EP0599925A1

EP0599925A1 - Process and device for producing multi-layered, fibre-reinforced plaster plates

Info

Publication number: EP0599925A1
Application number: EP92917577A
Authority: EP
Inventors: Jörg Bold
Original assignee: Babcock BSH AG
Priority date: 1991-08-23
Filing date: 1992-08-20
Publication date: 1994-06-08
Also published as: EP0599929A1; DE4127930A1; WO1993003899A1; DE4127932A1; WO1993004008A1; JPH07503910A; US5520779A; CA2116132A1; JPH07504856A; CA2116137A1

Abstract

On produit des carreaux de plâtre renforcés par des fibres selon un procédé de filtration en continu à couches multiples. A cet effet, on déshydrate sur au moins deux tamis sans fin une suspension de plâtre et de fibres préparées par voie humide, de préférence à partir de vieux papiers. Au moins deux couches sont générées dans des unités de filtrage essentiellement identiques fonctionnant en sens contraire. On renverse ensuite les couches, de sorte que leurs faces supérieures soient en vis-à-vis. Lorsque l'on travaille avec trois couches, la couche centrale peut être composée d'un matériau dispersible contenant un liant. L'invention concerne plusieurs dispositifs et configurations permettant de mettre en oeuvre le procédé.Fiber reinforced plaster tiles are produced using a continuous multi-layer filtration process. To this end, a suspension of plaster and fibers prepared by the wet process, preferably from old paper, is dehydrated over at least two endless sieves. At least two layers are generated in essentially identical filter units operating in opposite directions. The layers are then inverted, so that their upper faces are opposite. When working with three layers, the central layer can be made of a dispersible material containing a binder. The invention relates to several devices and configurations for implementing the method.

Description

METHOD AND DEVICE FOR PRODUCING MULTILAYER FIBER REINFORCED PLASTERBOARDS

- The wet dad preparation is a perfect mastery

Technology that does not apply to dry processing.

- The wet pulp consumes much less electrical energy than the dry one. This more than compensates for the disadvantage of higher thermal energy consumption when drying the plate.

Wet processes do not require high-performance presses, which consume a large part of the investment costs in dry processes. The specific investment costs are therefore lower for wet processes with small plant outputs.

In the wet process, one often uses the well-known Hatschek process, or. related processes, as are common in the technology of asbestos cement slabs. A patent application of this type is DE 1 104 419. A suspension of gypsum and fibers is suspended on a sieve or textile felt and transferred as a fleece to a roller with a large diameter, where it is wound up until the desired plate thickness is reached is. Then the layer is separated along a jacket line of the roller and the development forms a raw plate which sets between sheets and is finally dried.

In 1973 Knauf resumed development (DE 23 36 220). The performance of a hat check machine was multiplied by using an aridized plaster. Another process is the so-called four-wire process, which is derived from paper production. An example is described in OS 23 65 161 of the Portland cement works in Heidelberg. A suspension of gypsum and waste fibers from cellulose production is formed into a plate in a single layer, allowed to set and dried.

Babcock tries to avoid the difficulties that arise in the processing of wet, plasterable gypsum by first producing an Eohplatte from paper fiber suspension and finely ground raw gypsum on a Fourdrinier molding machine. The plate is then treated in an autoclave, as a result of which the dihydrate is converted to α-hemihydrate which is capable of setting. The plate is then cooled, allowed to set again in its own moisture and dried (DE 34 19 558).

Numerous wet-process GF plates have been developed in Japan. These include NIPPON HARDBOARD (OS 28 23 550), 0N0DA-ASAN0 (OS 2 517 558) and NIHON CEMENT (US 3,951,735). The Japanese processes prefer α-gypsum as a binder in order to obtain thin plates with high strength. They are all modified Hatschek or Fourdrinier processes.

