WO2009033943A1 - Procédé et installation permettant le traitement de boues dérivées de l'usinage d'articles de matière à base de pierres agglomérées - Google Patents

Procédé et installation permettant le traitement de boues dérivées de l'usinage d'articles de matière à base de pierres agglomérées Download PDF

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Publication number
WO2009033943A1
WO2009033943A1 PCT/EP2008/061112 EP2008061112W WO2009033943A1 WO 2009033943 A1 WO2009033943 A1 WO 2009033943A1 EP 2008061112 W EP2008061112 W EP 2008061112W WO 2009033943 A1 WO2009033943 A1 WO 2009033943A1
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WO
WIPO (PCT)
Prior art keywords
sludges
machining
slabs
stone material
resulting
Prior art date
Application number
PCT/EP2008/061112
Other languages
English (en)
Inventor
Dario Toncelli
Original Assignee
Dario Toncelli
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Application filed by Dario Toncelli filed Critical Dario Toncelli
Publication of WO2009033943A1 publication Critical patent/WO2009033943A1/fr

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Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B09—DISPOSAL OF SOLID WASTE; RECLAMATION OF CONTAMINATED SOIL
    • B09B—DISPOSAL OF SOLID WASTE NOT OTHERWISE PROVIDED FOR
    • B09B3/00—Destroying solid waste or transforming solid waste into something useful or harmless
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/06—Treatment of sludge; Devices therefor by oxidation
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/06—Combustion residues, e.g. purification products of smoke, fumes or exhaust gases
    • C04B18/10—Burned or pyrolised refuse
    • C04B18/103—Burned or pyrolised sludges
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B18/00—Use of agglomerated or waste materials or refuse as fillers for mortars, concrete or artificial stone; Treatment of agglomerated or waste materials or refuse, specially adapted to enhance their filling properties in mortars, concrete or artificial stone
    • C04B18/04—Waste materials; Refuse
    • C04B18/16—Waste materials; Refuse from building or ceramic industry
    • C04B18/167—Recycled materials, i.e. waste materials reused in the production of the same materials
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B28/00—Compositions of mortars, concrete or artificial stone, containing inorganic binders or the reaction product of an inorganic and an organic binder, e.g. polycarboxylate cements
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/121—Treatment of sludge; Devices therefor by de-watering, drying or thickening by mechanical de-watering
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F11/00—Treatment of sludge; Devices therefor
    • C02F11/12—Treatment of sludge; Devices therefor by de-watering, drying or thickening
    • C02F11/13—Treatment of sludge; Devices therefor by de-watering, drying or thickening by heating
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2101/00—Nature of the contaminant
    • C02F2101/30—Organic compounds
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2103/00—Nature of the water, waste water, sewage or sludge to be treated
    • C02F2103/12—Nature of the water, waste water, sewage or sludge to be treated from the silicate or ceramic industries, e.g. waste waters from cement or glass factories
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F2209/00—Controlling or monitoring parameters in water treatment
    • C02F2209/02—Temperature
    • C—CHEMISTRY; METALLURGY
    • C02—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F—TREATMENT OF WATER, WASTE WATER, SEWAGE, OR SLUDGE
    • C02F9/00—Multistage treatment of water, waste water or sewage
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W10/00—Technologies for wastewater treatment
    • Y02W10/40—Valorisation of by-products of wastewater, sewage or sludge processing
    • Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
    • Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
    • Y02W—CLIMATE CHANGE MITIGATION TECHNOLOGIES RELATED TO WASTEWATER TREATMENT OR WASTE MANAGEMENT
    • Y02W30/00—Technologies for solid waste management
    • Y02W30/50—Reuse, recycling or recovery technologies
    • Y02W30/91—Use of waste materials as fillers for mortars or concrete

