RU2104254C1 - Method for production of redoksid porous ceramics and production line for its embodiment - Google Patents

Abstract

FIELD: methods and production lines for production of REDOKSID porous ceramics. SUBSTANCE: method consists in laying by layers of clay dry granules into vessel for molding 8-80 mm in height, preliminary heating to temperature 220-280 C at the rate of 2.0-2.5 C/min and isothermal holding for 10-80 min. Then granules are subjected to thermal shock up to beginning of granule swelling at the rate of 30-50 C/min and isothermal holding for 10-40 min. Next isothermal holding is accomplished within the interval of swelling at 1120-1260 C for 20-110 min. Then temperature is reduced to hardening temperature of material pyroplastic state at the rate of 2.0-3.0 C/min and isothermal holding for 20-110 min. After controlled cooling at annealing temperature of 400-1000 C, isothermal holding is carried out for 10-60 min and active noncontrolled cooling is undertaken to obtain REDOKSID porous ceramics with interconnecting open surface and depth pores. EFFECT: higher efficiency. 10 cl, 11 dwg, 5 tbl

Description

 The invention relates to the production of porous ceramsite clay "Redoxide", which can be used both for loading biological filters used in technologies for deep wastewater treatment, and as a heat-insulating building material.

 Known loading from expanded plastics or honeycomb structures made of plastics for biological filters, which are used in wastewater treatment plants for wastewater treatment [1].

 A disadvantage of the known loading is that the manufacture of honeycomb structures requires accurate welding and soldering of plastic plates. These works can be performed in the presence of a large number of highly skilled workers and expensive technological equipment. The biocenosis developing in the load cells is unstable, which reduces the quality of wastewater treatment.

The closest in technical essence and the achieved result is a method of manufacturing a redoxide material for biological wastewater treatment, including preparing plastic molding granules from clay, drying granules, layer-by-layer laying of granule layers in a molding container, determining the temperature of the beginning of expansion, the range of expansion temperature and hardening temperature the pyroplastic state of the initial clay, heat treatment of the granule bed in the zones of the working channel of the heat generator by pre-heating va, roasting and sintering directional swollen granules from the material surface to the center with the lowest temperature difference in the center layer on the surface of the granules and with subsequent cooling to a temperature annealing and subsequent reduction in temperature to 70-80 ^o C with air and water vapor to power teplootbora carrying out four isothermal extracts in the working channel of the heat generator at the temperature of the beginning of expansion of the material, in the range of temperatures of expansion of the material, at the temperature of hardening pyroplastic the condition of the material and the annealing temperature, removal of the material from the molding tank.

 The specified method is implemented in a production line for the production of redoxide material for biological wastewater treatment, containing a clay pellet preparation workshop established during the process, connected by an elevator with a feed hopper of a batching station with a belt feeder and a batcher, functionally connected to the station for loading granules in a tank for molding, a heat generator in the form of a kiln with a power metal frame and a foundation, while the metal frame is lined with a lining with the formation of the walls of the roof and bottom of the furnace, as well as the working channel with zones of preheating, firing, isothermal exposure, cooling, a system for moving granules inside the working channel, energy sources and automation and communication systems, a material discharge station on pallets connected by a conveyor to a container preparation station for molding, the output of which is connected by a reverse transport connection and the entrance to the granule loading station in the molding containers and the finished product warehouse [2].

The disadvantage of this technology for the manufacture of redoxide material for biological wastewater treatment is that a quick rise in temperature in the preheating zone to the temperature at which the pellets from clay begin to swell leads to dehydration of the granules and high internal stresses in the granules, which increases the likelihood of burnt material bursting at this stage , and with further firing and sintering, the likelihood of cracking of the redoxide material and a significant decrease in mechanical strength and hardness increase. The mass formed by the glass at the hardening temperature of the pyroplastic state of the material at the moment of the onset of intensive cooling to 800-1000 ^o C clogs the surface pores that have opened during swelling and instantly freezes in them. The above reasons do not ensure reliable production with the required parameters and lead to significant rejection (up to about 40%) when selecting material for use in biofilters in wastewater treatment plants. At the same time, control over the products is complicated, and the likelihood of burnout increases. The cost of manufacturing products is high, because scarce heat-resistant steel is required for the manufacture of containers for molding.

 The basis of the invention is the task of improving the reliability of the manufacturing technology of the material "Redoxide" for biological wastewater treatment, reducing the percentage of culling of finished products with increasing its strength and hardness, eliminating dehydration of granules, burning and cracking of redoxide material and reducing both energy and financial costs by eliminating the burst of the calcined material from large internal stresses in the preheating zone, preventing glazing of those opened on the surface material and pores in high temperature firing zone and the initial cooling step, and also increasing the life of the containers for molding.

 The problem is solved by a new method of manufacturing porous redoxide ceramics and a new production line for its implementation.

The essence of the invention lies in the fact that in the new method of manufacturing porous ceramics "Redoxide", which includes determining the temperature of expansion, the range of temperature expansion and temperature of hardening of the pyroplastic state of the original clay, the preparation of granules from clay with a diameter of 8-16 mm, drying and dosage of granules, layering granule formations into a molding container, heat treatment of granule formations in the zones of the heat generating channel by preheating, applying thermal shock before the granules expand, implementation and thermal excerpts in the range of expanding temperatures to ensure directional sintering of expanded granules from the surface of the porous ceramic "Redoxide" to the center with a minimum temperature difference in the center of the granule layer and on the surface at the solidification temperature of the pyroplastic melt, controlled cooling of the solidified melt to the annealing temperature with subsequent isothermal aging and the implementation of active uncontrolled cooling at 70-80 ^o C using air and water vapor for enhanced heat removal and extraction of the porous Redox porous ceramics from the molding container, claydite clay is used as the initial clay, including shale with a layered structure in dark gray to black color with plasticizing additives, the prepared granules are dried up to 2-4% humidity and layer by layer lay the layers in the molding container with a height of 8-80 mm, preheating is carried out to 220-280 ^o C at a speed of 2.0-2.5 ^o C / min and at this temperature carry out isothermal exposure for 1 0-80 min, after which a thermal shock is applied to the temperature of the onset of expansion of the granules at a speed of 30-50 ^o C / min with isothermal holding at this temperature for 10-40 minutes, after which the temperature is raised to the expansion interval of 1120-1260 ^o C and at this temperature, the following isothermal exposure is carried out, it is carried out at a hardening temperature of the pyroplastic state of the material for 20-110 min, while the temperature of the expansion interval is reduced at a speed of 2.0-3.0 ^o C / min, and after controlled cooling at a temperature annealing 400-1000 ^o C conduct isothermal exposure for 10-60 minutes and switch to active uncontrolled cooling, after which receive porous ceramic "Redoxide" in the following ratio of components, wt.%:
Silica - 30 - 65
Iron oxide - 4 - 8
Alumina - 14 - 21
Alkali metal oxides - 2 - 6
Other products on ignition - Other
with interconnected open surface and deep pores with a diameter of <20 mm and a total porosity of 77-95%.

