Classifications

• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03B—MANUFACTURE, SHAPING, OR SUPPLEMENTARY PROCESSES
  • C03B19/00—Other methods of shaping glass
  • C03B19/10—Forming beads
  • C03B19/108—Forming porous, sintered or foamed beads
• • C—CHEMISTRY; METALLURGY
  • C03—GLASS; MINERAL OR SLAG WOOL
  • C03C—CHEMICAL COMPOSITION OF GLASSES, GLAZES OR VITREOUS ENAMELS; SURFACE TREATMENT OF GLASS; SURFACE TREATMENT OF FIBRES OR FILAMENTS MADE FROM GLASS, MINERALS OR SLAGS; JOINING GLASS TO GLASS OR OTHER MATERIALS
  • C03C11/00—Multi-cellular glass ; Porous or hollow glass or glass particles
  • C03C11/007—Foam glass, e.g. obtained by incorporating a blowing agent and heating

Definitions

• the following invention related 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.
• foam glass is also related to the issues of glass waste utilization and aimed at solving environmental issues.
• foam glass heat-insulating porous material is known to be produced mainly by the means of sintering fine glass powder with gasifier and usually comes in a form of small-sized granules used e.g. as aggregate.
• foam glass production methods such as crushing and grinding of utilizable glass or glass products to form granulated fine disperse glass powder for further production of foam glass batch by adding foaming agent. It is known that production of foam glass from waste simultaneously solves both the issues of waste utilization, and environmental issues.
• batch that contains ground glass and carbonate gasifier (patent RU2266874, C03C 11/00, 10.11.2003) or batch based on the mixture of glass forming component and powder additives including carbon gasifier that contains water alkaline solution of sodium and/or potassium (liquid glass) silicate as the glass forming agent, and fine crushed glass as the powder additive (patent RU2255058, C03C 11/00, 27.06.2005) can be distinguished.
• the above mentioned system for granulated foam glass production is a processing line of functional devices and equipment that includes cullet and ground glass storage, crushers and mills for refinement and fine grinding, containers and mixers for storing and mixing the ingredients, batchers, granulator for foam glass batch granule production, driers for cullet and granule drying.
• the processing line also consists of connecting pipes, conveyors and pumps for feeding materials and ingredients.
• the production equipment and functional devices connected with pipes and conveyors form a processing line that ensures implementation of the set technological process.
• the process involves primary production and storage of cullet; it's crushing, drying, and fine grinding to form fractions of less than 40 microns, simultaneous production of powder mixture of quartz, chalk, and carbon of component fractions of less than 40-60 microns by fine re-grinding.
• the mixture is further mixed with glass powder and liquid glass water solution.
• the acquired mixture is fed to the mixers and granulator, where raw granules are formed.
• the granules are dried and fed further for thermal treatment.
• [15] difficulties of washing and cleaning of the system and the equipment from harmful and dangerous additives, such as glass dust and cullet; waste from batch and finely crushed glass, water or other solutions of foaming agent that accumulate on the equipment and in the facilities, thus worsening work conditions; [16] 1. - significant volume and emission of waste by the production itself.
• harmful and dangerous additives such as glass dust and cullet
• [16] 1. - significant volume and emission of waste by the production itself.
• the suggested invention and its technological result are aimed at removing the above mentioned shortcomings and, first of all, solving environmental problems related to utilization of heterogeneous glass waste, including waste varying in its composition and form.
• the invention has also been designed to ensure cost-effectiveness of utilization and to create conditions for producing foam glass from non-standard glass of varying composition and, at the same time, to improve the quality of end-product (construction materials that contain foam glass).
• the suggested invention is also aimed at improving the mobility of the system, simplifying its dismantling, transportation, installation at new facilities, and reducing the cost on these operations.
• the invention also addresses the issue of harmful emissions and waste of the in-house fabrication, ensures clean equipment and improves work and environmental conditions, provides wider technological range of equipment for recycling glass waste and helps build clean production of granulated foam glass from this waste.
• Carbonate foaming agent including glycerin - 1-2;
• CaC0 3 or MaC0 3 or BaC0 3 or SrC0 3 of maximum 1 % by weight are used as the carbonate foaming agent.