Definitions

  • the present invention relates to a process and a plant for treating the process sludges resulting from the manufacture and machining of agglomerated stone materials, in particular obtained using the so-called Bretonstone technology.
  • the technology in question essentially envisages the preparation of a mix comprising a granulated stone material or the like, with a suitably selected particle size, and a binder consisting of a hardenable organic resin, with addition preferably, to the mix, of a very fine inorganic substance, called filler, preferably consisting of stone powders.
  • the mix which is deposited in the form of a thin layer on a temporary support or used to fill a suitable mould (in the case where a block must be produced), undergoes a vacuum compaction step and at the same time is subject to a vibratory movement of predetermined frequency, following which the rough-formed article is transferred for a step involving hardening of the binding resin by means of the action of heat and/or a catalyst.
  • abrasive tools operating under a continuous water flow used to cool the tools of the sizing and polishing machines and at the same time eliminate the dust generated by machining.
  • These abrasive tools in die most recent versions are composed of diamond-coated granules embedded in a metal or resin matrix.
  • the machining water containing said dispersed powders is treated with various substances (for example flocculating and anti-foaming agents) and passes into decanting apparatuses so that the powder may be deposited while the water is used again to supply the cooling circuits of the cutting, sizing and polishing tools.
  • substances for example flocculating and anti-foaming agents
  • the sludges consisting of powder and water and collected inside decanting devices, are fairly fluid and contain a large quantity of water so that, during an initial phase of the disposal cycle, they are conveyed into concentrating apparatus such as centrifuges or more often filter presses so as to be able to extract as much water as possible, this water being then reintroduced into the cycle for machining the slabs of agglomerated stone material.
  • the filter -pressed sludges which have a water content by weight varying between 15% and 30% depending on the type of filter press, are at present transferred to suitable storage and disposal centres with the associated complications and costs.
  • the machining sludges are essentially composed of the following:
  • machining tools i.e. diamond and organic or metal binder.
  • the main object of the invention is to manage to eliminate the problem associated with disposal of the machining sludges and preferably be able to use them in the same process for the production of agglomerated stone material and in particular in Bretonstone technology.
  • the present invention envisages a process for treating and using sludges resulting from the machining of slabs of agglomerated stone material, in which the machining sludges, after at least one step involving mechanical elimination of the water content resulting in a concentrated sludge, undergo the following steps: (a) drying the concentrated sludge so as to remove, by means of evaporation, the water contained therein;
  • said operation (b) involving calcination of the dried sludge is preferably performed at a temperature of between 450 and 650° C, preferably between 550 and 600° C, and kept at this temperature for several tens of minutes so as to be able to ensure that all the organic substances contained in the dried sludge are eliminated by means of combustion.
  • the process envisages that the fumes produced during this operation undergo a post- combustion treatment at a temperature of about 950° C, with the aim of eliminating any organic compounds which are contained in the gases and are then introduced into the atmosphere, after suitable cooling with recovery of the energy.
  • the process envisages that the water removed by means of evaporation during the drying step (a) is condensed, for example by means of a scrubber, and used to replenish the cooling circuit of the machines for machining of slabs of agglomerated stone material.
  • the step (d) involving use of the powder resulting from the process according to the invention envisages preferably a check as to the colour of the powder and transfer to storage silos for subsequent use as a filler during the cycle for manufacturing conglomerate slabs and/or blocks.
  • the plant according to the present invention in turn comprises a decanter and a concentrator for obtaining concentrated sludges and is characterized in that, downstream of said concentrator, it comprises a drier for removing the water by means of evaporation and an incinerator for eliminating, by means of calcination, the organic substances contained in the dried sludges, equipped with post-combustion unit.
  • the plant also comprises:
  • the particle size of the powders of fine stone material which can be obtained depends not only on the nature of the said material but also on the grain of the tools used during the cutting and sizing/polishing operations.
  • the most appropriate machining tools may be chosen depending on the particle size of the filler needed for the required production of Bretonstone slabs and blocks. For example, it has been established that if a filler with a particle size less than 20 ⁇ m is required, the abrasive granules of the tools must be smaller than 100 mesh.
  • the colour of the powder obtained from calcination of the sludges requires special comment in that the agglomerated material is normally coloured: the resin is in fact mixed with pigmenting agents which may be of an organic or inorganic nature (normally metal oxides).
  • the organic pigments which may be present in the sludges are eliminated by means of combustion together with the organic binder and the organic additives during the high- temperature calcination step, so that the resultant powder has the same colour as the stone present in the manufactured article and therefore in the sludge, the stone normally having a very light and often white colour.
  • the resultant filler therefore has a light/white appearance so that it is perfectly suitable for use in a mixture for manufacturing agglomerated stone materials of any colour.
  • the pigments are of an inorganic nature, they are not eliminated during calcination of the sludges, so that the powder obtained from calcination of the sludges is not perfectly white, but slightly coloured.
  • the arrow Fl indicates raw slabs entering the plant while the arrow F2 indicates the finished slabs leaving the plant. If the slabs are obtained by sawing blocks, frames for sawing the blocks into slabs are situated upstream of the abovementioned machines (even though not shown in figure). Said frames have been known for many years and are described for example in the patent GB 951389.
  • the reference number 16 denotes a common header for supplying cooling water to the abovementioned machines by means of the branch lines 16A, 16B and 16C, while the reference number 18 indicates a header for collecting, via the branch lines 18A, 18B and 18C, the machining sludges discharged from the machines in question and having the previously mentioned composition.
  • the header 18 leads into a decanter 24 from where the supernatant fluid is removed via the line 26 and recycled along the line 28 to the header 16, if necessary together with the replenishing water supplied via the line 30.
  • the sludges discharged from the decanter 24 are transferred by means of the line 32 to the concentrator, such as a well-known filter press 34 of the conventional type, which has the function of extracting further water from the sludges and concentrating the latter.
  • the water recovered in this way is added by means of a line 35 to the line 26 and recycled together with the water recovered from the decanter 24.
  • the concentrated sludges discharged from the filter press 34 are collected inside a settling tank 36 and from here transferred to a drier 38 inside which evaporation of the water still contained in the sludge is performed.
  • the sludge is then transferred into an incinerator 40 operating at a temperature sufficient to produce calcination, namely ensure that all the organic substances contained in the sludges are eliminated by means of combustion.
  • Both the drier and the incinerator are apparatus which are well-known in waste material treatment technology.
  • the drier and incinerator form a single incineration apparatus which performs both functions.
  • the water removed by means of evaporation during drying is condensed, for example by means of a scrubber 39, and recycled together with the water recovered from the decanter along the line 37.
  • the incinerator 40 operates at a temperature of between 450 and 650° C, and preferably between 550 and 600° C, and the sludge remains inside it for the time necessary to ensure the aforementioned complete combustion of the organic components. This time period is normally in the region of a few tens of minutes.
  • the fumes from the incinerator are conveyed to a post- combustion unit 42 operating normally at temperatures suitable for ensuring that the said fumes do not contain toxic substances (in particular dioxin), and therefore being operating at temperatures in the region of 950° C, and from there to a filter 44 which retains any powders contained in the said fumes.
  • a post- combustion unit 42 operating normally at temperatures suitable for ensuring that the said fumes do not contain toxic substances (in particular dioxin), and therefore being operating at temperatures in the region of 950° C, and from there to a filter 44 which retains any powders contained in the said fumes.
  • the incinerator produces powders which, via the conveyor 46, are transferred to a dispersion mill 45, a separator device 47, if necessary, and then to a storage tank 48 so as to be used as filler in the process from manufacturing the agglomerated stone material, such as the Bretonstone process, and then recycled back into the plant for production of the slabs to be machined, i.e. those which reach the sizing machine 10.
  • the powders retained inside the filter 44 are also transferred to the storage tank 48 via the line 50.
  • the plant may contain a section for checking the colour of the powder obtained from the incinerator 40 so as to use it in varying forms.
  • a plurality of tanks 48 are envisaged, one of these tanks being intended to receive substantially white or colourless powders, since obtained from slabs, colouring of which was performed using organic pigments, while the other tanks are intended for the powders resulting from the machining of slabs coloured with organic pigments, so that the powders after incineration are also coloured.
  • agglomerated stone material in particular Bretonstone slabs and blocks, is therefore an increasingly more ecological and environmentally friendly process, in particular if one considers that the resin to be used could be of an organic type as described in the patent application PCT/IB2007/051949.
  • the resin contained in the sludges acts as a fuel so that the energy balance nearly breaks even.
  • the heat generated by combustion of the resin contained in the sludges is almost sufficient to ensure evaporation of all the water and heating of the dry residue to about 550-
  • the gases generated during calcination and subsequent post-combustion may also pass through a heat exchanger so that the heat contained in them may be recovered and used to preheat the air necessary for the drying operation.
  • the energy requirement for this treatment stage is therefore substantially reduced.

