WO2007084023A1

WO2007084023A1 - Method for producing a flake material from a mineral melt, device for carrying out said method and a polymer composition filled with flake material for obtaining a protective barrier coating on different surfaces

Info

Publication number: WO2007084023A1
Application number: PCT/RU2006/000134
Authority: WO
Inventors: Dmitry Danilovich Dzhigiris; Aleksei Aleksandrovich Nicolaenko
Original assignee: Obschestvo S Organichennoi Otvestvennostyu 'bazaltoplastik'
Priority date: 2006-01-18
Filing date: 2006-03-22
Publication date: 2007-07-26
Also published as: RU2306325C1

Abstract

The inventive method for producing flake material consists in supplying a melt by gravity to a cup rotating with a speed of 2000-5000 m/sec, in mechanically agitating for 0.5-1.5 sec, in forming a thin layer by means of a centrifugal force whose acceleration jump at the exit from the cup is equal to 20-50 times, in cooling the material in the area of an annular blast with a pressure of 0.5-1.2 kg/cm 2 , in crushing a film , in collecting and dividing the flake mass. The inventive plant comprises a furnace used for preparing the melt and provided with a feeder, a draw hole feeding unit provided with an outlet opening , a film forming cup provided with a stepped annular slot embodied at the edge thereof, wherein the edge of the opening is outwardly deflected, an annular slot blow head, a crushing unit, a deposit chamber , a reception unit provided with a vacuum chamber arranged thereunder and dividing unit. The cup comprises an annular comb embodied in the form of a hollow ring provided with hollow downwardly oriented vertical fingers. The cavity of each finger is divided by means of a vertical partition. The film crushing unit is embodied in the form of a ring arranged concentrically with respect to the cup at the level of the deflected edge thereof to which regularly spaced vertical knives are fixed and positioned vertically to the film displacement direction, wherein the blades of the knives are turned at an angle of 10-20° with respect to the film direction of rotation: The polymer composition for producing a barrier protective coating comprises components with the following ratio: epoxy dian resin 32-41 mass %, 1-10 mass %dibutyl phthalate and/or aliphatic epoxy resin DEG.1, 4-6.5 mass % polyethylene polygamine hardener, 30-40 mass % andesite basalt flakes whose plate thickness ranges from 0.2 to o.7 mkm, when required 0-6 mass% aerosil, and 0-30 mass% organic solvent. Said invention makes it possible to increase yield, the homogeneity degree of flakes , the wearability of the coating, the chemical resistance thereof to aggressive media and to decrease the composition toxicity.

Description

A method of manufacturing a flake material from a mineral melt, a plant for its implementation and a polymer composition based on it.

DESCRIPTION

The invention relates to methods and devices for producing flake particles from natural minerals, in particular basalt flake particles, and also relates to the production of a protective barrier coating on various surfaces based on a polymer composition filled with such flake particles. In this case, we are talking about the claimed group of such inventions, which can be used for the production of glassy fillers used in enterprises of the chemical and electrical industries, building materials industry, ship and automotive industries, machine and aircraft industries, as well as other areas of the national economy and in particular upon receipt of protective coatings.

Prior art and description of known methods.

The use of highly silicate inorganic fibers, as well as scaly particles from natural materials of acidic rocks as raw materials, makes it possible to produce environmentally friendly, weather-resistant, replacing in many cases asbestos, glass,

SUBSTITUTE SHEET (RULE 26) metal, wood and other materials used in construction. Therefore, the need for these materials is increasing.

Mineral melt flake fillers are used both for applying thin-layer coatings to objects for various purposes in order to protect them from corrosion and abrasive wear, and in the manufacture of chemically resistant and durable composites, heat-insulating materials, roofing materials, paper and other products.

From RU 2105734, 02.27.1995, a method for producing superthin basalt fibers is known.

The method consists in the following: carry out the melting in an induction furnace of bulk material from basalt rocks at a temperature of 1950 - 2200 ° C. Then, the fibers are formed by blowing a vertical melt jet with an energy carrier jet in the blowing head, followed by deposition on the outlet container in the fiberization chamber, while lowering the temperature to 1450 - 1500 ⁰ C by feeding the melt on the cast-iron tray installed in front of the blowing head. The method provides high-quality fiber with a diameter of 0.1 - 22 mm, length up to 40 mm with a low content of non-fibrous inclusions. 2 ill. The method does not provide a flake material.

From RU 2211193, 08/27/2003, a method for producing mineral fiber, including basalt fiber, is known. The known invention solves the problem of creating a highly efficient and energy-saving method for producing mineral fibers with high operational parameters and a device for its implementation. The method of producing mineral fiber is to continuously feed the mixture into stabilized volume of a plasma reactor with a plasma temperature of up to 4000 ° C, followed by flow of the formed melt through a water-cooled tray into the battery volume (option 1), or in a metered supply of the charge into the melting volume of the reactor with ignition of the arc between the carbon electrodes by introducing a graphite track (option 2 ) Next, the melt enters the aerodynamic system of Laval nozzles, where it is blown, primary separation into fiber and solid metal oxides, grinding of solid oxides. After that, continuous circular cleaning of the obtained mineral fiber from crushed metal oxides in the fiber deposition chamber is carried out, as a result of which fiber is obtained up to 25 cm long, 4 to 7 μm in diameter, with a content of solid metal oxides of not more than May 4. % A device for producing mineral fiber contains an aerodynamic system consisting of a rotating with notches, mounted on plates, a circular disk, around the perimeter of which are Laval nozzles.

However, this method and device for its implementation also do not allow to obtain flake mineral material.

From US 3325263, 1967, a method for manufacturing flakes is known, comprising preparing a glass melt, forming separate melt streams under the influence of centrifugal force, forming a thin film of glass from melt streams thrown onto a fixed surface, when a thin layer of melt flows down under gravity, crushing the film compressed air in the zone of annular blasting on discrete flakes and their selection using rarefaction.

However, the known method is labor-intensive and material-intensive, and the obtained film is not sufficiently thin and uneven in thickness, while the flakes obtained as a result of random crushing of the film by compressed air are not identical in linear dimensions. From RU 2070166, 12/10/1996, a (installation) line for producing finely dispersed flocculent particles, mainly from a mineral melt, is known. The line works as follows.