 In addition, in the high-temperature zones of the working channel of the heat generating unit and the zone of controlled cooling, an inert medium is created by feeding nitrogen or inert gases into the zones, such as argon or xenon, or neon.

 In addition, voids in porous ceramics "Redoxide" and on its periphery are created in the form of through holes with a diameter of 40-60 mm and a total volume of 55-60% by machining on drilling and milling machines or special devices installed in the molding tank.

 At the same time, lignin or bauxite sludge, or sludge sludge from sewage treatment plants are used as plasticizing additives.

A new technological line for the production of porous ceramics "Redoxide", containing a clay pellet preparation workshop installed during the technological process, connected by an elevator to a feed hopper of a metering station with a belt feeder and a metering unit, functionally connected to the granule loading station in the molding tank, the heat generator in in the form of a kiln with a power metal frame and a foundation, while the metal frame is lined with a lining with the formation of walls, a vault, a hearth and a working channel with zones of preheating, firing, high-temperature isothermal holdings, cooling, a system for moving granules in molding containers inside the working channel, energy carriers and automation and communication systems, a material discharge station onto pallets connected by a conveyor to a molding containers preparation station, the output of which is connected by a return transport connection with the entrance to the post loading granules in containers for molding and the warehouse of finished products, equipped with a post for machining products, which its input the house is connected by a conveyor to the post for unloading material on pallets, and the exit to a warehouse for finished products, the cooling zone of the working channel of the kiln is divided into the zone of controlled cooling and the zone of active cooling, energy carriers are installed in pairs in the walls or on the walls of the working channel in the areas of preheating, burning and high-temperature isothermal extracts, and the ratio of the lengths of the zones along the axial line to their internal width at the same working height of the kiln is assumed to be
L _I / B = 2.9 ^° C 3.3; L _II / B = 10 ^° C 11.2; L _III / B = 2.9 ^° C 3.3; L _IV / B = 5.2 ^° C; 6.2; L _V / B = 12.0 ^o C 14.0,
where L _I is the axial length of the first preheating zone;
L _II is the length along the axial lines of the second firing zone;
L _III - the length along the axial line of the third zone of high-temperature isothermal extracts;
L _IV is the axial length of the fourth zone of controlled cooling;
L _V is the length along the centerline of the fifth active cooling zone;
In - the internal width of the first, second, third, fourth and fifth zones of the working channel.

In addition, the lining of the kiln in the first, second, third and fourth zones of the working channel is multilayered and consists of three layers in the furnace walls, the first layer closest to the maximum temperatures made of fireclay bricks / SB /, the second of lightweight fireclay / ШД / and the third - from foam-diatom brick / ПД / with the ratio of the thickness of the first layer to the subsequent layer thicknesses equal to ШБ: ШЛ: ПД = 1: / 0.4 ^o C0.6 /: / 0.4 ^o C0.6 /, respectively , in the arch of the furnace - from three layers, and the first layer closest to the maximum temperatures is made of SB, Torah - of mullite wool / MKRV / and third - TP at a ratio of thickness of the first layer to a subsequent layer thicknesses equal SB: MKRV: PD = ^{1: / 10,0 o C13,0 /: /} 1,5 o C2,5 / respectively, and in the hearth of the furnace - from four layers, the first layer closest to the maximum temperatures is made of SB, the second is made of SL, the third is made of PD, and the fourth is made of MCRV with the ratio of the thickness of the first layer to the subsequent layer thicknesses, equal to WB: WL: PD: MKRV = 1: / 0.4 ^o C0.6 /: / 0.4 ^o C0.6 /: / 1.0 ^o C2.2 /, respectively, and in the fifth zone the lining is made of a single layer of SB.

 In addition, silicon-carbide electric heaters or gas burners or solar fuel with draft blowers are installed in the kiln as energy carriers, and the furnace is equipped with an air curtain device or mechanical partitions - gates, a device for creating an air-hydraulic curtain, and a system for creating an inert environment in high-temperature zones and controlled cooling zone, while the devices for the air curtain or the mechanical partitions of the gate are installed between at the exit of the first preheating zone and the entrance to the second firing zone, as well as between the exit of the third zone of high temperature shutter speeds and the entrance to the fourth zone of controlled cooling of the working channel, a device for creating an air-hydraulic curtain is installed between the exit of the fourth zone of controlled cooling and the entrance to the fifth zone of active cooling working channel, and a system for creating an inert medium in high-temperature zones and a controlled cooling zone is installed near the kiln and made in the form of cylinders with an inert medium and pipelines connected to closed cavities made in the hearth or foundation with gas-permeable screens in high-temperature zones of controlled cooling of the kiln.

 In this case, the kiln is made tunnel or ring, or chamber.

 In addition, the tunnel kiln is equipped with a jumper and a freewheel inside the kiln working channel, rails are installed in the jumper and a freewheel for molding containers made in the form of carts or carts with extended sides, and the fifth zone of active cooling is located in the working channel of the furnace or in the jumper and overtaking path, and the system for moving granules in the working channel of the furnace, in the jumper and overtaking path is made in the form of hydraulic pushers or gearboxes with chain conveyors and an electric drive, which matured installed at the entrance of the first working zone in the furnace channel post loading and mutually perpendicular end faces jumper movable trolleys or carts forms with accrued boards in the working channel of the furnace, the lintel and overtaking path.

 In addition, the annular furnace is made with a rotating hearth, the system for moving the granules in the working channel of the furnace is made in the form of an electric drive and a reducer, while the electric drive is mounted on a foundation under the hearth of the furnace and connected to it through a reducer.

 Moreover, the chamber furnace is equipped with turntables installed in the areas of high-temperature isothermal shutter speeds and controlled cooling, and hydraulic pushers are installed with the possibility of moving carts with molds or carts with extended sides in all areas of the chamber furnace and in the workshop for preparing granules and at the post of stripping molds or carts with extended sides.

The set of essential features presented above is aimed at achieving a technical result and is in a causal relationship with it, because allows
to increase the reliability of output for biofilters with the required parameters for deep biological wastewater treatment and reduce the percentage of rejection, because the selected modes in the first preheating zone of the initial granules prevent them from breaking from internal stresses, and the measures introduced in the third zone of high-temperature holdings and the separation of the cooling zone into a controlled and active cooling zone with the selected modes prevent glazing of surface pores that opened during swelling in the Redoxide material;
to increase the strength and hardness of the material for biofilters and use it as a self-supporting building material, which is especially important when using biofilters for treatment facilities with artificial aeration;
reduce energy and financial costs, as the number of rejected products is significantly reduced, and the life of equipment and containers for molding is increased.

 In addition, the invention is industrially applicable, because can be used for the manufacture of ceramic products.

 Thus, we can conclude that the invention meets the conditions of patentability of the invention.

