RU2348590C1 - Method of production of semidry pressed brick, processing line for its manufacturing and presser bar for this line - Google Patents

Abstract

FIELD: construction.

SUBSTANCE: method of production of semidry pressed brick includes clay crushing with separation of particulate matter; placing crushed clay into the disintegration type mixer, milling and intermixing, compressing of piecework with over one cycle heat treatment. Crushed clay is loaded into the disintegration type mixer along with fuel additives. Milled and mixed in the disintegration type mixer batch mixture is sent for drying into the drying chamber with simultaneous removal of air and moisture. After drying hot batch mixture is placed for the secondary crushing into air - tight cutting machine - activator. Processing line for manufacturing of semidry pressed brick contains arranged in technological sequence clay receiver, equipment for cutting and drying of clay mixture, presser bar, brick burning device, transfer mechanisms. Processing line additionally contains a disintegration type mixer. Presser bar for the processing line of brick manufacture contains bearing columns, rigidly fixed by upper and bottom - ends transverse members, hydraulic cylinder for moving of the press mold, top and bottom male cores.

EFFECT: reduction of power consumption and improved quality of the produced brick.

3 cl, 9 dwg

Description

The invention relates to the building materials industry, namely for the manufacture of bricks by the method of semi-dry pressing.

Closest to the proposed method for the manufacture of bricks is the method protected by RF patent No. 2126371, IPC 6 С04В 33/00.

The method consists in preparing a pressing mass, including grinding clay with the separation of mechanical impurities, drying, grinding, mixing and moisturizing, pressing products from the resulting mass and their subsequent heat treatment. After grinding, quarry clay is placed in a disintegrator type mixer for simultaneous grinding, mixing, drying or wetting to a pressing humidity. The pressed products are subjected to a closed cycle heat treatment for 3.5–4 hours, as a result of which the products are dried at a temperature of 105–110 ° С with a directed flow of a hot air medium, secreted by products calcined at a temperature of 400–700 ° С, and cooled with water vapors formed during drying, together with water vapor containing carbon monoxide, formed during the firing of products.

The disadvantages of the method are:

- low quality of brick manufacturing and reduced reliability of the equipment due to the fact that the firing chamber, cooling chamber and the brick itself experience sharp thermal shock when the brick is moved from chamber to chamber; in addition, the temperature of 400-700 ° C is insufficient for firing, and the time of 3.5-4 hours is insufficient for heat treatment of the mass of bricks laid on the trolley, since there is underheating of the inner layers of the brick laying, which leads to a decrease in the quality of its manufacture;

- the complexity and cumbersome design of a disintegrator type mixer that converts the kinetic energy of oncoming clay streams into thermal energy to remove moisture from it, which complicates the creation of a line of high productivity;

- increased energy costs due to heat loss due to evaporation of moisture from clay, which is removed to the atmosphere in the form of steam;

- increasing the complexity associated with additional costs for laying raw on carts.

The closest technological line to the proposed one is a line for the manufacture of ceramic bricks (RF patent No. 2131808, IPC 6 V28B 15/00), containing an clay receiver located in the technological sequence, equipment for grinding and drying clay mass, a press, brick firing devices, transfer conveyors, wherein the grinding and drying equipment is designed as a drying drum mills, processing and refining coarse fraction clay mass to press powder with a specific surface area of 1500-2500 cm ² / g and mind reducing the humidity of the mass as a result of drying of the brick firing zones by an overheated gas-air medium, the press is made with the possibility of pressing under pressure of 50.0-60.0 MPa, the firing device is made in the form of vertical shaft furnaces with elevators-reducers to move the brick from the place of cage to the lower zone and for block selection of finished bricks in the lower zones of furnaces and moving to the finished goods warehouse.

The disadvantages of this production line are:

- heat loss spent on the evaporation of moisture from clay in the form of steam, which is removed into the atmosphere;

- the large dimensions of the equipment due to the combination of high shaft furnaces and the dryer drum of a large mill;

- the high complexity of the brick stacking in the furnace due to the fact that the brick moves through the shaft furnaces in the form of a column of special laying, which makes increased demands on the brick stacking in the furnace;

- long time for heat treatment of products, as they are stacked in the form of a vertical column.

The closest technical solution to the proposed press is a vertical hydraulic three-position turret press K-150 (Nadein AA "Mechanical equipment for the production of building ceramics", NGASU, 2002, p.136-138). The press has a periodically rotating table worn on one of the three columns and resting on a ball bearing. The columns are rigidly connected to each other by the upper and lower crossbars. Three floating molds are mounted on the table. A stamp is rigidly fixed to the upper cross member, and a cylinder with a piston having a heel abuts during pressing against the lower movable stamp is mounted in the lower cross member. The stamp is in a "floating" mold, rotating with the table and keeping from falling out on the shoulders. The table rotation drive, providing a rotation of 120 °, consists of a hydraulic cylinder, a ratchet mechanism, gears and a gear rack mounted on a bracket. Braking and fixing the table at the end of the turn is carried out using a spring brake and a stopper.