As a source of raw materials use basalt gravel. From the hopper - feeder with the help of a conveyor - dispenser, the feedstock enters the melting furnace. In a melting furnace, basalt gravel is melted and then the melt is fed to a dispersion device. By means of pneumatic transport, flocculent particles (gray scales) obtained after dispersion enter the hopper - the accumulator of inactive particles. Then, from the storage hopper, particles are fed by a pneumatic conveyor to the flake particles activation furnace, where activation occurs at 700 - 800 ⁰ C. The activation furnace is designed for chemical-thermal treatment of basalt flakes in air. The activation furnace contains a feeder, a lined heating chamber with an electric heater in the lower part of the chamber, a drum with baffles for transporting and mixing the product located on supports in the heating chamber, loading and unloading heads, a drum drive, means for adjusting the angle of the drum, means for continuously feeding the product into the air environment and means of monitoring operational parameters and dust collection system.

Activated particles come from the furnace to a fine grinding mill, for example a spring mill. After the mill, fine particles enter the classifier, where they are divided into several fractions. From the classifier, lamellar flakes divided into fractions are fed by pneumatic transport to the bunkers - storage rings of finished products in the form of inactive lamellar flakes, for this the hopper-accumulator is connected by an additional pneumatic transport to additional bunkers - drives for collecting "gray garbage". From the storage bins, the activated flocculent particles separated into fractions are transferred from non-activated particles to a machine for packing the obtained powder. The line is equipped with a dust collection system, including a number of dust collectors, combined into a single closed circuit, which ensures environmentally friendly production of flocculent particles.

The process is quite long, the line itself is technologically complex.

From SU 1823293, 07.25.1995, a device for producing fine scaly particles is known. Mainly mineral, containing a receiver of molten mass with an electric motor, a casing, a spray placed in the casing, and cooling means, while it is equipped with a unit for vertical and horizontal movement of the spray made in the form of a horizontal beam placed on a rigidly mounted telescopic support with latches for positioning the beam wherein the beam is made with a groove to accommodate the telescopic support, the sprayer is mounted on one of the ends of the supporting beam and is made in the form of a turbine with an axis, steam a parallel axis of the supply of molten mass, an electric motor is installed at the other end of the carrier beam, and the cooling means is made in the form of an annular manifold for air supply with nozzles communicated by the casing cavity. In addition, it is equipped with interchangeable turbines with a different number of blades, and for the purpose of intensively removing flakes from the zone of the turbine, its base is made with two concentric channels having a parabolic profile.

However, this device, as well as the method carried out with its help, is also not without certain drawbacks: the device is quite difficult to perform, does not provide obtaining scaly particles of a uniform fractional composition. From GB 989671, 1965, a method for producing glass flakes from a thermoplastic material is known, comprising preparing a molten glass, forming separate streams from it under the action of centrifugal force, dropping them onto a fixed surface and forming a thin layer of melt when these streams move down, turning it when cooled to a glass film, crushing it with a stream of compressed air onto discrete flakes in the zone of annular blasting, depositing them and selecting them using rarefaction.

The disadvantage of this method of manufacturing flakes is its complexity, since the process of film formation proceeds in two stages: first, trickles of melt are formed, and then a film of them. In this case, the film turns out to be uneven in thickness, as a result of which the flakes formed during its crushing are also heterogeneous in thickness and, accordingly, in elasticity. In addition, the holes in the bowl through which the trickles of the melt exit under the action of its high temperature and pressure will gradually increase in diameter, which will eventually lead to an increase in the thickness of the trickles and, accordingly, the film. Moreover, with chaotic destruction of the film by a stream of compressed air, it is rather difficult to obtain flake material with predetermined linear sizes of flakes.

The disadvantage of this method is its increased material consumption.

From US 5017207, 1991, a method is known for manufacturing flakes of molten glass by feeding the latter by gravity in a downward direction to the inner surface of a rotating funnel, forming a thin layer of molten material on it under the action of centrifugal force, forcing this material to radially advance through a pair of parallel plates to keep it flat pulling it under vacuum with simultaneous cooling by air flow before the formation of the film and its destruction into discrete flakes with their subsequent deposition and separation into fractions in accordance with the mass and speed.

This method, as a one-stage process, is less labor-consuming and material-intensive, however it is also complicated, as the previous one, due to the need to stretch the molten material between the plates so that it does not touch their surfaces, does not roll and does not fold into folds.

The disadvantage of this method also relates to the fact that the size and thickness of the obtained glass flakes depend on many process parameters: the rotation speed of the surface to which the melt is fed, the temperature and viscosity of the melt, the distance of this surface from the annular parallel plates, the gap between the plates and their diameter, the amount of vacuum in the vacuum chamber. These parameters can vary widely, and they are all interconnected with each other. Therefore, the disadvantage of this known method is the difficulty in selecting the parameters necessary for the manufacture of glass flakes of a given size. Because of this, this method is not suitable for the industrial production of flake material.

From SU 1731746, 1992 there is also known a method closest to the claimed method according to the totality of the features of making flake material from a glass melt by feeding the melt by gravity in a downward direction into a truncated inverse cone, forming a thin layer of molten material on its inner surface under the action of centrifugal force, cooling it compressed air flow in the zone of annular blasting until a film is formed with simultaneous crushing of the latter into discrete flakes by an annular pulse flow of compressed air, collecting them under vacuum and cyclone separation of flake material into fractions according to the size of the mass and, accordingly, the speed of movement of the flakes.

This method of manufacturing flakes in comparison with the previous one is simpler and less material intensive, therefore it is used for the industrial production of flake material.

However, this method of manufacturing flakes does not allow maintaining the uniformity of the glass melt in temperature and viscosity when it is supplied from the feeder to the inner surface of the truncated inverse cone, since the outer layer of the melt jet gives off some of the heat to the environment. As a result of this, the film formed from it turns out to be uneven in thickness, and, consequently, the scales are obtained with different thicknesses. When exposed to a film by a pulsed stream of cold compressed air, it is randomly crushed into discrete flakes, as a result of which their surface areas are inhomogeneous in size. In addition, when the film is cooled during exposure to a stream of cold compressed air, brittleness increases and the elasticity of the resulting flakes decreases. In addition to the deterioration of the quality of the scaly material, environmental pollution by the flakes can occur, since when the film is crushed by a pulsed stream of compressed air under a pressure of 1.8-2.2 kg / cm ² , the flakes may escape from the flaking and deposition chambers.