 Figure 1 shows the optimal schedule of firing granules from clay raw materials of the Eldiginsky quarry of the Moscow region in containers of heat-resistant steel for forming a volumetric load for biofilters in the form of blocks 400 • 250 • 200 mm of porous ceramic "Redoxide"; figure 2 is an optimal schedule of firing granules for flat loading for biofilters in the form of plates 500 • 500 • 50 mm of porous ceramics "Redoxide"; figure 3 is a graph of the firing of granules from expanded clay clays according to the prototype; figure 4 is a General view of the production line for the manufacture of porous ceramics "Redoxide" with a heat generator in the form of a kiln tunnel with a bypass; figure 5 is a view along arrow D in figure 4; in FIG. 6 - section aa in figure 4; Fig.7 is a section bB in Fig.4; on Fig is a General view in plan of the production line for the manufacture of porous ceramics "Redoxide" with a heat generator in the form of an annular furnace with a rotating hearth; figure 9 is a section bb in Fig; figure 10 is a General view in plan of the production line for the manufacture of porous ceramic "Redoxide" with a heat unit in the form of a chamber furnace; in FIG. 11 - section GG in figure 10.

 A method of manufacturing a porous ceramic "Redoxide" is as follows.

 At the initial stage of the manufacture of porous ceramics "Redoxide", initial clay raw materials are brought from the quarry, using claydite clay with a shale layered structure in color from dark gray to black, and plasticizing additives. The chemical composition of clay raw materials from the Eldiginsky quarry, determined by the method of x-ray phase analysis (XRD), are given in table. 1. The sand-aleurite fraction of the raw material is represented mainly by rolled and angularly-rounded form of quartz grains. The clay part of the rock is represented by hydromica flakes, montmorillonite aggregates and kaolinite particles.

 The method of thermomechanical analysis / TMA / determines the temperature of expansion, and also using the thermomechanical analyzer TMA-1 of the company "Rigaki" (Japan) determine the hardening temperature of the pyroplastic state of the material (clay).

 Then, granules with a diameter of 8-16 mm are made from clay raw materials by plastic molding and dried to 2-4% moisture. After that, the granules are dosed to fractions of 8, 10 and 12 mm and layered in layers in containers for formation with a height of 8-80 mm. The height of the granule formation is determined by the type of loading (volumetric or flat) for biological filters and the coefficient of expansion. The loaded granules in the molding vessel are transferred to a heat generator in which the granules are fired. Firing modes for specific examples of the method for various types of finished products and the prototype are given in table. 2 and 3.

 Figure 1 and 2 presents the best options for examples of the firing mode of the proposed method; figure 3 - according to the prototype.

 After firing and cooling, the manufactured redox porous ceramic is removed from the molding container and machined.

The result of this technology is porous-hollow ceramics "Redoxide" in the following ratio of components, wt.%:
Silica - 30 - 65
Iron oxide - 4 - 8
Alumina - 14 - 21
Alkali metal oxides - 2 - 6
Other products on ignition - Other
with interconnected open surface and deep pores with a diameter of ≤20 mm and a total porosity of 77-95%, as well as through holes with a diameter of 40-60 mm in the center and around the periphery with a total volume of 55-60%.

Example 1. The initial clay raw material is represented by the Eldiginskoye deposit of the Moscow region, its third section in depth. The content of oxides, wt. %: silicon 64.26; iron 5.98; aluminum 14.33; alkali metals 5.56; other components of 9.87, which include a plasticizing additive, lignin 0.05. The name of the group of clay raw materials: in terms of alumina content - semi-acid, in terms of plasticity - 12.4, i.e. moderately ductile (average), in terms of refractoriness 1200-1210 ^o C, i.e. fusible. Granules from clay raw materials are dispensed to fractions of 10 mm, dried to 3% moisture and layered layer by layer with a layer 70 mm high in a container for molding (mold) with dimensions 450 • 250 • 210 mm made of heat-resistant steel. In the forms, special devices are provided for the formation in the center of the volumetric loading (block) for biofilters of porous ceramic "Redoxide" of two vertical holes with a diameter of 60 mm, and along its periphery in the vertical plane of eight through channels in the form of a half cylinder of the same diameter, as well as floating covers serving as a load for the pellets during their expansion. The firing of granules laid in the molds is carried out in a heat generator in the form of a pilot industrial tunnel electric furnace (TEC) with a capacity of 2500 m ³ per year in the following order. In the preheating zone in the heat generator, the granules bed is first heated to 220 ^° C at a rate of 2.0 ^° C / min and isothermal exposure is carried out for 30 minutes at this temperature, preventing the granules from breaking from large internal stresses due to the predominance of stages of predominantly convective heat transfer and excluding the complete dehydration of the granules. Then the heating rate in the firing zone is increased to 30 ^o C / min with the application of thermal shock to the temperature of the lower boundary of the beginning of the expansion of the granules. The heating rate at this stage is limited by the amount of decomposition of aluminum-containing complexes in the original clay. Below the boundary of the beginning of swelling of the granules - / ≈ 1100 ^o C / in the firing zone of the heat generator, the following isothermal exposure is performed until the temperature is equalized to the height of the granule layer for 20 minutes. After this, the granules are porized by raising the temperature to the middle of the expansion interval of 1150 ^° C, and at this temperature the following isothermal exposure is carried out for 110 minutes. With this isothermal exposure, sintered granules are sintered directionally from the surface of the Redox porous ceramic to the center with a minimum temperature difference in the center of the granule layer and on the surface by filling the intergranular space. This process is carried out without the formation of a low viscosity melt, because pores at this time are combined into large and isolated. The next isothermal exposure is carried out at the hardening temperature of the pyroplastic state of the porous Redox ceramic for 60 minutes, while the temperature is lowered from the expansion interval at a speed of 2.0 ^° C / min and the temperature is equalized over the entire volume of the Redox porous ceramic blocks. Then, the Redox porous ceramic molds are transferred to the controlled cooling zone, the high-temperature isothermal holding zone is separated from the controlled cooling zone by a partition with a gate, the temperature is intensively reduced to 1000 ^o C in 10 minutes, and at this temperature the next isothermal holding is carried out until the temperature is equalized throughout the volume of porous ceramics "Redoxide" for 40 minutes After this, the porous redox ceramic molds enter the zone of active uncontrolled cooling, the inlet of which is separated by an air-hydraulic curtain from the outlet of the zone of controlled cooling, and the temperature is reduced to 80 ^o C in the zone of active cooling using air and water vapor for enhanced heat removal. From the cold part of the heat generator, containers for molding with finished porous ceramics are redistributed and sent, if necessary, for machining.

 Example 2. The initial clay raw material and the technology for preparing granules from it are the same as in example 1, but the firing and cooling modes, as well as the isothermal exposure modes are taken from the average values needed to obtain blocks of porous ceramic "Redoxide" with sizes 400x250x200 mm

In the preheating zone in the heat generator, the granule bed is first heated to 250 ^° C with a temperature rise rate of 2.2 ^° C / min, and isothermal exposure is carried out at this temperature for 60 minutes. Then, the heating rate in the firing zone is increased to 37.5 ^o C / min and the temperature is raised to the lower boundary of the beginning of the expansion of the pellets (or slightly below the border) in the firing zone of the heat generator, an industrial tunnel furnace with heat carriers in the form of electricity or gas, the following isothermal exposure for 30 minutes After this, granules are porized by raising the temperature 40 minutes before the middle of the expansion interval of 1180 ^° C, which is optimal for amorphization of this clay raw material and expansion of granules, and the next isothermal exposure is carried out at this temperature in the zone of high-temperature isothermal extracts of the heat generator for 75 minutes. After that, the temperature in this zone is reduced from the expansion interval at a rate of 2.5 ^o C / min to the hardening temperature of the pyroplastic state of the material and at this temperature the next isothermal exposure is performed for 90 minutes. Then, in the zone of controlled cooling of the heat generator, the temperature is reduced to 660 ^° C. in 30 minutes, and at this temperature the last isothermal exposure is carried out for 60 minutes. Moving the material into the zone of active cooling of the heat generator, reduce the temperature in it to 80 ^o C and maintain the material in this zone for 360 minutes.