As already mentioned above, the biggest problem by far is the mechanical drainage of a gypsum-fiber suspension. The Hatschek process takes advantage of the fact that the filtration speed decreases with the square of the filter cake thickness, but the mass flow rate only decreases linearly with the thickness. A large number of thin, dewatered layers are therefore wound one above the other on a roller in order to achieve the desired plate thickness. Then the "coil" is separated and spread along a surface line. It is obvious that the production output of such a system is limited, since centrifugal forces and the inertia of the mass limit the peripheral speed of the roller when the plate is laid down.

In the four-wire process, the dewatering time and thus the areas subjected to negative pressure increase quadratically with the thickness, so that the necessary drive power can no longer be transferred to the sieve from a certain sieving speed. In the four-wire process, the pressure drop in the cake can also be greater than the suction suction applied above a certain filter cake thickness, so that the top layer of the filter cake is not drained. This occurs especially with ordinary stucco, which tends to break down into the finest particles in contact with water and thus builds up an enormous filter resistance. This limits the maximum thickness of a filter layer.

Some basic principles that must be observed in the four-wire process are described below:

The choice of gypsum is of great importance for the success of the process. So that a suspension can be easily filtered, the particle size distribution and the shape of the suspended solid must meet certain conditions. The following requirements apply to the plaster

a) a bulk density of greater than 950 g / 1 in the case of α-hemihydrate, or of greater than 700 g / 1 in the case of β-hemihydrate.

b) a pond size distribution that corresponds to a pitch angle of greater than 40 ° in the RS grit network.

c) In the case of ß-hemihydrate, it must be aridized and after the

Calcination can no longer be ground.

Hydraulically setting binders can advantageously be added to the fired gypsum. This cannot be taken for granted, e.g. in the semi-dry process, the amount of water present in the raw plate is usually not sufficient for the hydraulic binder to set correctly. This risk does not exist with the filtration process. For example, alumina cement and blast furnace cement (HOZ) or ground blast furnace slag and Portland cement can be mixed in with a particularly good result. The raw plates must then go through a longer maturing period before drying. Thereby plates are obtained which have an improved water resistance.

The addition of 10 to 30% alumina cement and 30% to 50% HOZ has proven to be particularly favorable. The addition of such hydraulic substances can improve the filtering properties of acicular or otherwise unsuitable gypsum in such a way that they can also be used.

A good filterability of the gypsum fiber suspension allows the drainage of relatively thick layers. The fiber distributed in the suspension and the gypsum itself act like a filter. Therefore, in this case it is not necessary to use a felt with high filter resistance as a filter belt, but a sieve is sufficient. The required filter area, the vacuum and the suction time depend on the combined filter resistance. It ultimately determines the throughput of a system and the drive power required for the filter belt and vacuum pumps.

A minimum thickness of the dewatered layer of 3 mm should not be undercut, since otherwise the losses of solid matter increase very strongly with the extracted water.

It has also been found that a content of at least 3% of the total mass of cellulose fibers or equivalent waste paper fibers should be used in order to reduce suction losses, but also to prevent segregation of the suspension. The preferred range when working with cellulosic fibers alone is 7% to 12%. With this fiber content, the density of the finished GF panel is between approx. 1.1 and 0.6 t / m3. At the same time, the strength passes through a maximum in this area. This applies in the event that the dewatered layer is not compacted with a press.

The layer is dewatered in at least two zones with different negative pressure. The more subdivisions you make, the better you can optimize the induced draft distribution for different criteria. The distribution for the lowest energy consumption of the pumps is different from that for the shortest possible drainage zone or that for the smallest possible sieve tension. In practice, however, the natural fluctuation range of the raw material properties is so large that a division into more than three zones does not appear to make sense. As a general rule applies that the drainage should begin with a low vacuum, ie up to 65mbar, with a medium vacuum, ie up to 150mbar and continue with a high vacuum, ie up to 550mbar. If only two drainage zones are used, the middle level will fail.

Dewatering should take place in the first zone until the surface of the layer has become matt. Given the given length of the dewatering zone, the speed of the screen and / or the negative pressure may have to be adapted to this specification.

