WO2011027194A1

WO2011027194A1 - Granulated foam silicate (penostek) production method

Info

Publication number: WO2011027194A1
Application number: PCT/IB2009/055993
Authority: WO
Inventors: Vladimir Valentovich Jegorov; Sergej Borisovich Rodin; Semion Sergejevich Rodin
Original assignee: Uab „Stikloporas‟
Priority date: 2009-09-07
Filing date: 2009-12-30
Publication date: 2011-03-10
Also published as: RU2424997C2; RU2009133384A

Abstract

The following invention relates to the production of light bulk construction material based on glass, in particular, the means of production of foam glass or foam silicate commercially marked e.g. as PENOSTEK, that are also heat-insulating and fire-resistant materials and can be used, for example, for thermal insulation and fire protection of vehicles, buildings, and equipment, as an aggregate added into concrete constructions and in other areas of technology. The method of production of granulated foam silicate (foam glass) includes the description of the set and sequence of the required technological operations and parameters, and the description of basic technological means of implementation of the method. The suggested method also implies production of fine disperse glass powder with particles of maximum 5 microns, which is achieved by repeated crushing and grinding of glass silicate products and their further crushing, adding binding agent (liquid glass, 10-20 % by the weight) and pore agent (mixture of glycerin (0.5-2% by the weight) and water (10-20 % by the weight)) to the powder in set weight or volume proportions; their mixing and granulation in the designed equipment; preliminary drying, further heating and annealing of the acquired granules at the foaming temperature (750°C-800°C), proceeded by cooling during vitrification and separation of the produced foam glass granules, separating environment, and slag from each other.

Description

Title of Invention: GRANULATED FOAM SILICATE

(PENOSTEK) PRODUCTION METHOD Technical Field

Technical Field

[1] The following invention relates to the production of light bulk construction material based on glass, in particular, the means of production of foam glass or foam silicate commercially marked e.g. as PENOSTEK, that are also heat-insulating and fire- resistant materials and can be used, for example, for thermal insulation and fire protection of vehicles and equipment, as an aggregate added into concrete constructions and in other areas of technology.

Background Art

[2] The method for the preparation of granulated foam glass production comprising

crushing utilized glass and glass products to acquire cullet is already known. The method includes further washing and preliminary drying, weight batching and grinding of cullet and adding of pore agent to produce the required specific surface or dis- persibility of the batch, its further granulation by adding water solution of liquid glass to the plate granulator; subsequent drying of granules, their foaming in the rotary furnace by adding river quartz sand; and subsequent separation of granules from the separating environment (for example, see patent RU216825, IPC C03C 11/00,

13.12.1998).

[3] The shortcoming of the above method is the use of foaming and pore agents in their solid states (such as coke, chalk, or dolomite). This, accordingly, requires grinding of the agent, single-stage granulation and the use of quartz sand in significant proportions, which reduces the efficiency of production.

[4] Another well-known method is the method of granulated foam silicate (foam glass) production is based on the production of fine crushed disperse glass powder by crushing glass products during their utilization and further grinding; adding binding and pore agent to the powder in the set weight or volume proportions; their mixing and granulation in special equipment; preliminary drying; subsequent sintering of the obtained granules in the foaming temperature with further cooling during vitrification; and separation of the separating environment (i.e. see patent RU2294902, IPC C03C 11/00, 03.08.2005).

[5] The shortcoming of the above method is the use of pore agent in its solid form,

which makes grinding and smooth mixing of components more difficult. The use of rather static granulation and raw material annealing equipment for production is also the weak part of the method, which negatively influences the quality of the production. Disclosure of Invention

Technical Solution

[6] The suggested technological solution is aimed at improving technological aspect and quality of the product by using liquid agents, such as liquid glass, glycerin, and water; at improving efficiency, reducing the energy costs, and creating conditions for stable continuous production.