This example for the initial clay raw materials from the Eldigi deposit of the Moscow region is optimal in terms of obtaining porous ceramics "Redoxide" with the required characteristics for wastewater treatment, namely
Bulk density, kg / m ³ - 200 - 240
Compressive Strength, MPa - Up to 1.0
Total porosity, vol.% - 77 - 95
Pore Size, mm - Up to 30
Pore nature - Pores of 6-20 mm in size with a complex developed inner surface predominate
Through holes, mm - 40 - 60
Voidness in the form of through holes with a total volume,% - 55 - 60
Water absorption - Up to 37%
Frost resistance, cycles - 100 or more,
The impact of salt solutions - a decrease in weight of not more than 8% / exceeds the requirements of SNIP /;
- exposure to acids - Reduction in weight of not more than 10% / exceeds the requirements of SNIP /;
Production defects,% - Not more than 10%
Example Z. The initial clay raw materials and the technology for producing granules are the same as in examples 1 and 2, but the firing and cooling modes, as well as the isothermal exposure modes, are taken at the maximum values necessary for producing blocks of porous Redox ceramic with sizes 400x250x200 mm

In the preheating zone of the heat generator, the granules bed is first heated to 280 ^° C with a temperature rise rate of 2.5 ^° C / min, and isothermal exposure is carried out at this temperature for 40 minutes. Then the heating rate in the firing zone is increased to 45 ^o C / min and the temperature is raised to the lower boundary of the beginning of the expansion of the pellets (or slightly below the border) in the firing zone of the heat generator, the next isothermal exposure is carried out for 40 minutes, after which the pellets are porous, raising the temperature to the middle of the expansion interval of 1210 ^o C and at this temperature carry out the next isothermal exposure in the zone of high-temperature isothermal extracts of the heat exchanger for 110 minutes The next isothermal exposure is carried out at the pyroplastic state of the porous Redox ceramic for 120 minutes, while the temperature is lowered from the expansion interval at a rate of 7.4 ^° C / min and the temperature is equalized over the entire volume of the Redox porous ceramic blocks. Then, the Redox porous ceramic molds are transferred to the controlled cooling zone, the high-temperature isothermal holding zone is separated from the controlled cooling zone by a partition with a gate, the temperature is intensively reduced to 400 ^o C in 50 minutes, and at this temperature the next isothermal holding is carried out until the temperature is equalized throughout the volume of porous ceramics "Redoxide" for 110 minutes After this, the Redox porous ceramic molds enter the zone of active uncontrolled cooling, the inlet of which is separated by an air-hydraulic curtain from the outlet of the zone of controlled cooling, and the temperature is reduced to 70 ^o C in the zone of active cooling using air and water vapor for enhanced heat removal. From the cold part of the heat generator, containers for molding with finished porous ceramics are redistributed and sent, if necessary, for machining.

Table 2 summarizes the modes for firing granules from black expanded clay clays and the modes for producing porous Redox ceramic in the form of 400x250x200 mm blocks of 1, 2, and 3 examples in heat-resistant steel tanks in a pilot industrial tunnel electric furnace (TEC) with a productivity of 2500 m ³ / year, and in FIG. 1 shows the optimal firing schedule (example 2).

Example 4. The initial clay raw materials are represented by the Eldiginskoye deposit of the Moscow region, the third section in depth. The oxide content and the name of the group of clay raw materials are the same as in example 1. Granules from clay raw materials are dispensed to a fraction of 8 mm, dried to 3% moisture and layered layer by layer with a height of 16 mm in a container for molding (mold) sizes 500 • 500 • x80 mm made of heat-resistant steel and covered with lids that act as weights for granules when they expand. The firing of pellets laid in the molds is carried out in a heat generator - a gas tunnel furnace of the PG-ZO type in the following sequence. In the preheating zone of the heat generator, first the pellet formation is heated to 220 ^° C at a speed of 2.0 ^° C / min and isothermal exposure is carried out for 40 minutes at this temperature, after which the heating rate in the calcination zone is increased to 30 ^° C / min s by applying thermal shock to the temperature of the lower boundary of the beginning of swelling of the granules. Below the boundary of the beginning of swelling of the granules (≈1100 ^o C) in the firing zone of the heat generator, the following isothermal exposure is performed until the temperature is equalized to the height of the granule layer for 10 minutes. After this, the granules are porized, raising the temperature to the middle of the expansion interval, and at this temperature the next isothermal exposure is carried out for 60 minutes. With this isothermal exposure, sintered granules are sintered directionally from the surface of the Redox porous ceramic to the center with a minimum temperature difference in the center of the granule layer and on the surface by filling the intergranular space. This process is carried out without the formation of a low viscosity melt, because the pores at this time are combined into large and isolated. The next isothermal exposure is carried out at the hardening temperature of the pyroplastic state of the porous Redox ceramic for 20 minutes, while the temperature is reduced from the expansion interval at a speed of 2.0 ^° C / min and the temperature is equalized over the entire volume of the Redox porous ceramic plates. Then, the Redox porous ceramic molds are transferred to the controlled cooling zone, the high-temperature isothermal holding zone is separated from the controlled cooling zone by a partition with a gate, the temperature is intensively reduced to 1000 ^o C in 10 minutes, and at this temperature the next isothermal holding is carried out until the temperature is equalized throughout the volume of porous ceramics "Redoxide" for 10 minutes After this, the Redox porous ceramic molds enter the zone of active uncontrolled cooling, the inlet of which is separated by an air-hydraulic curtain from the outlet of the zone of controlled cooling, and the temperature is reduced to 70 ^o C in the zone of active cooling using air and water vapor for enhanced heat removal. From the cold part of the heat generator, containers for molding with finished plates of porous ceramics are redistributed and sent, if necessary, for machining.