Landscapes

  • Engineering & Computer Science (AREA)
  • Chemical & Material Sciences (AREA)
  • Ceramic Engineering (AREA)
  • Environmental & Geological Engineering (AREA)
  • Organic Chemistry (AREA)
  • Civil Engineering (AREA)
  • Materials Engineering (AREA)
  • Structural Engineering (AREA)
  • Inorganic Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Life Sciences & Earth Sciences (AREA)
  • Hydrology & Water Resources (AREA)
  • Water Supply & Treatment (AREA)
  • Combustion & Propulsion (AREA)
  • Treatment Of Sludge (AREA)

Abstract

La présente invention concerne un procédé selon lequel les boues dérivées de l'usinage d'articles de matière à base de pierres agglomérées, notamment des dalles et des blocs produits au moyen de la technologie de Bretonstone, après concentration, sont soumises au séchage et à l'incinération en vue de récupérer l'eau contenue dans les boues et des poudres qui sont utilisées comme charges lors du même procédé d'usinage de blocs et de dalles.
PCT/EP2008/061112 2007-09-10 2008-08-26 Procédé et installation permettant le traitement de boues dérivées de l'usinage d'articles de matière à base de pierres agglomérées WO2009033943A1 (fr)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
IT000149A ITTV20070149A1 (it) 2007-09-10 2007-09-10 Procedimento ed impianto per il trattamento di fanghi di lavorazione di manufatti di materiale agglomerato lapideo
ITTV2007A000149 2007-09-10

Publications (1)

Publication Number Publication Date
WO2009033943A1 true WO2009033943A1 (fr) 2009-03-19