The residual moisture and ultimately the density of the finished board is determined by various parameters, some of which are determined by the properties of the materials used. If these are regarded as constant, the most important influencing variables are the thickness of the dewatered layer, the consistency of the suspension and the content of cellulose fibers in the suspension. The thickness of the layer and the consistency primarily determine the necessary suction time, i.e. the maximum speed of the sieves, on the other hand, the limit moisture is mainly determined by the content of cellulose fibers. The maximum suction draft and the suction time are of minor importance.

If you want to get rid of these dependencies, the only way out is to retrofit them by squeezing out water. Although this does not contradict the possibilities of the method according to the invention, it is nevertheless undesirable because the presses suitable for it are expensive and complicated.

Stucco is three to four times more soluble in water than dihydrate. With the large amounts of water circulating in the process, this fact can cause some problems. If, for example, the water obtained in the dewatering of the gypsum fiber suspension is used again for paper preparation, up to 2% of the stucco plaster used in the paper suspension can precipitate out as a dihydrate. This is not only a loss of binder but can destabilize the process because dihydrate has a strong accelerating effect on the setting of the gypsum. It is therefore important that the water cycles of paper preparation and plate forming are largely separated. The water cycle in the plate forming system results from the fact that the water which is removed from the gypsum fiber suspension is returned to the mixture. When dewatering, about 1% to 3% of the solid, mainly gypsum, is entrained. In order to prevent the gypsum from precipitating in the intermediate buffer container, it is removed in a sedimentation funnel and returned to the mixer over a short distance. The separation of the solid is supported by the addition of known polymeric flocculants.

The quality of the slab formed by the drainage is largely determined by the consistency of the gypsum fiber suspension. This must be set so that the material can flow freely. If the consistency is too low, the drainage times and the loss of binding agent increase. If the consistency is too high, the fibers can become matted. This hinders the orientation of the fiber in the plane of the plate and leads to net-like zones with a lower fiber content and thus to a weakening of the overall strength of the plate. A water content of the suspension must therefore be selected which is as low as possible but which still ensures the flowability.

The flowability is primarily a function of the fiber content. The binder content plays a subordinate role. A content of approx. 3% of cellulose fiber based on the amount of water in the suspension, which should not be exceeded, can be assumed as an orientation variable. In practice, the optimal value may differ slightly from this value.

Once the plate is formed, it is trimmed on the side edges. The edge strips are mixed with circulating water as quickly as possible and fed back to the mixer. It is not irrelevant how large the proportion of edge strips is in the total mass in the mixer. Each passage through the circuit increases the proportion of the finest particles which impede the filtration considerably. There is therefore a source of instability here as well as that of the germs which accelerate the setting. Unfortunately, in this case there is no simple and safe way to counter this, except to discard the verges. This is not economically justifiable. It must therefore be ensured that the proportion remains as small as possible and that the digestion is done as gently as possible. One way to reduce the share is to choose a large working width. Great care must also be taken to keep the inevitable marginal effects in the transverse mass distribution small so that the section can also be kept small.

Before the start of setting, the continuous strand of the GF plate must be divided and the parts moved apart, because the plate grows up to 5 mm / m when setting. If the plate was not divided, this would lead to warping.

The division into individual panels gives you the option of choosing how the panels are temporarily stored until they dry. A suitable long conveyor belt is suitable for quick setting gypsum. When hydraulic binders are also used, stacking between sheets or other suitable plates is known.

The present invention describes a possibility of overcoming the above-described problems in realizing large product inputs with a wet process and of realizing a four-wire process for the production of gypsum fiber boards with high performance. Its main characteristic is that

the dewatering takes place by means of negative pressure in at least two separate strands on essentially the same devices which work in opposite directions, and that at least two of the dewatered gypsum fiber layers are brought together in the further course of the process before the gypsum sets, mirrored and laid on top of one another and connected become.