[7] The suggested method of granulated foam silicate production includes the stages of production of fine ground disperse glass powder by crushing silicate glass products during their utilization and further grinding; adding binding and pore agent to the powder in the set weight or volume proportions; their mixing and granulation in special equipment; preliminary drying; subsequent heating and annealing of the acquired granules under foaming temperatures, with further cooling during vitrification; and separation of the acquired foam glass granules, separating environment, and slag from each other, which has already been defined by the prototype. The main binding agent is

[8] liquid glass that constitutes 10-20 % based on the weight of glass powder. The main pore and granulating agent is the glycerin mixture of 0.5-2 % and water of 10-20 % based on the weight of powder. The glass powder is refined by several stages and sieved to achieve the dispersion of glass particles of maximum 5 microns. The powder is further mixed with water solution of glycerin and liquid glass in the set proportions for minimum 15 minutes in planetary- screw cone mixers. The screw auger moves in the set pitch down the conical surface of the mixer to form the granules of the required form. The granules are then compressed and rolled by a plate type granulator with the container of inclined rotary plate type. The prepared granules are dried at the temperatures of 150°C to 400°C for minimum 10 minutes, sieved and separated from the waste. The acquired granules of the set size are mixed or powdered with kaolin or kaolinite that constitutes 1-3 % based on the weight of granules. The powdered granules are fed to rotary furnace, where the granules are heated to 750-800°C for foaming by the rotating furnace, and kept at the temperature of foaming for 5-10 minutes. The granules are further gradually cooled until the process of sintering and vitrification of the foam glass (foam silicate) in the granules is finished. The granules are finally cooled and packed.

[9] The described set of technological operations suggests a new technological result related to simultaneous use of exceptionally fine disperse glass powder and mixture of liquid agents including liquid glass, glycerin, and water. This makes the batch more homogeneous and ductile. The result is also related to multi-stage approach and improvement in quality of formation of granules that are fed to the furnace, including the features of using kaolin and rotary furnace for sintering. Provided totality of technological methods and operations including temperature regimen allow getting standard quality of row granules and reducing the time of sintering. This improves the quality of the produced granules, reduces energy costs, and promotes overall productivity and efficiency.

The above mentioned set of technological operations is new and not known on the technology level. Based on the tested production and inspected operation of prototype equipment, this method is considered to be industrially applicable, which proves the possibility and need of patenting the described method.

Implementation of the described method has been presented in the scheme and drawings (these may be excluded from the description during the appraisal procedure). Description of Drawings

Figure 1 presents an example of possible structural scheme of technological embodiment of the suggested method, the scheme is also provided in the description. Figure 2 demonstrates one of the possible cutaway schemes of planetary- screw cone mixer.

Planetary- screw cone mixer (see Figure 2) is one of the most important pieces of equipment in the suggested method and is used for primary production of raw granules. The mixer consists of conical body 1 with rectilinear screw auger (vertical pivot axis) 2 that is kinematically connected to the pivot rotation drive 3, with the axis being parallel with the generatrix (director) of cone. Simultaneously, with the help of the carrier 4 and other drive 5, screw auger 2 performs circular (conical) motion.

Best Mode

The suggested method includes the following technological operation and can be implemented as follows:

Operation 1.1 - glass products made of silicate glass are subject to primary selection by using silicon dioxide and by applying crushing (the warehouse for cullet is created);

Operation 1.2 - foregrinding of the collected glass is performed in, for example, jaw crushers or ball mills, after operation 1.1.;

Operation 1.3 - the cullet is washed after operation 1.2;

Operation 1.4 - preliminary drying of the cullet is performed in drum drier after operation 1.3;

Operation 1.5 - secondary fine crushing of the cullet for fractions of maximum 0.5 mm is performed in, for example, hammer mill after operations 1.2 and 1.3 (the cullet is collected from e.g. storage hopper of glass powder); [20] Operation 1.6 - the necessary dose of glass powder is drawn from the storage hopper by volume batcher, e.g. scooper, and fed to the fine grinder, for example, attritor with metal balls of 8-10 mm diameter to achieve the required fraction with the particles of glass being less than 5 microns;