• the suggested system of granulated foam glass production represents a processing line of functional devices and equipment that includes cullet storage, crushers and mills for refinement and production of fine glass powder, containers and mixers for storing and mixing the glass powder, liquid glass, water, and foaming agent ingredients; batchers, granulator for foam glass batch granule production, drum drier for granule drying.
• the processing line also consists of connecting pipes, conveyors and pumps for connecting functional devices, feeding materials, and ingredients, which is already known from the prototype.
• the given system is different for its processing line being designed out of several, minimum four, container-type modules and incorporating batch planetary-screw mixer successively connected with the plate granulator; sieves, including vibrating sieves; a machine for powdering the granules; furnace for foaming and annealing the granules; closed reverse water supply system with pumps, water containers, filters, and washing equipment.
• the first module incorporates cullet washing equipment with drainage system and filter; and coarse crusher for the fractions of maximum 1 mm.
• the second module incorporates refill containers for storing and mixing water, liquid glass, and ingredients of the foaming agent; their pumps, batchers, and mixers interconnected by pipelines, and general mixing outlet.
• the third module contains containers for cullet and water interconnected by pipelines and fixed for 90 degrees moving ability; fine grinders for glass powder fractions with maximum 0.005 mm particles; planetary-screw mixer and plate granulator with outlet for raw granules; drum drier; separator for prepared raw granules in the form of e.g. sieve.
• the fourth module contains a device for powdering granules, foaming furnace for sintering foam glass, separator for ready foamed granules in the form of sieve.
• the basis of the modules is solid with sealed sloping floor in the form of perforated baths for drainage, interconnected with the reverse water supply system. Connecting pipelines between the containers are installed with the possibility of overlapping and separation from each other e.g. during transportation.
• the suggested system allows the possibility of creating closed system of reverse water supply that can consist of two loops, each of them incorporating at least one storage container for drainage water and at least one storage container for industrial water; containing own clarifier device with settling tank and filter, filtered water outlet of which is connected to the storage container of industrial water and washing equipment through the pump.
• the system may also incorporate the third module in the form of parallelepiped or rectangular prism.
• the bath of the third module is formed by sealed floor and adjacent side walls with the drainage holes between them.
• foaming furnace is suggested to incorporate heat- isolating cylinder pipe with several separate areas of heating along its length.
• the pipe contains rotation drive and is installed for pivot rotation and inclination of up to 5 degrees horizontally.
• the furnace can be equipped with pipe cooler that should be e.g. in the form of heat- insulated cylinder, the inner diameter of which would exceed the external diameter of the foaming furnace.
• the cylinder is fixed to allow pivot rotation and limited telescopic movement along the axis of the foaming furnace.
• One of the modules may be provided with the supports in the form of lifting jack, and installed with the possibility of moving it up, down, inclining it, and fixing its position.
• the suggested type of technological solution allows simultaneous solving of several set tasks, in particular, the task of creating cost-efficient production of the construction material under demand - granulated foam glass; the task of creating mobile production that can be transported quickly in the containers to other areas with the ability of changing its efficiency by changing the number of modules based on the present raw material and market demand; the task of solving environmental issues related to glass waste and other waste utilization, environmental protection and labor protection issues by developing this kind of low- waste production.
• Figure 1 shows schematic functional flowchart of the main version of the module system, interconnection of functional devices and sequence of implementation of the technological process.
• Figure 2 represents schematic version of binding of a module (container) of system 1.
• Figure 3 shows schematic version of binding of a module (container) of system 2.
• Figure 4 shows schematic version of binding of a module (container) of system 3 in a vertical operating (for the given version) position.
• Figure 5 shows schematic version of binding of a module (container) of system 4;
• Figure 6 shows schematic version of installation of modules during assembly of the system.
• Figure 7 shows schematic scheme of the reverse water supply system.
• Figure 8 represents schematic version of the batch planetary-screw mixer.
• the analyzed version of technological process represents the system consisting of a range of functional devices, the major part of which can be located in modules- containers 1, 2, 3, 4 made according to the or based on the freight containers for carriage by sea and other.
• the area of the floor of the containers amounts to 15.22 or 30 square meters with the length of 6.9 or 12 meters.
• Standard rectangular parallelepiped modules are used; however, modules of other prism forms, for example, simple parallelepiped with inclined walls are also acceptable.
• the containers may have side openings 5, and their outside perimeter equipped with work stations 6 (not indicated schematically).