 Example 5. The initial clay raw material and the technology for preparing granules from it are the same as in example 4, but the firing and cooling modes, as well as the isothermal exposure modes are taken according to the average values necessary to obtain plates from porous Redox ceramic with dimensions 500x500x50 mm

In the preheating zone of the heat generator, the granules bed is first heated to 250 ^° C with a temperature rise rate of 2.2 ^° C / min and isothermal exposure is carried out at this temperature for 25 minutes. Then, the heating rate in the firing zone is increased to 37.5 ^o C / min and the temperature is raised to the lower boundary of the beginning of the expansion of the pellets and just below the temperature boundary of the expansion of the pellets, the following isothermal exposure is carried out in the firing zone of the heat generator for 20 minutes After this, granules are porized by raising the temperature 40 minutes before the middle of the expansion interval 1180 ^° C and the next isothermal exposure is carried out at this temperature in the zone of high-temperature isothermal extracts of the heat generator for 40 minutes. Then, the temperature in this zone is reduced from the expansion interval at a rate of 2.2 ^° C / min to the hardening temperature of the pyroplastic state of the material, and at this temperature the next isothermal exposure is carried out for 40 minutes. Then, in the zone of controlled cooling of the heat generator, the temperature is reduced to 600 ^° C. in 30 minutes, and at this temperature, the last isothermal exposure is carried out for 48 minutes. Moving the material into the zone of active uncontrolled cooling of the heat generator, reduce the temperature in it to 80 ^o C and maintain the material in this zone for 360 minutes. After active uncontrolled cooling, the Redox porous ceramic slabs in the molds go to the form stripping station, and then to the mechanical section, where, if necessary, holes with a diameter of 40-60 mm are drilled in the slabs on drilling and milling machines.

 This example is optimal for the manufacture of plates with dimensions 500x500x50 mm from porous ceramics "Redoxide". The characteristics of these plates are close to the characteristics of the blocks specified in example 2.

 Example 6. The initial clay raw material and the technology for preparing granules from it are the same as in example 4, but the firing and cooling modes, as well as the isothermal exposure modes, are taken according to the maximum parameters necessary for producing plates from porous Redox ceramic with dimensions 500x500x50 mm

The modes by zones of the heat generator are as follows:
in the zone of pre-heating the formation of granules to 280 ^o C, the temperature is raised at a speed of 2.8 ^o C / min, then at this temperature isothermal exposure for 10 minutes;
in the firing zone, the heating rate is 45 ^o C / min with raising the temperature to the lower boundary of the beginning of the expansion of the granules (≈1110 ^o C), the next isothermal exposure is carried out for 25 minutes, then the temperature is raised to the middle of the interval of expansion of the granules 1210 ^o C and the specified temperature is isothermal exposure for 20 minutes; the next isothermal exposure is carried out at a hardening temperature of the pyroplastic state of the material for 20 minutes at a rate of temperature decrease from 1210 ^o C of 2.5 ^o C / min;
in the zone of controlled cooling, reduce the temperature to 400 ^o C in 70 minutes and conduct isothermal exposure for 30 minutes;
in the zone of active uncontrolled cooling, reduce the temperature to 70 ^o C and maintain it for 360 minutes

 In the table. 3, the modes of firing granules from black expanded clay clays and obtaining porous ceramics “Redoxide” in the form of plates with sizes 500x500x50 mm according to examples 4-6 in containers of heat-resistant steel in a tunnel gas furnace of the PG-30 type are summarized, and Fig. 3 shows the optimal firing schedule (example 5).

 Examples 7 and 8. The initial clay raw materials are represented by the Eldiginsky deposit in the Moscow region, the third section in depth. The oxide content and the name of the group of clay raw materials are the same as in examples 1 and 4. The technology for the production of granules is similar. Granules are dispensed to fractions of 8 and 10 mm and laid in a reservoir in a container for molding 70 and 16 mm, respectively. The molds are made in sizes 450x250x210 and 500x500x70 mm from ordinary steels.

 When firing pellets in molds, scale formation plays a large role. To exclude scale formation, i.e. remove oxidation processes, examples 7 and 8 provide for the introduction into the high-temperature zones and the zone of controlled cooling of the working channel of a nitrogen or inert gas heat generator, which use argon or xenon, or neon.

 The introduction of nitrogen or inert gases has no effect on the modes of pellet firing to obtain blocks or plates. Scalding in the forms is not observed. The service life of molds from ordinary steels is similar to molds from heat-resistant steels. The cost of manufacturing blocks or plates of porous ceramics "Redoxide" is reduced by 20-30%.

 In the table. 4 shows the compositions of the porous ceramics "Redoxide" obtained in examples 1-8.

 The use of the material "Redoxide" on the example of blocks made from it is as follows.

Wastewater enters the biofilter collected from coarse porous hollow blocks from the expanded amorphized material Redox. On the developed surface of pores up to 20 mm in size, a biofilm with immobilized microorganisms is formed. To provide the biofilm with oxygen, through-holes are provided in the blocks through which the biofilm is naturally aerated. In the process of life, the biofilm microorganisms oxidize organic substances and ammonium nitrogen in the waste water being treated and restore the nitrates and nitrites formed in this process to molecular nitrogen. The dead biofilm is taken out by a stream of wastewater into a special chamber standing in the treatment plant after the biofilter, where it precipitates, which is periodically discharged into a special zone. Rinsing the filter load from the claimed material with a reverse flow of water for regeneration is not required, since suspended solids and dead biofilm are removed from the filtering zone by a stream of water and natural aeration with air
Example. They carry out the purification of a mixture of domestic and industrial / 10% / wastewater that has undergone primary sedimentation in a two-tier sedimentation tank of urban wastewater treatment plants, with the following characteristics, mg / l: suspended solids 87.0; COD 208.3; BOD ₅ 65; BOD ₂₀ 91.2; ammonia nitrogen 36.3; nitrites up to 0.34; nitrates up to 0.70; the total content of inorganic nitrogen is 36.5. The hydraulic load on the biofilters ranged from 2.0 to 47.3 m ³ // m ³ . day. Data on the effectiveness of wastewater treatment are given in table 5.

 A method of manufacturing porous ceramics "Redoxide" is being implemented in a production line for the manufacture of porous ceramics "Redoxide".

The production line for the production of porous ceramics "Redoxide" consists of a clay granule preparation workshop 1 installed during the technological process, including an elevator (not shown), a clay receiving hopper 2 with a cultivator 3, a box feeder hopper 4, a plate conveyor 5, three conveyors inclined belt 6, screw press 7 with an attachment for granulation 8, horizontal conveyor 9, dryer 10, hopper storage 11 dry granules with a dispenser (not shown), trolley 12 with molds 13 for loading granules, power frame 14 s a hydraulic pusher 15, of the furnace compartment 16, which includes, in the first embodiment, a tunnel electric furnace consisting of a foundation 17, on which a loading station 18 of granules is installed, equipped with a storage hopper 11, trolleys 12 with molds 13, a power metal frame 19 lined with a lining 20 s the formation of the working channel 20 from the walls 22, the arch 23 and the hearth 24 (Fig.6). In the working channel 21 in the course of the technological process (Fig. 4), the first preheating zone 25, the second firing zone 26, the third zone of high-temperature isothermal holdings 27, the fourth zone of controlled cooling 28 and the fifth zone of active uncontrolled cooling 29 are placed at the exit from the working channel 21 on the foundation 17 has a post of finished goods unloading, including a rail 30, forming a freewheel 31 with rotating circles 32, a stripping post 33 forms 13, a machining section 34 (Fig. 5 ) The ratio of the lengths of the zones along the axial line L ₁ , L ₂ , L ₃ , L ₄ and L ₅ to their internal width B at the same height from the hearth 24 to the arch 23 of the furnace is accepted
L ₁ / B = 2.9 ^° C; 3.3; L ₂ / B = 10 ^° C; 11.2; L ₃ / B = 2.9 ^° C; 3.3; L ₄ / B = 5.2 ^° C; 6.2; L ₅ / B = 12.0 ^o C14.0,
where: L ₁ , L ₂ , L ₃ , L ₄ , L ₅ - the length along the centerline of the first, second, third, fourth and fifth zones; B is the internal width of these zones.