A device for producing thin glass flakes is known from JP 59-21533, 1984, including a furnace for preparing molten glass with a feeder, a die feeder with an outlet, a mushroom-shaped element mounted for rotation around its axis, a slotted ring blower, and an assembly for collecting flakes under the effect of rarefaction.

The disadvantage of this device is that with an increase in the speed of rotation of the mushroom element to reduce the thickness films can melt away from its surface and, consequently, disrupt the process of its formation. Another disadvantage of the device is that when the film is drawn on the surface of the mushroom-shaped element, it rapidly cools, after which further thinning of the film stops. Therefore, the device has limited performance, and therefore the glass flakes made by this device are relatively thick. Moreover, they are also relatively large, since when crushing a thick film by a stream of compressed air, coarse-grained particles are obtained.

From GB 956832, 1964 A device is known for the manufacture of films and flakes of thermoplastic material, comprising a chamber with an annular dispensing outlet and two concentric side walls extending down from this chamber, a device for supplying a gas stream parallel to the inner wall, a pair of perforated rolls installed with the possibility of rotation towards each other, each of which includes two longitudinal cavities, one of them being under vacuum, and the other under pressure. The molten glass exiting the annular hole forms a continuous thin-walled cylinder by means of a gas flow, since the specified flow creates a certain temperature regime for the molten glass flowing from the chamber. A thin-walled cylinder is captured by perforated rolls, and due to their tight fit to each other, the thin walls of the cylinder break down and turn into shapeless flakes, which are sucked into the cavity under vacuum and are pushed out of the other cavity by a gas stream into the container. From the container, the finished flake material enters a cyclone device for separating the flakes into fractions. This device, created on the basis of the formation of a thin film in the form of a thin-walled cylinder and the mechanical destruction of the film using a cutting tool, in comparison with the previous device provides thinner and smaller flakes.

However, this device is also characterized by low productivity and does not provide the possibility of obtaining micro-thin flakes, since to create cylinders with micro-thin walls, it is necessary to create very high speeds for drawing them out of the melt, which is practically impossible. Another disadvantage of the device is the design complexity of the mechanical destruction unit of thin-walled cylinders, which is characterized by low productivity and high energy intensity, since mechanical destruction of flakes is accompanied by a relatively large energy consumption for rotating the rolls, creating a vacuum and increased pressure in the hollow chambers of the latter.

From SU 1772088, 10/30/1992, another installation for producing flake material from glass melt is known, comprising a furnace for preparing a melt with a feeder, a die feeder with an outlet, mounted under the die feeder with the possibility of rotation around its axis of the film-forming element in the form of a truncated cone, the input the hole is facing up, and the edge of the hole is radially bent outward, the mechanism of crushing the film into discrete flakes by an annular pulse stream of compressed air, a deposition chamber of flakes, p iemnoe device with a camera and the vacuum underneath the separation unit mass of scaly fractionated configured as a set of cyclones. In this case, the reverse truncated cone is made with an opening angle of 10 - 45 ° and truncating it at a distance equal to 1/3 - 1/2 of the height of the cone. This installation is more productive and more efficient than the above devices, but in the same way as they have a number of disadvantages.

The disadvantages of the installation are, first of all, the heterogeneity of the melt located in the film-forming element in temperature and viscosity and the low degree of amorphism of its structure, as a result of which a relatively thick and also non-uniform thickness film is obtained. Due to this, the scaly material obtained from this film contains thick and non-uniform thickness flakes. In addition, the installation’s disadvantages include too much depth of the truncated inverse cone, which increases the heat loss by the melt and accordingly reduces its viscosity. As a result, the process of extrusion of the melt from the cone and the formation of a thin film is disrupted, and this, in turn, worsens the quality of the flake material: the flakes are heterogeneous in thickness and have a reduced degree of elasticity. Such a scaly material is ineffective as a filler of coatings resistant to corrosion and abrasive wear. Another disadvantage of the installation is the ingress of flakes into the atmosphere during crushing of the film by a pulsed stream of compressed air, which leads to environmental degradation of production facilities.

All these known known methods for the production of flake mineral material and devices for their implementation are aimed at obtaining flake mineral material, for example, basalt flakes, which is widely used in various industries, as mentioned above. It is the areas of use of it (scaly mineral material, in particular basalt scales) that determine further research on the creation of more advanced methods and devices for obtaining flake mineral materials.

In particular, basalt scales, in view of their special valuable qualities, are widely used in materials used to create various compositions intended for wear-resistant thixotropic polymer coating, resistant to aggressive environments on structural elements of buildings and structures made of metal and concrete, corrosion protection of structural elements of pipelines, anticorrosive protection of metal components and assemblies of various branches of technology, devices of wear-resistant anticorrosive bulk floors s, resistant to solvents and petroleum products, decorative finishes specified protected surfaces. The following prior art justifies all the advantages of flake fillers. Thus, polymeric anticorrosion coatings are generally known to be filled, in particular highly filled. As fillers, for example, quartz sand RU 2250946, 04/27/2005, hollow quartz microspheres RU 2004113553, 10.20.2005, silicate glass RU 2004102396, 05/10/2005, various aluminosilicates (andesites, concrete, perlites, vermiculites, etc.) are used, metal oxides, carbonates (chalk, dolomite) RU 2265619, 12/10/2005, talc, graphite RU 2264428, 11/20/2003, silicon, free metals (aluminum powder) RU 1678038, 10.20.2003, RU 2215763, 10.11.2003, fine zinc RU 2004110933, 10.10.2005.

Fillers can be plate-shaped, spherical, finely dispersed with a developed surface without a specific shape.

