Construction materials production.

Application of the ABC-100 unit

Expanded clay industry

In the process of expanded clay

production the argillous raw material

homogenizes and mills in the drilling

mud mixers and rollers. But these

equipments not ensure qualitative

desintegration. As result we obtain the

expanded clay of low quality.

Insufficiently desintegration and homogenizing of

raw materials lead to the result when even 3% of

carbonate inclusion in the low-melt expanded clay can

make it unusable. Obtained in such way expanded clay

lose its durability or destroyed upon storage by the

reason of CaO hydration.

The oversanded glay with free SiO2 content to 10-

30% is also not suitable for expanded clay production.

All those problems can be successfully resolved by

using Vortex Layer Machine – ABC-100 PC

GlobeCore production. When we are using the unit

ABC-100 for desintegration and homogenizing of the

burden material we obtain the expanded clay of general

engineering and special designations. In this case we

also reduce the volume weight and increase the durability.

Intensifier of Technological

Process ABC-100 by PC GlobeCore

Table 1

Results of desintegration and homogenizing of the burden material for

expanded glay production by using ABC-100

№ o

f e

xp

erim

ent

Raw materials

characteristics and

treatment duration

in ABC-100

Expanded glay mechanical properties

Treatment of the burden

material

in АВС

Mixing of the burden

material

out of АВС

Vo

lum

e w

eigh

t, γ

,

g/c

m3

Sh

ear

stre

ngth

lim

it

σс*

10

-5, P

а

stre

ng

th-d

ensi

ty r

atio

Vo

lum

e w

eigh

t, γ

,

g/c

m3

Sh

ear

stre

ngth

lim

it

σс*

10

-5, P

а

Str

ength

-den

sity

rat

io

1. CaS04 with 26% of

free SiO2 content

(treatment of slurry

30 с)

0,24 2,25 10,3 0,38 1,60 5,1

2. The same with 41%

of free SiO2 content

(treatment of slurry

30 с)

0,34 2,45 7,8 0,84 3,24 4,1

3. hydromicaceous clay

(dry treatment 7

min)

0,85 29,4 36 1,6 9,81 6,5

Slip treatment of CaS04 with content of free SiO2 up to 40% leads to reducing

of volume weight of the expanded glay in 2 times and increasing of its durability.

The expanded glay strength-density ratio is almost in two times higher in the

expanded clay, which is made from the burden material the unit ABC-100. The

reason of sharp properties increase of the expanded clay is obviously activation of the

high-silica sand caused by creation of active center or other words free radicals

creation which are produced by the reason of the bond rupture of Si—O.

Activation of SiO2 leads to active participation of the expanded glay in the silication

and glass formation. After the expanded glay baking in its granules are absent coarse

particles of SiO2, which are the concentrator of tension. Presence of SiO2 in the glass

content increases its durability and thermostability.

Good results are obtained by dry treatment of the raw material by the

vortex layer. For example, from the monothermite (hydromicaceous clay) we

obtained the light-weight fireproof aggregate which has the volume weight in 2

times lower but the durability in 2 times higher than which we have for the

control sample (experiment 3, table 1). The positive result was obtained by dry

treatment of the multicomponent burden material (with 50% ashes content) by vortex

layer.

The given examples shows you that the application of ABC-100 (Intensifier

of Technological Process) is very perspective for obtaining of the expanded glay

of high durability and thermostability from oversanded and over-carbonized

materials, burden materials which contain up to 50% of waste product, for

example, the coal ash.

Cellular concrete production

Cellular concrete is made in result of

solidification preliminarily blown-out

mixture of the cementing medium, water,

silicious component using gasifier of

components. Most frequently as foaming

agent used aluminum powder. The

aluminum powder reacts with water

solution of calcium hydroxide and

disengages hydrogen.

In fact, the quality of cellular concrete is

high when the size of pores decreasing and

homogeneity of porosity is rising.

In order to ensure best quality of

cellular concrete is necessary to distribute aluminum powder in its weight and

increase the degree of dispersion. Besides, the one of technological factors which

determines the cellular concrete structure is content of active CaO in mixture.