If you work with three drainage devices, the middle layer can have a different composition than the two outer ones within the limits set by the method. For example, the fiber content can be reduced or an additive can be added. A particularly advantageous embodiment of the method is that an essentially dry mixture of binder, aggregates and possibly fibers is sprinkled on at least one of the dewatered layers. The mixture is then pressed onto the first layer with a light press and pre-compacted before the last layer is deposited (see FIG. 3 and Example 4).

Essentially dry here means that the mixture can be spread. It can contain up to approx. 25% moisture based on solids (compared to over 400% in the GF suspension). Few fibers means that they do not loosen the mixture. In the case of cellulose fibers, the upper limit can already be 1%, in the case of certain mineral fibers the maximum possible proportion can be 10%.

Since it is always difficult to moisten a dry mixture, it is advantageous to use the lignocellulose-containing fiber which has been wet-processed and mechanically dewatered again. This means that a small part of the water can already be introduced. In addition, part of the machinery required for dry digestion becomes superfluous.

In one embodiment of the method according to the invention, the sprinkling can take place after the first stage of the dewatering. In this case, it is advantageous to interrupt the dewatering by means of negative pressure and to resume it where the compression with the press takes place. This supports the ventilation of the scattered layer. If the mixture contains no or only very few fibers, pre-compression can be dispensed with.

The most important advantage of this procedure is that the residual moisture in the outer layers is reduced to values that can otherwise only be achieved by dewatering presses, since the dry mass of the moist layer extracts water by capillary forces.

Another advantage is that you can, for example, add perlite to the plate without having to soak it in water, which takes a lot of time and thermal energy to dry. Demixing can also be largely avoided during dry application. In a special embodiment of the process, the perlite or another is made lighter Granulated aggregate with the binder in a suitable device with the addition of water. This results in a particularly even distribution of binder and aggregate and prevents the formation of dust when spreading (see Example 5).

Extremely light panels or panels with a very low fiber content are not particularly strong and tend to chalk in the case of lightweight panels. In one embodiment of the method according to the invention, reinforcing or protective fabrics or nonwovens are therefore placed on the sieve belt before the gypsum fiber suspension is added. If a reinforcing effect is desired, the textile web must be tensile and have a high modulus of elasticity. Particularly worth mentioning is a plastic-bonded glass fiber fleece, which has the advantage of being non-flammable.

When dewatering, gypsum penetrates the textile and firmly connects it to the layer. This is not possible if only one layer is drained. Then a textile placed on top of the dewatered layer does not bond to the layer. However, a plate with only one textile layer will bend.

A special variant of the method is that the middle layer is not sprinkled or filtered, but is poured. A slurry of binder plastically mixed with water and any additives and additives is poured onto a filter layer and covered with the second filter layer (see FIG. 6). This design of the process is reminiscent of the production method of plasterboard.

In this variant, the binding agent can also be made up with prefabricated aqueous foam. This creates an easily distributable mass that still contains little water and has a porous structure after setting. if you want to improve the connection to the filter layers, you can add an anti-foaming agent to the filtered suspension, which compresses the mass at the boundary layers. Such a procedure is particularly suitable for boards with a thick core and thin cover layers.

In an embodiment of the method according to the invention, light aggregates such as perlite can also be used, which tend to accumulate in the upper layer of the drained gypsum fiber layer. With the sym In this way, etrical merging of the layers leads to an accumulation in the core of the plate, which has a particularly favorable effect on the mechanical properties of the plate.

Figure 1 shows the family tree of the method according to the invention. The solid lines correspond to the variant with two strands, the dashed lines describe the variant with dry material sprinkled onto a strand. The arrowed circles Kl and K2 indicate the separate water circuits. A third watercourse, which is coupled to the second, is not listed and is also not dealt with in the preceding description. It is the wash water circuit for the screens and belts involved in the drainage.