[21] Operation 1.7 - 5 microns fraction of powder is fed to powder storage hopper with weight batcher for feeding into the cone mixer 1 after operation 1.6;

[22] Operation 1.8 - simultaneously with the loading of storage hopper and other operations, dosage of glycerin (pore agent) is performed (the required proportion of glycerin should be 0.5-2 % based on the weight of powder);

[23] Operation 1.9 - simultaneously with the loading of storage hopper and other operations, dosage of water (pore agent) is performed (the required proportion of water should be 10-20 % based on the weight of powder);

[24] Operation 2.0 - after dosage of glycerin and water (operations 1.8 and 1.9), glycerin and water are mixed together (combined) in the set proportions;

[25] Operation 2.1 - simultaneously with the loading of storage hopper and other operations, dosage of liquid glass (binding agent) is performed (the required proportion of liquid glass should be 10-20% based on the weight of powder);

[26] Operations 2.2 - after the dosage of liquid glass, glycerin, and water in the set proportions (operations 2.0 and 2.1), the agents are mixed together;

[27] Operation 3.0 - after dosage, the set portion of glass powder from the storage hopper (operation 1.7) and the set portions of liquid glass, glycerin, and water (operation 2.2) are fed to the body 1 of the planetary- screw mixer; violation of sequence of operations 1.8; 1.9; 2.0; 2.1; 2.2 is possible during direct supply of all the mentioned components to the body 1 and further mixing in it;

[28] Operation 3.1 - mixer drives 3 and 5 are actuated, and the components of the batch are mixed for 15-30 minutes until raw granules of the required size and density are formed. Parameters of granules and the process of their formation are preliminary tested. Parameters of produced granules are further adjusted by, for example, changing the speed and duration of operation of drives 3 and 5;

[29] Operation 3.2 - rolled (formed) granules are fed in several portions from body 1 to, for example, plate granulator in the form of inclined pivot plate, after operation 3.1. The rotation of the granulator plate for 10-20 minutes helps compress granulated composition to form wet granules of the required size.

Claims

[Claim 1] 1. The method for production of granulated foam silicate

(PENOSTEK) that includes the stage of production of fine disperse glass powder by crushing glass products during utilization and grinding; adding binding and pore agent to the powder in set weight or volume proportions; mixing of the components; granulation in the designed equipment; preliminary drying; further heating and annealing of the produced granules at foaming temperature; proceeding cooling during vitrification; separation of the produced foam glass granules, separating environment, and slag from each other, characterized in that there is used liquid glass of 10-20 % based on the weight of glass powder as the main binding agent, and the mixture of glycerin (0.5-2% based on the weight of powder) and water (10-20 % based on the weight of powder) as the main pore agent and granulator, wherein glass powder is also refined by several stages and sieved to achieve dispersion of glass particles of maximum 5 microns, wherein powder is further mixed with water and glycerin solution and liquid glass in the set proportions for at least 15 minutes in planetary-screw cone mixers, wherein the screw auger moves in the set pitch down the conical surface of the mixer to form blank granules of the required form, wherein the granules are then compressed and rolled in a plate type granulator with the container of inclined rotary plate type, wherein the prepared granules are dried at the temperatures of 150°C to 400°C for minimum 10 minutes, sieved and separated from the waste, wherein the acquired granules of the set size are mixed or powdered with kaolin or kaolinite that constitutes 1-3 % of the weight of granules, wherein the powdered granules are fed to rotary furnace, where the granules are heated to 750-800°C for foaming by the rotating furnace, and kept at the temperature of foaming for 5-10 minute, wherein the granules are further gradually cooled until the process of sintering and vitrification of the foam glass (foam silicate) in the granules, wherein the granules are finally cooled and packed.