As usual the preparation of gasifier reduces to partial paraffin film stripping from

aluminum particle surface by mixing of this film with water and surfactant species,

after these action need to introduce suspension into solution.

Because of low efficiency of mixing devices, paraffin film practically not

removed.

In addition, there is a coagulation of aluminum particles, which leads to the

local concentration of gas in the products, the appearance of voids and cracks.

Because of shortage of gas emission in the case of gas silicate production is necessary

to introduce up to 25% of lime into the mixture.

The necessity of additional introduction of a lime into the mixture is specified

by requirement to obtain the durability of concrete which allows to keeps it in

vesicular condition by the end of gas emission using the hydration cementation.

Application of ABC-100 unit for preparation of aluminum powder

suspension in production of the gas silicate allows avoiding the coagulation of

aluminum particles, raises their activity, gas yield and homogeneity of the

mixture. At the table 2 you can see some of the comparative data of physicochemical

properties of the gas silicate which was made by using the aluminum suspension

fabricated by different methods.

Table 2

Comparative data of physicochemical properties of the gas silicate which

was made by using the aluminum suspension fabricated by different methods

№ o

f e

xp

erim

ent

Conditions of

suspension

preparation

Unit

А

ВС

-10

0 p

roduct

ivit

y, L

/h

Mechanical properties of the gas silicate

Treatment of aluminum

silicate suspension by

ABC

Preparation of aluminum

powder suspension by

mixing machine

Vo

lum

e w

eigh

t, γ

,

g/c

m3

Sh

ear

stre

ngth

lim

it

σс*

10

-5, П

а

Str

ength

-den

sity

rat

io

Vo

lum

e w

eigh

t, γ

,

g/c

m3

Sh

ear

stre

ngth

lim

it

σс*

10

-5, П

а

Str

ength

-den

sity

rat

io

1 Aluminum

powder - 100%

against the

estimated

quantity

120 385

377

414

18,7

10,3

11,8

2,56

1,47

1,41

396

419

438

15,2

79,5

10,8

2,03

0,92

1,14

2 The same –

90% against

the estimated

quantity

950 386

427

375

14,5

15,2

12,3

1,85

1,70

1,80

437

—

—

14,1

—

—

1,51

—

—

The table shows that usage of treated aluminum suspension by ABC-100

allows to obtaining the gas silicate which has the durability up to 10-30% and

quality index up to 20-60% higher in comparison with the control sample (table

2, experiment 1).

Application of ABC gives a possibility decrease by 10 % gasifier

consumption and by 2% lime consumption. At the same time there is no weighting

of gasifier. On the contrary, the volume weight of the gas silicate is reduced but its

durability is increased. Obviously, the quality of the blown-out concrete can be

increased by the treating process by ABC-100 unit in the vortex field of sand-lime

mixture or in the sand-cement mixture on purpose of activation of SiO2 like we do the

same in expanded-clay aggregate production.

The silica brick production

The raw material for the silica

brick production is the high-silica

sand (92-95% of dry mixture) and

the lime (5-8%). Structural

capabilities of the brick directly

depend from the degree of activation

of SiO2 and mixing uniformity of

components.

According to this fact,

application of ABC for the treatment

of dry mixture by the reason of mixing and activation of components is of the utmost

interest. We have investigated the ways of sand-lime mixture activation by

spillage of material through the vortex layer of the unit ABC-100.

It is interesting to note that, in this short-duration treatment of the mixture

(mixture particles locate into the vortex field for a fraction of a second) the

grinding of the sand and the lime is not observed. The degree of activation can be

determined by the changing of mechanical properties of obtained silica brick.

Table 3

Conditions of the mixture treatment

by ABC

Compressive resistance

σс*10-5

, Pа

Without treatment 91,2

One-time spillage through the layer 239,5

Double spillage through the layer 324,5

Triple spillage through the layer 328,1

As you can see from the table by the short-duration treatment of the

mixture you can increase the durability of the silica brick in 3,5 times.

Obviously, similar processing sand-lime, lime-ash and lime-silica mixtures

leads to an marked increase of the mechanical properties of silicate concrete, which

are widely used in prefabrication.