When creating such anti-corrosion coatings, various epoxy resins are especially widely used due to their good adhesion to various surfaces and chemical resistance to aggressive environments. From Pat. SU 431198, 06/05/1974 known anticorrosive composition designed to protect equipment made of carbon steel, containing epoxy diane resin, dibutyl phthalate, an acid hardener and an accelerator, for example dimethylaniline, highly dispersed silicon dioxide with a specific surface area of 150 - 400 m ² / g. and mineral filler and components are taken in the following ratio (in parts by weight):

Epoxy Dianova resin 100;

Dibutyl phthalate 10-20;

Highly dispersed silicon dioxide 1.5 - 3;

Acid hardener 30 - 50;

Mineral filler 100 - 550;

Accelerator, for example, dimethylaniline 0.1 - 0.5.

The epoxy Dianova resin can be used resin ED - 6, ED - 20 or E - 40, as an acid hardener - phthalic and maleic anhydrides, as a mineral filler - diabase, basalt, andesitic flour, silicon carbide or electrocorundum.

The composition provides increased heat resistance and wear resistance under conditions of hydroabrasive wear, but is difficult to prepare, multicomponent, relates to hot cure coatings, which limits its use.

From Pat. SU 443047, 09/15/1974 known epoxy composition used to protect concrete surfaces from destruction, such as surfaces of sewer pipelines and which is a mixture of epoxy Dianova resin, anthracene oil (as plasticizer), hardener - polyethylene polyamine and triethanolamine, and a filler, which is used as basalt flour with a specific surface area of 2000 to 3000 cmVg., and the ingredients are taken in the following ratio, parts by weight:

Epoxy Dianova resin 50 - 80;

Anthracene oil 50 - 20;

Polyethylene polyamine 4-6;

Triethanolamine 1 - 2;

Basalt flour (specific surface 2000 - 3000 cm ² / g.) 300 - 500.

The composition provides increased wear resistance to the coating, does not require chemical treatment, but has a long curing time of 6-18 hours, is quite toxic due to the high content of anthracene oil in it.

It is known from the prior art to use basaltic filler both in the form of basalt flour (SU 443047, 1974), in the form of basalt fibers (RU 2260022, 09/10/2005; SU 827511, 05/21/1979) and in the form of basalt scales.

So from SU 1831871, 05/27/1995, a chemically resistant polymer composition for coatings based on acrylate monomers is known in combination with polyisocyanate, perchlorovinyl resin, divinylbenzene and containing basalt scales as a filler. The composition is quite toxic and is intended mainly for the protection against corrosion of gas desulfurization plants; it is difficult to prepare.

An oil and petrol resistant coating composition is known from RU 2057157, 03/27/1996, including ED - 20 (50 - 95 parts by weight), 2 - furylaldehyde as a polymer binder; (10 - 40 parts by mass), hardener - a solution of diethylene triaminomethylphenol in acetone (30 - 95 parts by mass), polybenzylpyridinium chloride (0.02 - 2.8 parts by mass), perchlorovinyl resin (0.03 - 3, 0 parts by weight) and filler — basalt flakes (5 to 250 parts by weight).

However, this known composition is difficult to prepare and contains quite toxic components.

Summary of the invention.

Therefore, the task is to solve all of the above problems with conventional technology and to develop an effective and economical method for producing flake material from mineral melt, as well as a device for its implementation, and to create a polymer barrier protective coating using the flake filler thus obtained.

The above problem is solved by the following claimed group of inventions.

So, the basis of one invention from the group of inventions is the task of creating a new method of manufacturing flake material from a mineral melt, which would make it possible to obtain microfine flakes more uniform in thickness and area by increasing the degree of amorphousness of the melt and maintaining its uniformity in temperature and viscosity, cooling obtained films with low-pressure compressed air without supercooling, giving it brittleness, crushing of the film mechanically under the action of identical impact forces and effect active separation of the obtained scaly mass into fractions with a narrow interval of linear sizes of flakes. In this way, as flake material is obtained in particular basalt scale, with a plate thickness of from 0.2 to 7.0 μm (in the form of various fractions).

The advantage of the proposed method for the manufacture of scales in comparison with the method taken as a prototype is to improve the quality of the scaly material by mixing the mineral melt before stretching it into a film, increasing the forces stretching the melt into a thinner layer without increasing energy consumption, by creating conditions for accelerating movement molten material on the surface of the bowl, preliminary cooling before crushing only until a solid film is formed, mechanical crushing rotates ysya film into flakes by the action of unidirectional, uniform and equivalent impact forces, and improve the degree of separation into fractions scaly weight with a narrow range of sizes of flakes by mechanical sieving it under the action of increasing centrifugal forces. An increase in the temperature-viscosity uniformity of the melt makes it possible to form an equal-thickness film, and an increase in the forces stretching the melt makes it possible to significantly reduce its thickness.

Uniform and unidirectional crushing of the film by mechanical means allows to increase the degree and uniformity of its grinding.

The problem is solved in that in a method for manufacturing flake material from a mineral melt, including feeding the melt by gravity in a downward direction into a rotating bowl, forming a thin layer of molten material on its side surface under the action of centrifugal force, cooling it with a stream of compressed air in the annular blast zone to film formation, crushing the latter into discrete flakes, collecting them under vacuum and dividing the flake mass into fractions according to the invention, melt, stumbling into a bowl rotating at a speed of 2000 - 5000 m / s, mechanically mixed for 0.5 - 1.5 seconds, the formation of a thin layer of molten material is carried out with a jump accelerating its movement at the outlet of the bowl in 20 - 50 times, it is cooled with compressed air under a pressure of 0.5-1.2 kg / cm before crushing, and the crushing of the obtained film on discrete flakes is carried out by mechanical action of unidirectional and uniform impact forces on it. Moreover, the separation of the scaly mass into fractions is carried out by mechanical sieving it under the action of centrifugal forces increasing in the direction of its movement, with a simultaneous increase in the size of the fractions as it is sifted, and the bottom of the bowl is cooled by a stream of cold compressed air supplied under a pressure of 0.5-1 0 kg / cm ² .