• the floor of at least module 1 has the shape of sealed bath 7 with the height of the welt of at least 0.1 meter.
• At least module 3 should be inclined at the angle of 90 degrees in its working state and mounted on one of the side surfaces.
• Each bath contains drainage perforations (spillways) 9 that are located in the lower point of the floor, along the edge of the intersection of the surfaces in module 1.
• the floor of baths 7 or the system of modules is mounted with certain inclination to ensure proper drainage. It is advisable to mount the modules in 2-3 levels (floors), for example, to reduce the used area by increasing efficiency and the number of modules (at least 3-4) and for more convenient supply of materials (to the upstairs), for example, to module 3.
• composition of the equipment of the system depends on the composition of the batch.
• the given example considers granulated batch of the following proportions (mass percent): ground glass - 70-88 , liquid glass - 5-15 , water - 5-15 ;
• Module 1 (or the area next to it) contains storage (container) 10 for cullet (glass waste), equipment 11 for washing cullet e.g. in the form of high-pressure water fluid oscillators, drainage system 9 and filters 12 for water filtering, and connected container 13 for industrial water.
• Module 1 also contains driers 14 for glass (after washing), primaries 15 and fine grinders 16 for glass (for example, of orbicular type) with vibrating or other sieves 17 for glass powder fractions with particles of maximum 1 mm, and connected containers 18 for storage.
• Module 1 also contains grinding equipment and containers 19 for temporary storage of ground glass of other fractions; the containers are connected with pipes in the same principle as vacuum-cleaner, aspiration systems or other product conveyers.
• Module 2 may incorporate a laboratory; a changing room; refillable drinking water container 20 and container with for industrial water 21 with batchers; replaceable container 22 for liquid glass with batcher; replaceable containers 23, 24, 25 with batchers for several possible carbonate ingredients of the foaming agent (for example, CaC0 3 or MaC0 3 or BaC0 3 ); replaceable container 26 with a batcher for glycerin.
• Batchers of containers 21 and 22 are connected to the mixer 27 via pipes, where is prepared liquid glass water solution in the set proportions.
• containers 23 or 24 or 25 with the required carbonate; container 26 with glycerin; water container 21 are connected via their respective batchers and pipes to mixer 28, where foaming agent mixture of, for example, glycerin, CaC0 3 (optional) and water, is prepared.
• foaming agent mixture of, for example, glycerin, CaC0 3 (optional) and water
• the complete mixture of foaming agent, water, and liquid glass is prepared in mixer 29 that is connected via pipes with regulatory valves to discharges of mixers 27 and 28, and to container 21 e.g. for cleaning water. It is possible to disconnect mixers 27 and 28, and to directly mix ingredients in mixer 29.
• Modules 1, 2, 3, and 4 may contain various devices of the closed reverse water supply system 30 with pumps 31, containers 32 and 33 for wastewater, devices 34 and 35 for cleaning wastewater with filters and settling tanks (not indicated), washing devices 36, 37, 38, 39 and containers 13, 21, 40 and 41 for industrial water for modules 1, 2, 3, 4 respectively.
• System 30 is also provided with mobile electric water heaters 42 (for modules 1 and 2) for heating water, or with cooling devices (for modules 3 and 4).
• system 30 is divided into two loops.
• the main function of the first loop is washing cullet that may contain any type of occasional dirt, in module 1, and for the possible cleaning of module 2.
• the main function of the second loop is recycling and re-use of batch waste in modules 3 and 4. For module 2, minor contamination and discharge of water during washing into container 30 of module 1 are anticipated.
• System 30 has been designed to connect discharge pipes 9 of the first and the second loops of system 30 to containers 32 and 33 respectively.
• Module 3 with the ability to turn it 90 degrees contains its own container 40 for industrial water, storage container 43 for glass powder, fine grinder 44 (attritor type) producing glass powder particles of maximum 0.005 mm, mixer 45 for planetary- screw mixer with the plate granulator 46 installed (successively connected) on the outlet, drum drier 47, separator 48 for granules e.g. vibrating sieve.
• the distinctive feature of module 3 in the given version of system is the ability to turn it 90 degrees, to change from horizontal to vertical position, by maintaining the same efficiency. In the given example, it is recommended to install module 3 under module 2, and mixer 45 above granulator 46, but under water container 40 and storage container 43 for convenience.