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Family Applications (1)

Application Number Title Priority Date Filing Date
PCT/EP2008/061112 WO2009033943A1 (fr) 2007-09-10 2008-08-26 Procédé et installation permettant le traitement de boues dérivées de l'usinage d'articles de matière à base de pierres agglomérées

Country Status (2)

Country Link
IT (1) ITTV20070149A1 (fr)
WO (1) WO2009033943A1 (fr)

Cited By (6)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITTV20090039A1 (it) * 2009-03-12 2010-09-13 Dario Toncelli Procedimento ed impianto per il trattamento di fanghi di lavorazione di manufatti di materiale agglomerato lapideo.
ITBG20090053A1 (it) * 2009-10-13 2011-04-14 Fil Tec S R L Sistema e metodo per filtrare l'acqua reflua derivante dal taglio dei blocchi e della lucidatura dei marmi, graniti e similari.
ITVE20100039A1 (it) * 2010-07-08 2012-01-09 Adriano Serena Processo e sistema integrato di recupero e riutilizzo degli scarti della lavorazione di materiali lapidei di natura calcarea
EP3653310A1 (fr) 2018-11-14 2020-05-20 Cosentino Research & Development, S.L. Mélange destiné à être utilisé comme sol artificiel comprenant de la pierre et/ou de boues d'usinage en céramique, son procédé de préparation et d'utilisations
US11325285B2 (en) 2014-07-30 2022-05-10 Breton Spa Method for manufacturing conglomerate slabs
EP4389718A1 (fr) 2022-12-22 2024-06-26 Cosentino Research & Development, S.L. Article en pierre artificielle agglomérée comprenant des granulés de matériau vitreux et procédé de fabrication de celui-ci

Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001278647A (ja) * 2000-03-30 2001-10-10 Takenaka Komuten Co Ltd 土木建築材素材およびその製造方法
WO2006072553A1 (fr) * 2005-01-05 2006-07-13 Dario Toncelli Procede de fabrication d'articles en pierre agglomeree dotes de proprietes antistatiques et articles en resultant
WO2007104368A1 (fr) * 2006-03-14 2007-09-20 Management & Innovation, S.L. Méthode de traitement de la boue produite par les procédés de taille et de polissage des pierres

Patent Citations (3)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
JP2001278647A (ja) * 2000-03-30 2001-10-10 Takenaka Komuten Co Ltd 土木建築材素材およびその製造方法
WO2006072553A1 (fr) * 2005-01-05 2006-07-13 Dario Toncelli Procede de fabrication d'articles en pierre agglomeree dotes de proprietes antistatiques et articles en resultant
WO2007104368A1 (fr) * 2006-03-14 2007-09-20 Management & Innovation, S.L. Méthode de traitement de la boue produite par les procédés de taille et de polissage des pierres

Cited By (9)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
ITTV20090039A1 (it) * 2009-03-12 2010-09-13 Dario Toncelli Procedimento ed impianto per il trattamento di fanghi di lavorazione di manufatti di materiale agglomerato lapideo.
WO2010103445A1 (fr) * 2009-03-12 2010-09-16 Dario Toncelli Procédé et installation de traitement de boues provenant de l'usinage d'articles en matériau aggloméré de pierre
ITBG20090053A1 (it) * 2009-10-13 2011-04-14 Fil Tec S R L Sistema e metodo per filtrare l'acqua reflua derivante dal taglio dei blocchi e della lucidatura dei marmi, graniti e similari.
ITVE20100039A1 (it) * 2010-07-08 2012-01-09 Adriano Serena Processo e sistema integrato di recupero e riutilizzo degli scarti della lavorazione di materiali lapidei di natura calcarea
US11325285B2 (en) 2014-07-30 2022-05-10 Breton Spa Method for manufacturing conglomerate slabs
EP3653310A1 (fr) 2018-11-14 2020-05-20 Cosentino Research & Development, S.L. Mélange destiné à être utilisé comme sol artificiel comprenant de la pierre et/ou de boues d'usinage en céramique, son procédé de préparation et d'utilisations
WO2020099501A1 (fr) 2018-11-14 2020-05-22 Cosentino Research & Development, S.L. Mélange pour utilisation en tant que sol artificiel comprenant des boues d'usinage de pierre et/ou de céramique, son procédé de préparation et ses utilisations
EP4389718A1 (fr) 2022-12-22 2024-06-26 Cosentino Research & Development, S.L. Article en pierre artificielle agglomérée comprenant des granulés de matériau vitreux et procédé de fabrication de celui-ci
WO2024133623A1 (fr) 2022-12-22 2024-06-27 Cosentino Research & Development, S.L. Article en pierre agglomérée artificielle comprenant un matériau vitreux granulé et procédé de fabrication dudit article

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