The basis of another invention from the group of inventions is the task of creating a new installation for the manufacture of flake material from mineral melt, which, by introducing a new structural element into the film-forming bowl and changing its depth and shape, would improve the quality of the film drawn from the melt, by introducing a new unit mechanical crushing of the film using cutting elements would provide an opportunity to increase the degree of its crushing, increase the yield of uniformly sized flakes and eliminate to pollute them with the air of the production room, and due to the use of a knot for separating the material into fractions in the form of a sieve borate, known in the glass industry, it would ensure the production of fractions with a narrow interval of linear sizes of flakes. With the help of this installation, basalt scales are obtained as flake material.

The advantage of the inventive installation for the manufacture of flake material in comparison with the prototype device is to increase the efficiency of its work by improving the conditions for the formation of the film by using a homogeneous melt and changing the principle of pulling it out of the bowl, improving the conditions for crushing the film by pre-cooling it to a state of hardening without increasing internal stresses in it, which make it more fragile, changing the principle of crushing the hardened film by mechanical unidirectional, uniform and equivalent effect on her shock forces. All this increases the degree of uniformity of the obtained flakes in thickness and area. An increase in the efficiency of the proposed installation is also positively affected by an increase in the degree of sieving of the scaly mass into fractions, as a result of which its finer fractionation is obtained. In addition, the inventive installation is more environmentally friendly than the device taken as a prototype, since it can significantly reduce the pollution of industrial premises, and with good sealing, completely eliminate it.

This object is achieved in that the installation for the manufacture of flake material from a mineral melt, comprising a furnace for preparing a melt with a feeder, a die feeder with an outlet, installed under the die feeder with the possibility of rotation of the film-forming cup, the inlet of which is facing up, and the edge of the hole is radially bent outward, an annular slotted blasting head for cooling a thin layer of the melt, a device for crushing the resulting film into discrete flakes, chambers deposition of scales, a receiving device with a rarefaction chamber and a unit for separating flake material into fractions, according to the invention, the film-forming bowl is made with a stepped annular recess at its edge and is equipped with an annular comb fixedly installed inside it and concentrically with it, made in the form of a hollow ring with hollow fingers directed perpendicularly downward, and the cavity of each finger is divided by a vertical partition, not adjacent to the arch of the finger, and the device for crushing the film is made in the form of a ring mounted concentrically with the bowl at the level of its bent edge, on which vertical knives are fixed at regular intervals, located perpendicular to the direction of movement of the film and with the blade blade rotated by an angle of 10-20 ° towards the direction of its rotation. In this case, the separation unit of the scaly mass into fractions is a rotatable sieve made in the form of an overturned truncated cone and consisting of separate sections, the diameter and cell size of which increase in the direction from the entrance to the sieve to its exit.

The problem is also solved by the fact that the installation for the manufacture of flake material from mineral melt is equipped with a mechanism for regulating the distance of the bowl from the feeder and a mechanism for supplying compressed air to the outer surface of its bottom, which is ribbed, and the depth of the bowl is 1 / 4-1 / 3 of the height conditional cone formed by the continuation of its sides.

The problem is also solved by the fact that the annular hollow comb is mounted on the shaft casing for rotation of the bowl, equipped with a mechanism for regulating its position along the height of the shaft and connected to a pipe for supplying cold compressed air to cool it. In addition, the deposition chamber of the scales, which is part of the installation, is made expanding downward like a diffuser.

Besides the technical task of the claimed group of the invention is to reduce the toxicity of the composition, simplify its preparation while improving the barrier protective properties when applying a coating based on this composition to various surfaces - metal, concrete surfaces and other surfaces, as well as expanding its functional purpose. The stated technical problem is achieved by the polymer composition to obtain a protective barrier coating on various surfaces, including epoxy Dianova resin, hardener and basalt filler, which contains polyethylene polyamine as a hardener, plate filler in the form of andesitic basalt flakes with plate thickness from 0.2 to as a hardener up to 7.0 μm, additionally contains dibutyl phthalate and / or aliphatic epoxy resin DEG-1 and, if necessary, aerosil, and organic stvoritel the following ratio of the components in wt.%:

Epoxy Diane resin 32.0 - 41.0;

Dibutyl phthalate and / or aliphatic epoxy resin DEG-1 1.0 to 10.0;

Polyethylene polyamine 4.0-6.5;

The aforementioned plate filler in the form of andesitic basalt scales with a plate thickness of 0.2 to 7.0 μm 30.0 - 50.0;

Aerosil 0.0 - 6.0;

Organic solvent 0.0 - 30.0.

As an epoxy Dianova resin, the composition contains, for example, epoxy Dianova resin brands ED-20, ED-5, ED-6, ED-24 and others. The aliphatic epoxy resin DEG-1 is a condensation product of epichlorohydrin with polyhydric alcohols. As an aerosil, the composition may contain silica fume — aerosil with various specific surfaces, for example, grades A-175, A-300.

As an organic solvent, the composition may contain various known traditionally used in epoxy organic solvents, for example, such as solvent, solvent P-4 (a mixture of acetone, butyl acetate and toluene), solvent 646 - (a mixture of ethanol, acetone, ethyl cellosolve, butyl acetate, toluene and butanol) and others.

As a plate filler, the composition according to the invention contains andesitic basalt scales with a plate thickness of 0.2 to 7.0 μm., Preferably 0.2 to 3.0 μm., And in particular, for example, grade ABCH-100, with a plate thickness of about 5.0 μm .. By varying the content of the components of the composition claimed as an invention, the rheological properties of the composition are changed, as well as the functional purpose of the coating: the composition can be used to obtain a primer coating, as a mastic coating, as a separate coating. ceiling elements protective coating on various surfaces, and capable for applying to vertical surfaces.

A brief description of the drawings.

The following is a description of the claimed group of inventions with reference to the accompanying drawings, which represent the following:

In FIG. 1 - installation for the manufacture of flake material, General view.

In FIG. 2 - device for crushing the film, top view.

DETAILED DESCRIPTION OF THE INVENTION

A method of manufacturing a flake material from a mineral melt is as follows.