 The energy sources in the tunnel kiln are made of silicon carbide electric heaters (KEN) 35, which are installed in special devices 36 near the walls 22. Lining 20 in the zones of preheating 25, firing 26, isothermal exposure 27 and controlled cooling 28 is layered and consists (figure 4 -7) in the walls of the furnace from three layers (Fig.6). The first layer of 37 walls 22, closest to maximum temperatures, is made of fireclay bricks (SB), the second 38 - of lightweight chamotte (SHL) and the third 39 - of foam diatom brick (PD). The arch 23 of the furnace consists of three layers (Fig. 7): the first layer 40 of the arch 23, which is closest to the maximum temperatures, is made of SB, the second 41 is made of mullite-siliceous wool (MKRV) and the third 42 is made of PD. Under the furnace, it consists of four layers (Fig. 7): the first layer 43 of the hearth 24, closest to the maximum temperatures is made of SB, the second 44 is made of SL, the third 45 is made of PD, the fourth 46 is made of MCR. The furnace also includes a device for creating an air curtain 47 (Fig. 4), installed along the process with the possibility of blocking the opening between the output of the third zone of isothermal shutter speeds 27 and the entrance to the fourth zone of controlled cooling 28, a device for creating an air-hydraulic curtain 48, installed between the output the fourth zone of controlled cooling 28 and the entrance to the fifth zone of active cooling 29, as well as an automation system in the form of instrumentation 49, a system for inert placement about gas in the form of cylinders 50 (Fig.6 and 7) with an annular pipe 51 (Fig.6) and formed in the hearth 24 of the high-temperature zones 26 and 27 and the controlled cooling zone 28 of a closed cavity with a gas-permeable screen (not shown) and a conveyor 58, connecting the formwork removal station 33 of the mold 13 and the machining section 34 with the preparation station (not shown) of the molding containers 13 and the loading station of 18 granules in the molding container 13.

 In the second alternative embodiment, the furnace for the manufacture of porous ceramics "Redoxide" for biological filters is made annular with a rotating hearth 24 (Figs. 8 and 9) and consists of a foundation 17, on which a granule loading station 18 is installed, a power metal frame 19, lined with a lining 20 with the formation of the working channel 21 from the walls 22, the arch 23 and the rotating hearth 24. In the working channel 21 in the course of the technological process, the first preheating zone 25, the second firing zone 26, and the third zone 27 are isothermally Extracts fourth controlled cooling area 28 and fifth area 29, active cooling. At the exit of the working channel 21, on the foundation 17, a finished product unloading station is installed, including a rail 30, a stripping post 33 of mold 13, a machining section 34 and a conveyor 58 connecting the stripping posts 33 and machining 34 with a preparation post (not shown) containers for molding 13 and a post of loading 18 granules in containers for molding 13. The ratio of the lengths of the zones L, determined by the development of the axial line of the annular hearth 24 to their width B, as well as the structural design of the lining 20, the power metal frame 19 pr nyaty same as for the embodiment of the tunnel kiln. The energy sources of the rotary hearth ring furnace 24 are made in the form of gas burners 52 with gas ducts 53 and air ducts 54. The rotary hearth ring furnace 24 also consists of a device for creating a jumper from the air curtain 47 installed between the exit of the third zone of isothermal shutter speeds 27 and the entrance to the fourth controlled cooling zone 28, a device for creating an air-hydraulic curtain 48 installed between the output of the fourth controlled cooling zone 28 and the entrance to the fifth active cooling zone 29, as well as technol cal equipment consisting of an electric motor 55, gear system 56, control system in the form of instrumentation (TRC) 49 and a system for placing an inert gas in a cylinder 50 with the annular conduit 51 (Figure 9).

 In a third alternative embodiment, the furnace for the manufacture of porous ceramics "Redoxide" for biological filters is made chamber (Figures 10 and 11) and consists of a foundation 17, on which a granule loading station 18 is installed, a power metal frame 19, lined with a lining 20 with the formation of a working channel 21 from the walls 22, the arch 23 and the hearth 24. In the working channel 21, in the course of the technological process, the first preheating zone 25, the second firing zone 26, the third zone of isothermal exposure 27, the fourth control zone are sequentially located cooling 28 and the fifth active cooling zone 29. At the entrance from the working channel 21, a base for unloading finished products is installed on the foundation 17, including a rail 30, a stripping post 33 forms 13, a machining section 34, and a conveyor 56 connecting the stripping posts 33 and machining 34 with a post for preparing (not shown) containers for molding 13 and a post for loading granules in containers for molding 13. The ratio of the lengths of the zones L to their width B, as well as the structural design of the lining 20 of the power metal frame 19 with They are similar to those for the tunnel kiln variant. The energy sources in the chamber furnace are made of silicon carbide electric heaters (KEN) 35, which are installed in special devices 36 near the walls 22. The lining 20 in the zones of preheating 25, firing 26, isothermal exposure 27 and controlled cooling 28 is multilayer and consists of (11 ) in the walls 22 and in the arch 23 of the furnace from three layers, and in the hearth 24 - from four layers, similar to those in the tunnel furnace. In a chamber furnace during the process between the exit from the preheating zone 25 and the entrance to the firing zone 26, between the exit from the zone of high-temperature isothermal extracts 27 and the entrance to the controlled cooling zone 28, as well as between the exit from the controlled cooling zone 28 and the entrance to the zone active uncontrolled cooling 29 installed mechanical shutters - gates 57. Part of the rail tracks 30 in the areas of high-temperature isothermal shutter speeds 27 and controlled cooling 28 is installed on rotary 32 ah, and in the area of these zones and the entrance of the preheating zone 25 has hydropushers 15 mounted on the power frame 14 (Figure 10). The chamber furnace also includes an automation system in the form of instrumentation (I&C) 49 and a system for placing inert gas in the form of cylinders 50 with annular pipelines 51 (Fig. 11), as well as a conveyor 58 connecting the formwork 33 and machining 34 s the post of preparation (not shown) of containers for molding 13 and the post of loading 18 granules into the container for molding 13.

 The technological line for the manufacture of porous ceramics "Redoxide" works as follows.