The disadvantages of this press are:

- the complexity of the design associated with the complexity of the mechanism of the rotating table, consisting of a hydraulic cylinder, ratchet mechanism, gears and gear rack, as well as the complexity of the loading mechanism of the press powder, consisting of a slide feeder and hydraulic cutter;

- insufficiently high quality of pressing due to the presence of air in the pressed powder.

The objective of the invention is to reduce energy consumption and improve the quality of the manufactured brick.

The task according to the first aspect of the invention is achieved by the fact that in the method of manufacturing semi-dry pressed bricks, including crushing clay with the separation of mechanical impurities, placing crushed clay in a disintegrator type mixer, grinding and mixing, pressing piece products with heat treatment in a closed cycle, according to the invention, crushed clay is introduced into the disintegrator type mixer together with fuel additives, after grinding and mixing in the disintegrator mixer Ipa clay is sent for drying in the drying chamber with simultaneous removal of moisture and air, after drying, hot clay is placed for secondary grinding in an activator grinder without air access with simultaneous activation and mixing of the mixture to obtain a compression mass, piece products are pressed from the obtained hot clay mixture in the form of raw, which enter the heat treatment in the hot state.

The task according to the second aspect of the invention is achieved by the fact that in the production line for the manufacture of bricks by the method of semi-dry pressing, containing an clay receiver located in the technological sequence, equipment for grinding and drying the clay mass, a press, a device for brick firing, transfer devices, according to the invention, the production line is additionally contains a disintegrating type mixer located after the clay receiver; equipment for grinding and drying clay mass includes a regenerative and conductive drying device, an activator grinder and a device for heating the production line, including a fan and a heater; the brick firing device is made in the form of a regenerative furnace with conveyors vertically located inside it; transfer devices located between the drying device and the activator grinder and between the activator grinder and the press are sealed and insulated, and the transfer device located between the press and the furnace is insulated; the fan inlet is connected to the press hopper, the heater outlet is connected to the conveyor inlet located between the drying device and the activator chopper, and the heater inlet is connected to the fan outlet and by means of a steam line to the drying device.

The task according to the third aspect of the invention is achieved by the fact that in the press for a brick production line, comprising supporting columns rigidly connected by upper and lower crossbars, a hydraulic cylinder for moving the mold, upper and lower punches, according to the invention, a hydraulic cylinder for moving the mold connected with it with the possibility of its reciprocating movement together with guides along the rollers located on the supporting beam, rigidly connected with the bearing columns; the mold and the lower punch are interconnected through an additional hydraulic cylinder with the possibility of entering it into the cavity of the Shabot until the mold contacts the end face of the Shabot; the upper punch is associated with a vibrating or impact device rigidly mounted on the upper cross member with the possibility of vertical movement; a loading hopper is fixed on the supporting columns to fill the mold, on one side of which a slide is fixed, and on the other hand, a product removal plate; the lower cross member of the frame is installed on soundproofing beams, and between this crosspiece and the base of the scabbot a soundproofing pad is installed.

The inventive production line allows heat to be returned to the coolant during clay drying, heat return during the heat treatment of the products, activation of the pressing mass, airless pressing, single-row processing of the products in the furnace, the supply of already hot raw material to the heat treatment, to create a reducing, then oxidizing atmosphere in the product in its firing process. All this significantly reduces energy costs and improves the quality of the manufactured brick.

Figure 1 presents a schematic diagram of a technological line for the manufacture of bricks by the method of semi-dry pressing.

Figure 2 shows a front view of the press for pressing raw brick.

Figure 3 shows a longitudinal section of a press for pressing raw brick.

Figure 4 (a, b, c, d, e, e) shows the full cycle of the press.

A method of manufacturing a brick is as follows.

The quarry clay is first crushed, separating mechanical impurities, and then placed in a disintegrator type mixer, where fuel additives are fed. In the mixer disintegrator type is the preliminary grinding and mixing of the mixture. Coal in the amount of 0.5-3% by weight of clay can serve as a fuel additive. The resulting mixture is sent for drying in the drying chamber with the simultaneous removal of moisture and air. Air removal during drying occurs up to 0.5-1% of the amount of steam, and moisture removal - up to 8-9% of the total mass of the charge. A semi-dry mixture leaves the drying device, the space between the particles of which is filled with steam. After drying, the hot mixture is placed for secondary grinding in a grinder-activator without access of air with simultaneous activation and mixing of the mixture to obtain a compression mass. After secondary grinding, the particle size is less than 1 mm, and their grinding and activation occurs by counter flows, the speed of which reaches 150 m / s. Activation allows to reduce the effect of clay carbonates on the quality of products, improve the compressibility of the press powder, reduce the sintering temperature during heat treatment of the product by an average of 50 ° C, and increase the frost resistance of finished products. Piece hot products are pressed from the obtained hot clay mixture. The pressed products arrive in a hot state for heat treatment in a closed cycle. The drying and firing of the products is carried out in a furnace with vertically arranged conveyors in a favorable redox-vapor-gas atmosphere.