The formation of a film from a mineral melt, for example, basalt, on the inner surface of a rotating bowl is that the melt basalt glass-microcrystalline-amorphous structure with a temperature of 1450-1500 ° and a viscosity of 30-50 poise is fed into the bowl, rotating at a speed of 2000-5000 m / s, and is mixed mechanically for 0.5 - 1.5 seconds, as a result of which it becomes uniform in temperature and viscosity and with a higher degree of amorphism due to a decrease in the size of microcrystallites in the melt and a decrease in heat transfer. From a homogeneous and more amorphous melt, a thinner and more equally thick film is obtained. The resulting melt is discarded on the side surface of the bowl by centrifugal force and, rising up to its edge, is distributed over it in a thin layer. Due to the presence of a stepped annular recess at the edge of the bowl, extrusion of the melt from the bowl by centrifugal force occurs with a jump in the acceleration of its movement by 20-50 times, which ensures a thinner film. Approaching the rounded edge of the bowl, the melt is ejected from it in the radial direction along the surface of the bent edge, is cooled by a stream of compressed cold air under a pressure of 0.5-1.2 kg / cm and turns into a solid microfine film. At a pressure of less than 0.5 kg / cm ^{2, the} film does not yet acquire the hardness necessary for its high-quality crushing, and at a pressure above 1.2 kg / cm, the film is supercooled and becomes brittle, which also makes the process of crushing worse. Therefore, it is not possible to obtain flakes with given linear dimensions when the film is destroyed. After the cooling process, the rotating film is crushed mechanically under the influence of unidirectional and uniform impact forces, that is, directed at the same angle and at an equal distance from each other around the circumference of the film. The obtained scaly mass settles in the deposition chamber under the action of rarefaction, and then the collected scales are divided into fractions according to particle sizes by sieving it in the process of moving along a rotating sieve under the influence of increasing centrifugal forces. Each fraction of the scales enters a separate collection container, from where it is poured into a bag and packaged.

Installation for the manufacture of flake material from mineral melt is schematically shown below in the drawings:

Fig.l - installation for the manufacture of flake material, General view.

Figure 2 - device for crushing the film, top view.

In accordance with FIG. 1, a plant for the manufacture of flake material comprises a furnace for preparing basalt melt with a feeder 1, a die feeder 2 with an outlet, a bowl 3 installed under the die feeder, the inlet of which is facing up, and the edge of the hole is radially bent outward, mounted motionless inside the cup and concentrically with it an annular hollow comb 4 with hollow fingers 5 directed perpendicularly downward, an annular slotted blasting head 6 placed concentrically with the cup 3 above the bent e edges, the device for crushing the film 7, made in the form of a ring mounted concentrically with the bowl at the level of its bent edge, on which vertical knives 8 are fixed at equal intervals, installed perpendicular to the direction of movement of the film with the blade blade turning 10-20 ° towards the direction of its rotation, a chamber 9 in the form of a diffuser for sedimentation of scales, a perforated conveyor 10 installed under the deposition chamber 9, a rarefaction chamber 11 installed under the conveyor 10, a unit 12 for screening flake material . Moreover, the bowl 3 is made with a stepped annular recess 13 at its edge and mounted on the shaft 14, on which the casing 15 is worn, and on the casing 15 of the shaft 14 is installed with the ability to move the annular hollow comb 4. The casing 15 of the shaft 14 and the annular hollow comb 4 are connected to supply and output nozzles cold compressed air to cool the shaft 14 and combs 4 with fingers 5 (not shown). The node 12 for separating flaky material into fractions is a rotatable sieve made in the form of a tilted truncated cone and consisting of separate sections 16 with cells 17, the diameter and mesh size of each subsequent section increasing in the direction from the entrance to the sieve to its exit . Under each section of the sieve mounted hoppers 18.

In accordance with figure 2, the device 7 for crushing the film is made in the form of a ring mounted around the bowl at the level of its edge. On the ring around the circumference, knives 8 are fixed at equal intervals, mounted perpendicular to the direction of movement of the film from the bowl 3 and with rotation of the blade at an angle of 10-20 ° to the direction of its rotation.

According to the invention of the claimed group, the composition for producing a protective coating (barrier) using, in particular, basalt flakes obtained by the method according to the invention using the device claimed as the invention is prepared as follows.

The composition according to the invention is prepared as follows.

All incoming components are thoroughly mixed together, except for the hardener - polyethylene polyamine, which is introduced into the composition immediately before its use.

Description of specific examples illustrating the claimed group of the invention, which includes a method for producing flake material, for example, basalt scales, an apparatus for its implementation, as well as a polymer protective barrier coating obtained using such basalt scales, with a thickness of 0.2 - 7.0 mcm. , especially ~ 5 microns., and more preferably 0.2 to 3.0 mcm. A specific example of the method. The melt with a temperature of 1500 ° C and a viscosity of 45 poise is fed into a bowl rotating at a speed of 4500 m / s. After drawing the melt from the cup, the resulting film is cooled with compressed air at a pressure of 1.0 kg / cm ² , and then it is crushed using knives, the angle of rotation of which is opposite to the direction of rotation of the film is 20 °. The resulting scales are precipitated, collected and separated into fractions.

Table 1 below shows comparative data on the degree of amorphous melt, thickness and area of flakes obtained by known and claimed methods.

Table 1

Installation works as follows.