• module 3 is suitable for horizontal transportation and operation with single-level system, for example, at replacing simple connecting pipelines with aspiration, auger pipes or conveyers with separate drives for material handling. It is also worth noting that dimensions of batch granules and foam glass at the outlet of the system are mostly determined by the dimensions of mixer 45, for example, diameter and pitch of auger 49, and the parameters of the rotary motion of its device 50 and granulator 46 that are set and determined by tests.
• Module 4 is longer than modules 1-3 with its length of e.g. 12 meters, and contains (or holds) machine 51 for powdering the granules and container 52 for powdering materials i.e. kaolin or kaolinite, raw granules container 53, heat-insulated pipe furnace 54 for foaming and sintering of foam glass with its rotation drive 55 and inclination drive 56, and pipe cooler 57 for cooling granules after sintering with its separate rotation and inclination drive 58, and computer device for automatic operation of the mentioned pieces of equipment (not indicated).
• machine 51 for powdering the granules and container 52 for powdering materials i.e. kaolin or kaolinite
• raw granules container 53 for powdering materials i.e. kaolin or kaolinite
• raw granules container 53 for powdering materials i.e. kaolin or kaolinite
• heat-insulated pipe furnace 54 for foaming and sintering of foam glass with its rotation drive 55 and
• Inlet flange of the furnace 54 is turned to (or connected to) the connecting pipe for feeding batch from drum drier 47 and granulator 46, while its outlet flange tele- scopically enters large-diameter pipe cooler 57 that allows limited telescopic movement along the furnace 54, for example, by using the guides (not indicated) with the possibility to compensate for linear displacement that may occur as a result of temperature expansion of the pipe of the furnace.
• Inclination of furnace 54 and cooler 57 may be ensured by lifting jack type movable supports 59 of module 4 that bear (at the corners) a module and provide the function of lifting, lowering, inclining (up to 5 degrees) and fixing, which is easier than separate inclination of the furnace and the cooler by using drives 56 and 58.
• Inclination of module 4 by lowering the part of outlet flanges of furnace 53 and cooler 57 is more preferable. In this case, position of module 3 and front part of module 4 with respect to drum drier 47 does not change.
• Independent drives 55 and 58 provide independent choice of speed of rotation of furnace 54 and cooler 57, which is comfortable during exploitation.
• the system is delivered to the site of future production of granulated foam glass (for example, in the industrial areas of waste recycling plants) in four major transport module containers 1, 2, 3, and 4.
• Modules 1, 2 and 4 are installed to form (one of the options) T form, symmetrically with the junction of front edges of modules 1 and 2 to the side edges of module 4.
• Module 3 is installed vertically on module 4 and on the smaller front edge in the form of bath 7, i.e. turned 90 degrees from the transportation position and the granulator 46 being in the lower part.
• modules or floors of all the modules are inclined up to 10 degrees towards drainage perforations 9.
• Each transport module ready for installation represents the prepared area of
• Module 1 has been designed for glass waste, glass tare, and cullet waste, which is delivered in the form of raw material, recycling into fine glass powder with maximum fraction of particles of 1 mm.
• the main function of module 2 is the production of a mixture made of various ingredients and used as a foaming additive.
• Module 3 is to be used for the production of raw granules, while module 4 incorporates furnace 54 for batch sintering and granulated foam glass production.
• the modules Prior to launching of the system, the modules are connected to each other via connecting pipes and ducts to form a single processing line according to the functional technological flowchart (Fig. 1).
• the system may also contain automatic control system (not indicated) that also includes automated control equipment that is usually installed into most functional equipment available on market.
• the equipment is connected to the major computer for control and management of the whole technological process by using a program that does not fall into the category of the given invention; therefore, is not discussed further.
• Glass waste delivered to module 1 is, if possible, checked for the level of cleanliness and homogeneousness and lots of homogeneous cullet, for example, silicate glass based on silicon dioxide, is selected, technology of processing the given lot is defined according to preliminary test results, ingredients, their composition, proportions and modes of the process are determined.
• the selected waste lot of, for example, silicate glass tare i.e. bottles, are sent from storage 10 to one of the primaries 15, are further fed for wetting and spray washing to washing device 11 connected with water container 13, and to gas drier 14.
• Container 20 is filled with drinking water from e.g. water supply system; container 21 is filled with industrial water from e.g. container 13 of module 1.