A complication can arise here if fresh water has to be introduced into the circuit: it is not technically possible to pre-drain the fibrous material noticeably below the amount of water that is carried out with the plate. There is therefore no scope for introducing fresh water into the GF circuit (K2). As a rule, the water balance is just balanced. The amount of water introduced by the laundry from the GF circuit (K2) must therefore be discharged and processed to the extent that it can be returned to the washing circuit or can be fed into the paper circuit (K1) with the fresh water.

The total water of the GF circuit (K2) and the laundry then expediently runs over the sedimentation in order to remove the suspended solids. When treating the residual water, only the dissolved gypsum is involved. The supersaturation of the water with respect to dihydrate, which is about three times, is expediently reduced to 1.5 to 2 times the supersaturation in a sufficiently large intermediate buffer in which dihydrate can precipitate. If it is then diluted with fresh water, no more dihydrate can fail.

As shown in Figure 1, the grinding dust is fed into the calcining system and converted back into material that can be set. In practice, this can also cause a problem because the grinding dust is very fine and can therefore impair the filtering properties of the plaster. It must be checked in each case what proportion of grinding dust in can return the plaster. In the case where dry scattering is applied as an intermediate layer, there is an elegant solution to this potential problem: since batches are calcined anyway, part of the gypsum can be burned with the entire grinding dust. It is then used exclusively for the middle class.

The sequence of the method will be explained using a few examples. The procedural steps, which do not need to be explained further, are therefore not dealt with in detail. The relevant process parameters are listed in Table 1.

- The gypsum is an aridized flue gas gypsum, which comes from a flue gas scrubber of a coal-fired power plant with limestone as an absorber.

- The fiber used is a wet processed waste paper with 15%

Kraft paper content.

- The necessary types and amounts of the are not specified

Additives that any specialist can easily determine.

- When pressed with 0.3 N / mm2, the Perlite has a density of 150 g / 1.

- The quantities used relate to the unpolished plate. At the

Loops are ground approx. 0.5 mm.

- Examples 1 to 3 can be run with a system according to Figures 2 and 3 explained later.

- Examples 4 and 5 can be used on a system according to the illustration

4 can be driven.

- The three extraction zones for each of the cover layers are every 2 m long.

^• In all cases, subsequent compression with a press is not used. TABLE 1 Examples

Ex. Ex. Ex. 1 2 3 4 5

Setting data for cover layers (wet filtering)

Belt speed m / min 14.7 9.8 7.8 31.6 31.6 corresponds to capacity m2 / h 2200 1500 1200 4700 4700

Cons. Fiber v. Dilution cons. Fiber after dilution Water in fiber after dilution Fiber content in GF raw mix Gypsum content in GF raw mix Consistency Suspension Fiber amount in suspension Gypsum in suspension Water in suspension Water in the circulation thereof in fiber thereof for edge strips thereof in mixer

II Setting data for core layer (dry spreading)

Fiber content in raw GF mix%

Gypsum content in raw GF mix%

Moisture in GF dry mix%

Fiber mass in GF dry mix kg / min

Gypsum mass in GF dry mix kg / min

Mass of water in GF dry mix. kg / min

Pearlite mass in GF dry mix. kg / min Table II continued

III Properties of the plates

Total thickness mm 10.5 10.5 12.9 12.0 11.0 of which cover layers mm 10.5 10.5 12.9 6.4 6.4 of which core layer mm -.- -.- -.- 5.6 4.6

Total density kg / m3 820 690 760 790 805 of which cover layers kg / m3 820 690 760 760 760 of which core layer kg / m3 -.- -.- -.- 824 867

Fiber content in outer layers% 7.0 10.6 8.8 8.8 8.8

Fiber content in core layer% -.- -.- -.- 10.6 0.0 Total water to be dried out% 40.0 58.3 49.2 27.6 26.7

Flexural strength of the plate N / mm2 6.0 5.5 7.5 6.0 5.0

Examples 1 to 3 vary the fiber content and the plate thickness. A maximum bending strength is found in the vicinity of 10% fiber content. There is also a strong dependency of the production output on the fiber content and thickness. In Examples 1 to 3, the moisture to be dried out is in the range around 50% based on the weight of the dry plate.