The method is implemented in the production line (figure 1). The technological line contains an clay receiver 1, a disintegrator type mixer 2, equipment for grinding and drying clay mass, which includes a regenerative and conductive drying chamber 3, an activator grinder 5, press 7, a device for heating the technological line, consisting of fan 10 and heater 11, regenerative kiln 9 for brick burning with conveyors vertically located inside it, transfer devices 4, 6, 8. Transfer devices 4 and 6 located between the drying device and the grinder-asset and chopper torus between the activator and the punch are sealed and heat-insulated, and the transfer device 8 arranged between the press 7 and the oven 9 - warmed. The fan inlet is connected to the press hopper, the heater outlet is connected to the conveyor inlet located between the drying device and the activator chopper, and the heater inlet is connected to the fan outlet and by means of a steam line to the drying device.

The technological line works as follows.

Clay raw materials are fed to clay receiver 1, where they are cleaned of stones and metal objects using standard equipment. Then the clay is fed into a standard disintegrator type mixer 2, where fuel additives are also fed. In the mixer disintegrator type is the preliminary grinding and mixing of the mixture. Then the mixture is sent for drying in the drying chamber 3 with the simultaneous removal of moisture and air. For these purposes, the device described in the application for invention No. 2007118122 "Method for drying bulk materials and a drying chamber for it" serves. The device has a sealed drying chamber, from which air is displaced during the drying of the charge and a vapor atmosphere is created. The drying chamber allows 2-2.5 times to reduce the cost of heat for drying the charge in comparison with conventional dryers. At the same time, hot water and a hot charge are obtained at the chamber exit. After exiting the pressurized chamber 3, the mixture flows through the pressurized conveyor 4 into the grinder-activator 5, in which fine grinding, mixing, and activation of the particles of the mixture occur. After exiting the pressurized grinder-activator, the press powder through the pressurized insulated conveyor 6 enters the hopper of the press 7. Moreover, the passage of the charge occurs through conveyors 4, 6, the grinder-activator and the hopper of the press, preheated with a fan and heater, and to displace air steam from the drying chamber 3 is used from these devices. Since the filling of the press mold occurs without air entering the press powder, before pressing the mixture contains a mixture of hot press cupboard and steam. In the process of pressing, the vapor condenses on the particles of the press powder, slightly increasing the temperature of the particles. Thus, raw brick comes out of the press, in the pores of which there is condensate and steam. In order to exclude intensive evaporation of moisture from the surface of hot raw material, it moves to the furnace 9 through insulated conveyors 8. This is necessary both to prevent cracking in the raw material and to prevent an increase in humidity in the production room. The brick is baked and fired in the kiln 9 described in the application for invention No. 2007104881 "Ceramic kiln". Since the moisture conductivity of hot raw materials is several times higher than the moisture conductivity of cold raw materials, and since time is not spent on heating, drying of raw materials in the furnace is significantly accelerated. Since fuel was introduced into the mixture at the first stage, in the process of firing, a reducing and then oxidizing atmosphere is created in the product. The reducing-oxidizing atmosphere positively affects the strength, frost resistance of clay products of various mineral compositions, and also reduces the sintering temperature of the product by 100-150 ° C, which positively affects the durability of the furnace parts, increases its productivity and economy.

In figure 2, 3 shows the press 7 included in the production line.

The press contains supporting columns 12, rigidly connected by the upper 13 and lower 14 cross members, a hydraulic cylinder 15 for moving the mold 16, the upper 17 and lower 18 punches. A hydraulic cylinder 15 for moving the mold is connected with it with the possibility of its reciprocating movement along with the guides 19 along the rollers 20 located on the supporting beam 21, rigidly connected with the supporting columns. The mold 16 and the lower punch 18 are interconnected through an additional hydraulic cylinder 22 with the possibility of entering it into the cavity of the Shabot 23 until the mold contacts the end face of the Shabot. The upper punch 17 is associated with a vibrating or impact device 24, rigidly mounted on the upper cross member 13 with the possibility of vertical movement. A loading hopper 25 is fixed on the supporting columns to fill the mold, on one side of which a slide 26 is fixed, and on the other hand is a product removal plate 27. The lower cross member 14 of the frame is mounted on soundproof bars 28. Between the lower cross member 14 and the base of the shutter 23 soundproof gasket 29.