• Replaceable liquid glass containers 22; insoluble calcium carbonate CaC0 3 (ground limestone) container 23; glycerin container 26 are placed.
• the required batch of liquid glass water solution is prepared in mixer 27, and appropriate batches of CaC0 3 with glycerin and water are prepared in mixer 28 by feeding the above ingredients from the batchers of the containers via pipes.
• the batch of the complete mixture of the foaming agent, water, and liquid glass is prepared in mixer 29.
• Parameters of mixer 45 in particular, parameters of rectilinear auger 49 (diameter, pitch) and rotation drive 50 with planetary gear, as well as parameters of granulator 46 are determined by tests, according to the required size of granules (1-1.5 mm) and their density. Further rolling of raw granules and increasing their size, for example, up to 2-3 mm while increasing their density are performed by plate granulator 46.
• Machine 51 is located in module 4 on the way of granules from drum drier 47 to the furnace.
• sieve separator 48 for separating fir dust can be installed. It is installed in the pipe on the way of the batch, between drier 47 and powdering machine 51.
• batch granules are free of undesirable dust after drier 47 and covered with a thin layer of kaolin by machine 51.
• Such processed batch granules are fed to the pipe furnace 54 for foaming and sintering to produce foamed granules of foam glass.
• Tunnel type pipe furnace 54 for foaming and sintering consists of the heat-insulated pipe of approximate diameter of 0.5 m with electric or other controllable heaters (not indicated), located along the pipe and allowing separate adjusting of temperature in several heating areas and reproduction of the set temperature curve inside the furnace along its length.
• control system (not indicated) is introduced with the temperature simulation curve with the maximum temperature of 750-800°C.
• the indicated time of heating and keeping in the foaming temperature from 10 to 30 minutes depends on the mode and parameters of the batch. Certain mode is actuated and controlled automatically, for example, according to the data of the thermocouples (not indicated) that are located in furnace 54 and cooler 57.
• Cooler 57 also consists of large diameter pipe with separate rotation and inclination drive 58.
• the pipe is telescopically connected with furnace 54 and serves as its extension.
• the speed of rotation of the pipe of cooler 57 should be 1-10 % higher than the speed of rotation of furnace 54, which allows avoiding dead zones at the transfer of granules from the furnace to the cooler and has been tested.
• the cooler stabilizes the temperature, process of cooling foam glass granules, change of their features and size, allows increasing the quality of the produced material.
• Production is usually taken from furnace 54 and cooler 57 as soon as ready,
• vibrating sieve fraction separator 60 granules are cleaned from dust and sorted by size and, possibly, put into containers 61 for end-product storage or into bags.
• the test bulk density of the produced foam glass granules amounted to 100-200 kg/m 2
• compression strength of the filler (in the cylinder) amounted approximately 6 kg/cm2
• thermal conductivity in the fill did not exceed 0.057 W/m°C.
• the process should be stopped or slowed down in the case of such defect to find the cause of decreased quality and to perform the appropriate changes of, for example, foaming agent composition or temperature mode.
• the equipment and modules are recommended to be regularly washed with industrial water by using washing devices with, for example, high-pressure pumps. Spray washing would remove all the waste from the equipment and floor of the modules into the storage containers. Afterwards, when the settling and filtration of wastewater is completed, refined industrial water would be sent for secondary use. Batch waste (in the second loop) should be fed as additives into new mixtures, while other waste from filters should be utilized as required. Such devices as vacuum cleaners and air aspiration systems can also be used for cleaning. Convenience and effectiveness of using the described mobile system have been proved by tests.

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• Chemical & Material Sciences (AREA)
• Engineering & Computer Science (AREA)
• Materials Engineering (AREA)
• Organic Chemistry (AREA)
• Life Sciences & Earth Sciences (AREA)
• Chemical Kinetics & Catalysis (AREA)
• General Chemical & Material Sciences (AREA)
• Geochemistry & Mineralogy (AREA)
• Manufacturing & Machinery (AREA)
• Processing Of Solid Wastes (AREA)
• Glass Melting And Manufacturing (AREA)

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• 2009
  • 2009-11-17 RU RU2009142125/03A patent/RU2424998C1/ru not_active IP Right Cessation
  • 2009-12-30 WO PCT/IB2009/055995 patent/WO2011061569A1/en not_active Ceased

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