The capacity and humidity values improve dramatically when you spread a middle class. However, the bending strengths decrease noticeably. It can be seen that the density of the plates is very low. They are consistently in the area of the GK panels. GF sheets that have been manufactured using a dry or semi-dry process have densities of 1100 to 1200 kg / m3 or 860 to 1000 kg / m3 with perlite. The use of perlite and fiber per unit weight is significantly higher. The lower amounts of perlite and fibers and, because of the lower density, also of gypsum reduce the manufacturing costs considerably in comparison with dry / semi-dry processes. The bending tensile strengths of the sheets produced by the process according to the invention are in the same range as those produced dry. This is why the strength-to-weight ratio and thus the handling of the wet-made panels is better. Another application-technical advantage over Gf plates from a dry or semi-dry process is that the resistance to screwing or nailing is lower due to the lower density. In particular, the countersinking of screw heads, which is associated with a compression of the material, is much easier here. A disadvantage, on the other hand, is that the surface hardness of wet-made boards is significantly lower than that of dry-made boards of the same strength.

An installation for carrying out the process essentially consists of:

a at least one continuous metering device for gypsum,

b at least one continuous metering device for water,

c at least one continuous mixing device for fiber suspension, water and gypsum and, if appropriate, additives and additives,

d at least two distribution devices for the gypsum fiber suspension,

e at least two dewatering sieve belts, each with at least two dewatering suction devices arranged below the sieve, which are operated with different negative pressure,

f optionally one or more devices for spreading a dry layer,

g optionally one or more devices for pre-compacting the scattered layer,

h a continuous press. FIGS. 2 to 6 show different designs of drainage and molding plants which are the core of the plant according to the invention.

Figure 2 shows the schematic structure of one of the two basic variants of the plate forming machine. One or more secondary sieves (2a) and (2b) are arranged above a main dewatering sieve (1), which specifies the speed as a guiding sieve. The dewatering performance is the same as that of the main sieve. In the present case, each sieve has a suction zone with a low vacuum (3) and one with a high vacuum (4). The suction zones (5) on the secondary sieves are low-pressure suction devices, which no longer have a drainage effect, but only ensure that the filter layer is held on the sieve. The deflection rollers (6) on the secondary sieves and the rubber rollers (7) have a large diameter in order not to pull the filter layer. The corresponding counter-pressure rollers (8) are arranged under the rubber rollers (7). The devices for the transverse distribution of the suspension (9) are identical for all sieves. Various designs are known which have proven themselves in asbestos cement technology.

The gypsum fiber suspension is prepared in a single mixer (10a). This ensures that the composition is at least the same in the outer layers. If the middle layer is to have a different composition, a second mixer (10b) is used. The suspension is divided between the individual sieves using volumetric pumps (11a) (11b) in such a way that the number of pumps is 1 less than the number of molding machines.

The plastered gypsum fiber web is finally pressed in with a press (12). As a rule, the press is nothing more than a smoothing press, which reduces the markings on the screens with very light pressure, for example less than 0.5 N / mm2. However, it is also possible to design the press as a dewatering press that is able to compact the gypsum fiber web. The pressures required are about an order of magnitude higher. If the press works as a dewatering press, then care must be taken that the squeezed water is removed. This is done, for example, by using deeply grooved rubber bands with high Shore hardness as press belts. FIG. 3 shows the second of the two basic variants for carrying out the method according to the invention. The main difference from the first variant is that the screens (13a) (13b) lie in one plane and abut one another on the end face. The deflection rollers (6) also have a large diameter here. The roller (14) is particularly large so as not to pull the thicker plate.