From the quarry or clay reserve of the black expanded clay clays, clay moves through the elevator (not shown) to workshop 1 for the preparation and manufacture of granules. At the first stage, the chemical composition of the clay raw material is determined in a laboratory (not shown), and the expansion temperature is determined by the method of thermomechanical analysis (TMA), and the hardening temperature of the pyroplastic state of the material of the initial clay raw material is determined using high-temperature thermomechanical analysis. Then the clay feed enters the receiving hopper 2 with a cultivator 3 and into the hopper of the box feeder 4, in which excess inclusions are removed from the clay feed. Through the conveyor 5, the lamellar clay is transferred to the first inclined belt conveyor 6 and fed to the screw press 7 with an attachment for granulation 8. From clay raw materials, granules with a diameter of 8.0 - 16 mm are made by plastic molding, which are then transported by horizontal conveyor 9 and the second inclined conveyor 6 go to dryer 10, where they are dried to 2-4% moisture. After that, the dry granules through the third inclined conveyor 6 fall into the storage hopper 11, in which they are dosed to fractions of 8, 10 and 12 mm, and then stacked in layers in molds 13 mounted on carts 12 located at the loading station for granules 18. Height layer loading granules in the form 13 is determined by the type of manufactured products from porous ceramics "Redox". Then the trolley 12 with molds 13 with granules using a hydraulic pusher 15 is moved to the furnace compartment 16 in its first pre-heating zone 25. In this zone of the furnace, the granule bed is heated to 220-280 ^o C at a speed of 2.0-2.5 ^o C / min and at this temperature carry out isothermal exposure for 10-80 minutes, depending on the dimensions of the manufactured products from porous ceramics "Redox". These modes are carried out by selecting the number of KEN 35 in this zone, while preventing the rupture of the granules from large internal stresses and eliminating the complete dehydration of the granules, because at this stage, the heating is mainly carried out due to convective heat transfer. Then, with a hydraulic pusher 15, the trolley 12 with molds 13 is moved to the second firing zone 26, the heating rate in this zone is increased to 30-50 ^° C / min by applying thermal shock to the temperature of the lower boundary of the beginning of the expansion of the granules. The heating rate at this stage is limited by the amount of decomposition of aluminum-containing complexes in the original clay. Below the boundary of the beginning of the swelling of the granules (≈ 1100 ^o C) in the second firing zone 26 of the furnace, the following isothermal exposure is performed until the temperature is equal to the height of the layer of granules for 10-40 minutes, depending on the dimensions of the manufactured products. After this, the granules are porized by moving the trolley 12 with molds 13 into the third zone of high-temperature isothermal extracts 27 and raising the temperature to the middle of the interval of expansion of the granules 1150-1210 ^o C and at this temperature the next isothermal exposure is carried out for 20-110 min depending on the dimensions manufactured products. With this isothermal exposure, sintered granules are sintered directionally from the surface of the Redox porous ceramic to the center with a minimum temperature difference in the center of the granule layer and on the surface by filling the intergranular space. This process is carried out without the formation of a low viscosity melt, because pores at this time are combined into large and isolated. The following isothermal exposure in the third zone of the furnace is carried out at a hardening temperature of the pyroplastic state of the porous Redox ceramic for 20-110 min, depending on the dimensions of the manufactured products, while lowering the temperature from the expansion interval at a speed of 2.0-3.0 ^o C / min and equalize the temperature throughout the volume of porous ceramics "Redoxide". The implementation of these firing modes and isothermal shutter speeds provide the selection of the number of KEN 35 and their placement in a special tool 36, as well as the design of the lining 20 of the working channel 21. Then the carts 12 with molds 13 and porous ceramic products "Redoxide" are moved to the fourth zone of controlled cooling 28 separate the zone of high-temperature isothermal extracts 27 from the controlled cooling zone 28 with an air curtain 47 or a shutter-gate 57, intensively reduce the temperature to 400 - 1000 ^o C for 10-15 minutes and at this temperature, another isothermal exposure is carried out until the temperature is equalized over the entire volume of the Redox porous ceramic product for 10-60 minutes. After that, carts 12 with molds 13 and porous ceramic products "Redoxide" enter the zone of active uncontrolled cooling 29, the inlet of which is separated by an air-hydraulic curtain 48 or a shutter with a gate 57 from the outlet of the controlled cooling zone, and the temperature is reduced to 80 ^o C in the zone of active cooling 29 are produced using air and water vapor for enhanced heat removal. From the cold part of the furnace, carts 12 with molds 13 and Redox porous ceramics are delivered via rail 30 to the stripping station 33 and, if necessary, to the machining section 34, and from there to the finished goods warehouse, and molding containers 13 via conveyor 58 moved to the post of preparation (not shown) containers for molding 13.

 The entire technological process for the manufacture of porous ceramics "Redoxide" is accompanied by an automation system in the form of instrumentation 49. In the manufacture of porous ceramics "Redoxide" in forms 13 of conventional steels, a system for placing inert gases in the form of cylinders 50 with an annular pipeline is provided 51 and formed in the hearth 24 of the high-temperature zones 26 and 27 and the controlled cooling zone 28 of a closed cavity with a gas permeable screen (not shown). Instead of a hydraulic pusher 15, ring furnaces with a rotary hearth 24 use technological equipment consisting of an electric motor 55 and a gear system 56 installed in the foundation 17. In chamber furnaces, as in tunnel furnaces, hydraulic pushers 15 are used, which are installed in three zones that provide continuous the process for moving carts 12 with molds 13 in the zones of the furnace compartment 16 and the preparatory workshop 1.

 Using the proposed method for the manufacture of porous ceramics "Redoxide" and a technological line for its implementation allows you to create high-performance biological filters that combine two simultaneously passing processes in wastewater treatment: oxidation of contaminants and the reduction of nitrates and nitrites into gaseous nitrogen.

 The oxidizing power of these filters is 5-6 times higher than the existing ones, which allows you to create compact treatment plants with improved quality and performance during cleaning, the cost of cleaning one cubic meter of contaminated water is reduced by 3-4 times compared to traditional treatment plants. The reliability of the production of the required Redox porous ceramic for biological filters is increased by 80-90%, the strength of the material is increased by 1.4-1.6 times, the hardness is 20-40%, the energy consumption for the manufacture of porous Redox ceramic is reduced by 1, 3-1.5 times.

Claims (10)