The mineral melt from the feeder 1 through the outlet of the die feeder 2 enters the bowl 3, where with the help of an annular comb 4 with fingers 5 it is mixed until it is homogeneous, under the influence of the centrifugal force of the rotating bowl 3 it is discarded onto its inclined walls, rises with a thin layer up to its edge and when entering the stepped annular recess 13 of the bowl 3 accelerates its motion, stretching into an even thinner layer, and then along the edge bent in the radial direction is thrown out. Moreover, the degree of stretching of the film along the side surface of the bowl is significantly affected by its depth. Optimal for this process is the depth of the bowl, equal to 1 / 4-1 / 3 of the height of the conditional cone formed by the continuation of its sides. At a depth of more than 1/3 of the height of the conditional cone, it is necessary to significantly increase the speed of rotation of the bowl in order to carry out the process of extruding the melt from the bowl, which will lead to high energy consumption. In this case, the melt will lose heat, resulting in a decrease in its viscosity, which will lead to a violation film forming process. With a bowl depth of less than 1/4 of the height of the conditional cone, the melt will be ejected from it, not having time to stretch into a thin film. Under the influence of a stream of cold compressed air coming from the slotted annular blasting head 6, the formed microfine layer of the melt turns into a hardened film. The film coming out of the bowl in the radial direction, during its rotation, strikes the cutting edges of the fixed knives 8, which are set to rotate in the direction of its rotation, and are crushed into discrete flakes under the influence of the same impact forces. The optimal angle of rotation of the cutting edges of the knives is an angle equal to 10-20 °, which provides an increase in the degree of grinding of the film and its uniformity over the areas of the flakes. When the angle of rotation of the cutting edges of the knives is less than 10 °, their strong collision with the film will lead to the formation of small flakes, which will adversely affect the quality of coatings made with flake filler. When the angle of rotation of the cutting edges of the knives is more than 20 °, the impact force on the film will noticeably decrease, which will lead to the formation of large flakes that will fold, not allowing them to maintain a flat shape during the manufacturing and coating process. Flake material obtained by crushing the film, is deposited in the chamber 9 by reducing the speed of the flakes due to its expansion downward and is collected on the conveyor 10 due to the placement of the rarefaction chamber 11 under it. The collected flake mass is fed to the node 12, in which as it passes through a rotating sectional sieve it is divided into fractions, each of which enters the corresponding receiving hopper 18.

Table 2 presents examples illustrating the invention, but a non-limiting polymer protective barrier coating.

table 2

* Andesitic basalt scales are used with a plate thickness of 4.0 microns., grade A-100. ** solvent P-4. Industrial applicability.

From Table 1 it can be seen that the degree of amorphism of the melt as a result of its mixing in the inventive method doubled in comparison with the known method for producing flakes. Flake particles obtained by the proposed method are more than two times thinner than the flakes obtained by the known method. Moreover, the thickness range in the first case is much narrower than in the second. And the size of the flakes by area in the present method is one and a half times lower than the flakes in the prototype, as evidenced by the total surface area of flakes in a unit of weight. And this means that the smaller the size of the scales, the finer they are, and, therefore, there will be more of them in one gram, and therefore their total area will be larger. In addition, the percentage of output of flakes 0.2-3.0 μm thick is 15% higher, which indicates a high percentage of obtaining fractions with a narrow range of linear values.

Thus, the distinctive features of the proposed method in comparison with the prototype are: an additional operation of mixing the melt, the formation of a microfine film from the melt by means of accelerating the movement of the melt at the outlet of the bowl, due to which the film is further thinned, the film is pre-cooled only to the state of solidification and mechanical crushing of the formed film as a result of its collisions of the same type with cutting elements. The first two operations in the known prototype device are missing. The operation of pre-cooling the film only to the state of solidification by a stream of compressed air with a pressure of 0.5-1.2 kg / cm ² followed by its mechanical crushing in the inventive method creates the conditions for more favorable grinding of the film than the combined operations of cooling and crushing it by a pulsed stream of cold compressed air a pressure of 1.8-2.2 kg / cm ² in the known method, when there is a supercooling of the film with an increase in its fragility and its chaotic simultaneous destruction.

To this we can add that in the known method, the separation of the finished product into fractions is carried out in a device containing a number of cyclones, in which the scales settle, depending on their mass and, accordingly, the speed of movement. The specified method of separation of scaly mass does not allow to obtain fractions in narrow intervals of linear dimensions with negligible energy consumption. In the inventive method, the operation of separating the finished flake product is highly efficient and has low power consumption.

The technical result of the proposed method for the manufacture of flake material from a mineral melt and device for its implementation is as follows:

- to improve the quality of the scaly material without additional energy consumption by reducing the thickness of the flakes by changing the design of the bowl and increasing their uniformity in thickness by introducing a melt mixing device into it;

- to reduce the energy intensity of the process by replacing the operation of the destruction of the film by a stream of cold compressed air with a pressure of 1.8-2.2 kg / cm ² in the prototype for the operation of mechanical crushing of the film using stationary cutting elements in the inventive object;

- in reducing the percentage of formation of dusty particles in a scaly material due to the unidirectional, uniform and equivalent impact of impact forces on the film;

- to increase the life of the bowl by performing the outer side of the bottom of the bowl ribbed and cooling it with a stream of compressed air pressure of 0.5-1.0 kg / cm ² ; - to increase the percentage of output of flakes of a given fraction by improving the conditions for the formation of the film, the conditions for its crushing into discrete flakes and their effective separation into fractions.

The socially useful result of the proposed method for the manufacture of flake material from a mineral melt and a device for its implementation is as follows:

- in providing the possibility of extending the life of ships, automobiles, chemical equipment and other objects by applying chemically resistant and mechanically durable coatings on their surface to protect against corrosion and abrasion;

- in providing the possibility of hardening concrete, gypsum boards, roofing materials, polymers and other composite materials in order to increase their service life;

- to ensure the possibility of manufacturing heat- and vibration-resistant non-combustible heat-insulating plates reinforced with flake filler, the use of which in shipbuilding, refrigeration, construction and other areas will increase their fire safety;

- in addition to the list of fillers inexpensive, lightweight, chemically resistant, not hygroscopic and effective material.

The introduction as an “barrier” filler of andesitic basalt flakes with a plate thickness of about 5 microns., And especially 0.2 - 3.0 microns. in a certain amount, the claimed composition of experimentally selected qualitatively-quantitative composition provides the obtained coating with high chemical resistance, since in particular it physically increases the path through the coating layer, which the liquid molecules (aggressive towards the substrate) and / or gas are trying to overcome. The main purpose of the coating obtained on the basis of the composition according to the invention is to prevent contact of the environment causing the corrosion of the protected surface due to the barrier structure of the resulting polymer coating and resistant to aggressive environments of the polymer base. The barrier structure of the coating is in particular due to the presence of a plate filler (basalt flakes), the plates of which have a thickness of about 5 μm. and overlap overlaps in the coating.

The thixopropic properties of the composition in particular are also provided by finely dispersed silicon oxide SiOg in the form of aerosil due to the developed active surface.

The resulting coating 7 days after application provides the following characteristics:

• tensile strength at separation, MPa = 40.0;

• ultimate strength in bending, MPa = 70.0;

• impact strength, A., kJ / sq.m. = 15.0;

• electric breakdown strength> = 25 kV / cm2;

• chemical resistance to solutions of acids and alkalis, solvents, oil products - high.