The screen (13a) is guided together with the screen (13b) around the roller (14). Perfect synchronization of the sieving speeds is thereby achieved. Furthermore, the screen tension of the screen (13a) produces a pressing effect which, depending on the screen tension and radius of the roller, can have a dewatering effect. For this reason, the press (12) may be omitted.

Figure 4 shows the system with a sprinkled middle layer. It is a descendant of the first basic variant shown in FIG. 2. Here the straight main sieve (1) is the carrier of the scattered layer, which cannot be bent over a roller without being damaged.

The spreading machine (14) is of the type used in the semi-dry process and which in turn was developed from the chipboard spreading machine. The mixer (15) for the dry mixers is a mixer adapted to the conditions of gypsum mixing, as is used for the gluing of chips. Such a mixer is used for the semi-dry process. It also allows the even distribution of small amounts of water in the mixture.

The pre-press (16) compresses the spread mat to about 30% of the spreading height. Only a very low pressure is required for this. Therefore a series of rollers are sufficient. They are protected from direct contact with the scattering layer by a circumferential band (17). If, as shown in FIG. 4, the pre-press starts after the dewatering section, the belt is expediently a sieve which allows the mat to be vented. If the press attacks over the last drainage zone, then a closed belt can be used. This has the advantage that the continuous cleaning of the belt is less expensive. The In addition to pre-compression, the pre-press also has the task of smoothing the spreading layer so that the applied covering layer can lay down smoothly.

The press (12) in the variant shown here must be made stronger than in other variants if the scattered layer contains more than about 5% dry processed paper fibers. The fibers build up considerable restoring forces that can only be overcome by relatively high pressures of the order of 1 Mpa.

The press itself can be constructed differently depending on the requirements. Isostatic presses are suitable in most cases. Distance-controlled presses can also be used for special requirements. It is also possible to use the press by using a smooth or structured press belt to design the plate surface.

FIG. 5 shows the variant with additional cover layers made of textile strips (18) which are placed on the sieve (1) before the suspension is put in. The webs run over stretching rollers (19) which prevent the formation of folds and pretension the webs. Otherwise, the system is the same as that of Figure 2 except that it works without a middle class. However, a middle class is also possible. With the additional reinforcement on the outside, the core can then be made very light-weight and without fibers. The textile webs can also be easily combined with the variant which is described in FIG. 6.

In the variant shown in FIG. 6, the middle layer is cast. The mass to be poured (mortar) is mixed in the mixer (20). This mixer can be a plasterboard mixer or a special mixer for the production of foamed mortar. The mass is applied to the dewatered layer on the sieve (1) with a distribution device.

The mortar is plastic and can be squeezed out under the pressure of the upper sieve. This is prevented by two belts (22) made of very soft rubber that run along the side, which have a rectangular cross section and are so thick that they are pressed between the sieves. In this case, a pre-press is not necessary. It is replaced by some smooth and form rollers (23) integrated in the dewatering machine (2) with counter pressure rollers (24), which can also be replaced by a simple plate (not shown).

Other combinations of the basic variables, not shown and described here, are of course also possible, e.g. the second basic variant (FIG. 3) can be combined with one or two overhead filter units as in FIG. 1 (2a).

It should not go unmentioned that the method of counter-rotating molding machines can also be usefully used for other binders and fundamentally different applications. The variant in FIG. 3 can also be used, for example, as a filter press for dewatering any sludge.

Claims

Expectations

Process for the continuous production of gypsum fibreboards from semi-hydrate gypsum and reinforcing fibers after a filtration process, whereby a low-viscosity slurry of stucco and lignocellulose-containing reinforcing fibers and possibly additives and additives are distributed on a water-permeable conveyor belt and the excess water is essentially removed by negative pressure , whereby a filter cake is formed, which is optionally further dewatered by the action of mechanical pressure, allowed to set by storage and finally thermally dried, characterized in that the dewatering takes place in at least two separate strands on essentially the same devices which work in opposite directions, and that at least two of the dewatered gypsum fiber layers are brought together in the further course of the process, before the gypsum sets, are put on top of one another in mirror image and connected.