1. A method of manufacturing porous ceramics "Redoxide", including the determination of the expansion temperature, the range of expansion temperature and the hardening temperature of the pyroplastic state of the original clay, the preparation of granules from clay with a diameter of 8 16 mm, drying and dosage of granules, layering layers of granules in a molding container, heat treatment layers of granules in the areas of the working channel of the heat generator by pre-heating, applying thermal shock to the temperature of the beginning of expansion of the granules, the implementation of isothermal extracts in temperature range of expansion to ensure directional sintering of expanded granules from the surface of the porous ceramic "Redoxide" to the center with a minimum temperature difference in the center of the layer of granules and on the surface and at the solidification temperature of the pyroplastic melt, controlled cooling of the solidified melt to the annealing temperature with subsequent isothermal exposure and the implementation of active uncontrolled cooling at 70 80 ^o With the use of air and water vapor for enhanced heat removal and the excavation of the made porous ceramic "Redoxide" from the molding vessel, characterized in that the clay used is claydite clay with a shale structure in color from dark gray to black with plasticizing additives, the preparation of the granules is dried up to 2 4% humidity and layer by layer lay the formations in a molding container with a height of 8 80 mm, preheating is carried out to 220 280 ^o With a speed of 2.0 2.5 degrees / min and at this temperature isothermal exposure for 10 80 minutes, then apply thermal shock to the temperature of the beginning of expansion of the granules at a speed of 30 50 degrees / min with isothermal exposure at this temperature for 10 40 minutes, then raise the temperature to the expansion interval of 1120 1260 ^o C and at this temperature carry out the following isothermal exposure for 20 110 min, the next isothermal exposure is carried out at a hardening temperature of the pyroplastic state of the material for 20 110 min, while lowering the temperature from the expansion interval at a speed of 2 3 deg. / min, and after controlled cooling at an annealing temperature of 400 1000 ^o C spend isothermal exposure for 10 to 60 minutes and switch to active uncontrolled cooling, after which receive porous ceramic "Redoxide" in the following ratio of components, wt. Silica 30 65
Iron oxide 4 8
Alumina 14 21
Alkali metal oxides 2 6
Other products on ignition
with interconnected open surfaces and deep pores with a diameter of up to 20 mm and a total porosity of 77 95%
2. The method according to p. 1, characterized in that in the high-temperature zones of the working channel of the heat generating unit and the zone of controlled cooling, an inert medium is created by feeding nitrogen or inert gases into the zones, for which argon, or xenon, or neon are used.  3. The method according to PP. 1 and 2, characterized in that the voids in the porous ceramics "Redoxide" and around its periphery are created in the form of through holes with a diameter of 40-60 mm with a total volume of 55-60% by machining on drilling and milling machines or special devices installed in the tank for molding.  4. The method according to PP. 1 to 3, characterized in that as plasticizing additives use lignin, or bauxite sludge, or silt sludge treatment plants. 5. Production line for the production of porous ceramics "Redoxide", containing a clay pellet preparation workshop installed during the technological process, connected by an elevator to a feed hopper of a batching station with a belt feeder and a batcher functionally connected to the station for loading granules into a molding tank, a heat unit in the form of a kiln with a power metal frame and a foundation, while the metal frame is lined with lining with the formation of walls, a vault, a hearth and a working channel from the zone and pre-heating, firing, high-temperature isothermal holdings, cooling, a system for moving granules in molding containers inside the working channel, energy carriers and automation and communication systems, a material unloading station on pallets connected by a conveyor to a molding containers preparation station, the output of which is connected by a return transport connection with the entrance of the post loading granules in containers for molding, and a warehouse of finished products, characterized in that it is equipped with a post for machining products II, which is connected via its inlet to the conveyor for unloading material onto pallets and the outlet to the finished goods warehouse, the cooling zone of the working channel of the kiln is divided into a zone of controlled cooling and an active cooling zone, energy carriers are installed in pairs in the walls or on the walls of the working channel in the preliminary zones heating, firing and high-temperature isothermal extracts, and the ratio of the lengths of the zones along the axial line to their internal width at the same working height of the kiln is assumed to be
L _I / B 2.9 3.3;
L _{I I} / B 10 11.2;
L _{I I I} / B 2.9 3.3;
L _{I V} / B 5.2 6.2;
L _V / B 12 14,
where L _I is the axial length of the first preheating zone;
L _{I I} centerline length of the second firing zone;
L _{I I I} the axial length of the third zone of high-temperature isothermal extracts;
L _{I V} is the centerline length of the fourth controlled cooling zone;
L _V is the centerline length of the fifth active cooling zone;
B is the internal width of the first, second, third, fourth and fifth zones of the working channel.  6. The line according to claim 5, characterized in that the lining of the kiln in the first, second, third and fourth zones of the working channel is multilayered and consists of three layers in the furnace walls, the first layer closest to the maximum temperatures being made of fireclay brick (ШБ), the second of lightweight chamotte (ШЛ) and the third of the foam diatom brick (ПД) with the ratio of the thickness of the first layer to the subsequent layer thicknesses equal to ШБ ШЛ ПД 1 0.4 0.6 0.4 0.6, respectively, in the code three-layer furnaces, with the first layer closest to the maximum temperatures in full of WB, the second of mullite-siliceous wool (MCW) and the third of AP with a ratio of the thickness of the first layer to subsequent layer thicknesses equal to WB MKRV PD 1 10.0 13.0 1.5 2.5, respectively, and in the hearth of the furnace of four layers, and the first layer closest to the maximum temperatures is made of SB, the second of HL, the third of PD and the fourth of MKRV with a ratio of the thickness of the first layer to subsequent layer thicknesses equal to SB SB SL PD MKRV 1 0.4 0.6 0, 4 0.6 1 2.2, respectively, and in the fifth zone, the lining is made of a single layer of SB.  7. The line for PP. 5 and 6, characterized in that in the kiln, silicon carbide electric heaters or gas burners, or on solar fuel with draft blowers, are installed as energy carriers, and the kiln is equipped with air curtain devices or mechanical shutter baffles, a device for creating an air-hydraulic curtain , as well as a system for creating an inert atmosphere in high-temperature zones and a controlled cooling zone, while devices for an air curtain or mechanical partitions gates are installed between the exit of the first preheating zone and the entrance to the second firing zone, and also between the exit of the third zone of high-temperature isothermal extracts and the entrance to the fourth zone of controlled cooling of the working channel, a device for creating an air-hydraulic curtain is installed between the exit of the fourth zone of controlled cooling and the entrance to the fifth an active cooling zone of the working channel, and a system for creating an inert medium in high-temperature zones and a controlled cooling zone is installed detecting near the kiln and is in the form of cylinders with an inert medium and the pipelines connected to the hearth or formed in the foundation closed cavities with gas-permeable screens in high-temperature zones and the zone controlled cooling of the kiln.  8. The line for PP. 4 to 7, characterized in that the kiln is made tunnel, or ring, or chamber.  9. The line for PP. 4 to 8, characterized in that the tunnel furnace is equipped with a jumper and overtaking path, rails are installed inside the working channel of the furnace, in the jumper and overtaking path, for molding containers made in the form of molds mounted on trolleys or trolleys with extended sides, while the fifth the active cooling zone is located in the working channel of the furnace or in the jumper and overtaking path, and the system for moving granules in the working channel of the furnace, in the jumper and overtaking path is made in the form of hydraulic pushers or gearboxes with chain conveyors and electric roprivodami that are installed at the entrance of the first working zone of the furnace channel at the post loading and mutually perpendicular end faces jumper movable trolleys or carts forms with accrued boards in the working channel of the furnace, the lintel and overtaking path.  10. The line for PP. 4 to 8, characterized in that the annular furnace is made with a rotating hearth, the system for moving the granules in the working channel of the furnace is made in the form of an electric drive and a gearbox, while the electric drive is mounted on a foundation under the hearth of the furnace and connected to it through a gearbox.  11. The line in paragraphs. 4 to 8, characterized in that the chamber furnace is equipped with turntables installed in the areas of high-temperature isothermal shutter speeds and controlled cooling, and the hydraulic pushers are installed with the possibility of moving carts with molds or carts with extended sides in all areas of the chamber furnace and in the workshop for the preparation of granules and at the post formwork of trolleys or trolleys with extended sides.

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