According to physico-chemical indicators, the composition meets the standards indicated in Table 3.

Table 3.

Thus, the great advantages of the composition according to the invention are, in particular, that it contains components that

• are optically opaque in the visible and ultraviolet region;

• do not contain functional groups that are easily susceptible to hydrolysis and corroding metal surfaces, which makes them resistant to moisture and increases the durability of coatings during operation and widens the possible range of their use. The composition is resistant to mechanical wear and tear, able to protect the surface on which they are applied from aggressive media, such as solvents, petroleum products, solutions of acids and alkalis, is gas and waterproof.

All these indicated properties of the composition according to the invention allow its use for the following purposes:

• Facing of concrete and steel tanks, tanks, tanks, basins, sedimentation tanks, drains, dams, dams, tunnels, collectors, etc.

• Replacing or repairing old, low-quality cladding.

• Protective coating for steel tanks and tanks, silos and pipes.

• A protective covering for a roof.

• Insulating coating for asbestos, lead - containing paints and other toxic materials.

• Sheeting for decorative objects, such as racks, supports, drains, drains, hatches, volumetric advertising, etc.

• Protection of floors and walls, which may cause liquids to cause corrosion.

• Anti-abrasive film for mining equipment, mills, crushers, for dump trucks and trucks.

• Protection of frozen salt water reservoirs (fishing trawlers).

Claims

Claim

1. A method of manufacturing a scaly material from a mineral melt by feeding the melt by gravity in a downward direction into a rotating bowl, forming a thin layer of molten material on its lateral surface under the action of centrifugal force, cooling it with a stream of compressed air in the annular blast zone until a hardened film is formed, crushing the latter on discrete flakes, collecting them under the action of rarefaction and separation of the flake mass into fractions, characterized in that the melt entering the rotating bowl at a speed of 2000 - 5000 m / s, they are mixed mechanically for 0.5 - 1.5 seconds, the formation of a thin layer of molten material is carried out with a jump to accelerate its movement at the outlet of the bowl by 20 - 50 times, it is cooled with compressed air under pressure of 0.5-1.2 kg / cm ² before crushing, and the crushing of the resulting film on discrete flakes is carried out by mechanical action of unidirectional and uniform impact forces on it.

2. The method according to p. 1, characterized in that the separation of the scaly mass into fractions is carried out by mechanical sieving it under the action of centrifugal forces increasing in the direction of mass movement, with a simultaneous increase in the size of the fractions as it is sieved.

3. The method according to claim 1, characterized in that the bottom of the bowl is cooled by a stream of cold compressed air supplied under a pressure of 0.5-1.0 kg / cm ² .

4. The method according to claim 1, or claim 2, or claim 3, characterized in that as a scaly material a basalt scale is obtained with a plate thickness of 0.2 - 7.0 microns. Using basalt melt as a mineral melt.

5. Installation for the manufacture of flake material from a mineral melt according to claims 1 to 4, comprising a furnace for preparing a melt with a feeder, a die feeder with an outlet installed under the die feeder with the possibility of rotation of the film-forming cup, the inlet of which is facing up, and the edge of the hole is radially bent outward, an annular slotted blasting head for cooling a thin layer of the melt, a device for crushing the resulting film into discrete flakes, a scale deposition chamber, a receiving device the closure with a rarefaction chamber underneath and a unit for separating the scaly mass into fractions, characterized in that the film-forming bowl is made with a stepped annular recess at its edge and is equipped with a ring comb installed motionless inside it and concentrically with it, made in the form of a hollow ring with hollow fingers, directed perpendicularly downward, and the cavity of each finger is divided by a vertical partition not adjacent to the arch of the finger, the device for crushing the film is made in the form of a ring installed concentrically with the bowl at the level of its bent edge, on which vertical knives are fixed at equal intervals, located perpendicular to the direction of movement of the film and with rotation of the blade by an angle of 10-20 ° to meet the direction of its rotation.

6. Installation according to claim 5, characterized in that the unit for separating the scaly mass into fractions is a rotatable sieve made in the form of an overturned truncated cone and consisting of separate sections, the diameter and cell size of which increase in the direction from the entrance to the sieve to his exit.

7. Installation according to claim 5, characterized in that it is equipped with a mechanism for supplying compressed air to the outer surface of the bottom of the bowl.

FIXED SHEET (RULE 91) ISА / RU

8. Installation according to claim 5, characterized in that the outer surface of the bottom of the bowl is ribbed.

9. Installation according to claim 5, characterized in that the depth of the bowl is 1 / 4-1 / 3 of the height of the conditional cone formed by the continuation of its sides.

10. Installation according to claim 5, characterized in that the bowl for forming a film is equipped with a mechanism for regulating its distance from the feeder.

11. Installation according to claim 5, characterized in that the annular hollow comb is mounted on the shaft cover for rotating the bowl and is equipped with a mechanism for adjusting its position along the height of the shaft.

12. Installation according to claim 5, characterized in that the annular comb is connected to a pipe for supplying cold compressed air.

13. Installation according to claim 5, characterized in that the scale deposition chamber is made expanding downward in the form of a diffuser.

14. The installation according to claim 5, characterized in that it is intended for the manufacture of basalt scales.

15. A polymer composition for obtaining a protective barrier coating on various surfaces, including epoxy Diane resin, dibutyl phthalate and / or DEG-1 aliphatic epoxy resin, hardener polyethylene polyamine, plate filler in the form of andesite basalt flakes with plate thickness from 0.2 to 7.0 microns., if necessary, aerosil and an organic solvent in the following ratio of components in wt.%:

FIXED SHEET (RULE 91) ISА / RU Epoxy Diane resin 32.0 - 41.0;

Dibutyl phthalate and / or aliphatic epoxy resin DEG-4 1, 0 - 10.0;

Polyethyl qnpolyamine 4.0-6.5;

Said plate ^'filler as andesite basalt scale plates with a thickness of 0.2 to 7.0 microns 30.0 - 50.0;

Aerosil 0.0 - 6.0;

Organic solvent 0.0 - 30.0.