A method according to claim 1, characterized in that the drainage of the gypsum fiber suspension takes place in three strands.

A method according to claim 2, characterized in that the composition of the suspension for the middle strand is different from that of the two outer strands.

Method according to claim 2, characterized in that the drainage of the layer takes place in at least two stages of different negative pressure.

A method according to claim 4, characterized in that the drainage takes place in three stages of different negative pressure, the negative pressure of the first zone being 15 to 65 mbar, in the second zone 65 to 200 mbar and the third zone being 200 to 550 mbar. Method according to claim 4, characterized in that an essentially dry layer of binding agent with possibly fibers, aggregates and additives is sprinkled on at least one of the layers.

A method according to claim 6, characterized in that the sprinkling takes place on the at least partially dewatered layer.

A method according to claim 7, characterized in that the Vorentwäs¬ serung takes place with controlled vacuum, such that a residual moisture of the dewatered layer of 50 to 80% based on the dry mass is established before the dry layer is sprinkled.

A method according to claim 8, characterized in that the dry layer is pre-compressed by mechanical pressure before being connected to another dewatered layer.

Method according to claim 9, characterized in that the pre-compression takes place over the last dewatering zone.

A method according to claim 4, characterized in that a water-permeable textile band is placed on the sieves of the two strands which form the cover layers before the suspension is applied, which band forms a bond with the plate which is being formed.

Method according to claim 4, characterized in that a layer of plastically pasted mortar is applied to the lower strand.

A method according to claim 12, characterized in that the mortar is a binder pasted with prefabricated foam, optionally with additives and additives. A method according to claim 4, characterized in that the thickness of the dewatered layers is 3mm to 20mm, preferably 4mm to 10mm.

A method according to claim 6, characterized in that a partial amount of the dewatered fibrous material is optionally mechanically dewatered to a consistency of 25 to 30%, ground in a mill and mixed in as fiber material for the scattered layer.

A method according to claim 15, characterized in that dry waste paper is added to a partial amount of the dewatered fibrous material, in an amount which gives a total moisture content of 20% to 50% based on the dry matter content, ground in a mill and mixed in as fibrous material for the scattered layer becomes.

Plant for carrying out the method according to one of the preceding claims consisting of:

a at least one continuous metering device for gypsum,

b at least one continuous metering device for water,

c at least one continuous mixing device for fiber suspension, water and gypsum and optionally additives and additives,

d at least two distribution devices for the gypsum fiber suspension,

f optionally one or more devices for spreading a dry layer, g if necessary one or more devices for pre-compacting the scattered layer,

h a continuous press.

Plant according to claim 17, characterized in that it contains a main drainage screen, above which at least one other secondary screen is arranged in opposite directions (Figure 2).

Installation according to claim 18, characterized in that it contains two counter-rotating drainage screens, which are arranged in one plane, abut one another on the end face and the two dewatered layers of gypsum fiber collapse over a large diameter drum (FIG. 3)

Plant according to claim 18, characterized in that a spreader for sprinkling mix is arranged above the main drainage screen and throws onto the dewatered gypsum fiber layer.

Plant according to claim 20, characterized in that a compression press with a screen covering is arranged above the main dewatering screen after the spreading machine, which pre-compresses and ventilates the spread material before it is combined with the second dewatered gypsum fiber layer (Figure 4).

Installation according to one of claims 18 to 21, characterized in that a press is arranged after the individual layers have been brought together.

Installation according to claim 22, characterized in that the press is an isostatic press. Installation according to claim 23, characterized in that the press acts essentially by its own weight.

System according to claim 22, characterized in that the press is distance-controlled.

Plant according to claim 22, characterized in that the press has a lower belt made of screen fabric and an upper closed press belt.

Installation according to claim 26, characterized in that the press has a lower belt made of screen fabric and an upper closed press belt with a structured surface.

System consisting of any combination of the basic variants according to claims 39 to 50.