carried out in ground chambers of dead end type. Due to the lack of steam, thermal moisture treatment is carried out by electrotenes. The entire process of thermal moisture treatment is automated, which increases production efficiency.

15. The designed production building is one-story, single-span, with a total width of the building of 24 m and a column pitch of 6 m. The height of the building to the bottom of the load-bearing structures is 9.6 m. The total length of the building is 48 m. The structural diagram of the designed building is frame span type, made according to a frame-link scheme .

16. On the territory of the master plan there are: a production workshop, a workshop for the production of decorative slag cement, a warehouse of granular slag ZSMK, an administrative building, a dining room, a warehouse of finished products, a garage, a repair and mechanical workshop, a transformer substation.

17. The design of the wall with a thickness of 727 mm meets all the requirements of SNiP 23022003 "Thermal protection of buildings" and can be used for the construction of wall structures in the city of Novokuznetsk.

18. According to the conditions of the process mode, the automation system of the steaming chambers should provide: the specified temperature of the steaming chambers with an accuracy of ± 5 ° С and the specified air humidity in the chambers with an accuracy of ± 2%.

19. Process and quality management methods are required to identify the causes of process deviations or defects in the finished product and to improve the quality of the finished product.

20. As a result of the calculations, the following technical and economic indicators of the workshop for the production of decorative slag bricks with a capacity of 15 million units were obtained:

Investments 181366 thousand rubles.

Cost of goods 27927 thousand rubles/year

Unit cost 1.86 RUB/pc.

Net profit 67586.4 thousand rubles.

Payback Period 2.1 years

21. The main measures on health, safety, fire safety and water bodies protection are considered.