Press works as follows.

The sequence of operations that make up the press cycle is shown in Fig. 4 (a, b, c, d, e, e). The initial state of the press is shown in figa. In this state, the mold 16 is located under the hopper 25, the upper 17 and lower 18 punch are in the highest position. The work cycle begins with loading the mold. In this case, the lower punch 17 with the help of the hydraulic cylinder 15 moves down to the depth of the backfill, and after it without the formation of voids comes press powder (figb). After filling, the mold with the help of the hydraulic cylinder 22 is moved to the shabot 23 under the upper punch (figv). In the process of pressing (Fig. 4d), the lower punch is lowered onto the shabot, and the upper punch enters the mold and compacts the press powder by vibrational or pulsed force. In the press powder, the vapor condenses on the surface of the particles of the press powder. The vapor-air mixture of the press powder contains less than 1% air, so the effect of air on the pressing process is minimal. After pressing, the upper punch takes its highest position. The lower punch using the hydraulic cylinder 15 pushes the pressed raw brick to the level of the removal plate 27 (Fig. 4e). After that, the mold together with the lower punch and the hydraulic cylinder 15 by means of the hydraulic cylinder 22 is moved to its original state with the finished product on the removal plate 27 (Fig. 4e). In this case, the raw material is delayed by a special emphasis and is shifted from the lower punch to the removal plate 27, which moves together with the mold. In the next cycle, the raw material moves with the removal plate and is above the raw material receiving conveyor 30. Then, when the mold moves to the initial state, the raw material is pushed from the removal plate onto the raw material receiving conveyor using a special shutter.

The invention in comparison with the known has the following advantages:

- reduction of energy consumption due to drying of clay with the possibility of returning heat from steam due to heat treatment in a compact furnace with oncoming movement of the brick rows, in which the heat from the heated brick is returned to the heated one, due to the full use of the heat of the exhaust gases by eliminating heat loss when switching to other operations due to the use of sealed and insulated conveyors;

- improving the quality of the manufactured brick due to high-quality grinding, mixing and activation of the press powder, as well as airless pressing of the raw material and single-row heat treatment of products in the furnace, which ensures uniform heating of the products;

- reduction of the dimensions of the equipment of the technological line;

- improvement of working conditions due to the absence of dust and gases;

- increase in labor productivity due to automation of the line.

Claims (3)

1. A method of manufacturing a semi-dry pressed brick, including crushing clay with the separation of mechanical impurities, placing crushed clay in a disintegrant type mixer, grinding and mixing, pressing closed-loop heat treated pieces, characterized in that the crushed clay is introduced into the disintegrating type mixer together with fuel additives, after grinding and mixing in a disintegrator type mixer, the resulting mixture is sent for drying in a drying chamber with simultaneous by removing moisture and air, after drying, the hot mixture is placed for secondary grinding in an activator grinder without access to air with simultaneous activation and mixing of the mixture to obtain a pressing mass, piece products in the form of raw material are pressed from the obtained hot clay mixture, which are sent to heat treatment in a hot state . 2. A production line for semi-dry pressing brick manufacturing, containing a clay receiver located in the technological sequence, equipment for grinding and drying the clay mass, a press, a brick firing device, transfer devices, characterized in that the production line further comprises a disintegrating type mixer located after clay receiver; equipment for grinding and drying clay mass includes a regenerative and conductive drying device, an activator grinder and a device for heating the production line, including a fan and a heater; the brick firing device is made in the form of a regenerative furnace with conveyors vertically located inside it; transfer devices located between the drying device and the activator grinder and between the activator grinder and the press are sealed and insulated, and the transfer device located between the press and the furnace is insulated; the fan inlet is connected to the press hopper, the heater outlet is connected to the conveyor inlet located between the drying device and the activator chopper, and the heater inlet is connected to the fan outlet and by means of a steam line to the drying device. 3. A press for a brick production line, comprising supporting columns rigidly connected by upper and lower crossbars, a hydraulic cylinder for moving the mold, upper and lower punches, characterized in that the hydraulic cylinder for moving the mold is connected with it with the possibility of its return - translational movement together with guides along the rollers located on the supporting beam, rigidly connected with the supporting columns; the mold and the lower punch are interconnected through an additional hydraulic cylinder with the possibility of entering it into the cavity of the Shabot until the mold contacts the end face of the Shabot; the upper punch is associated with a vibrating or impact device rigidly mounted on the upper cross member with the possibility of vertical movement; a loading hopper is fixed on the supporting columns to fill the mold, on one side of which a slide is fixed, and on the other hand, a product removal plate; the lower cross member of the frame is installed on soundproofing beams, and between this crosspiece and the base of the scabbot a soundproofing pad is installed.

Images