01 mixture and rmp

8/13/2019 01 Mixture and RMP

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JVB - 20/04/2010 FC Training April-May 2010 - Mixtures & RM Preparation 1

FC Training

Mixtures and RM Preparation(J.V. Buritic)


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The product properties will be the result ofthe used raw materialsand the way they areprepared and put together.

WHY?


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Mixtures


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Raw Materials type

Three different types of raw materials areused in the FC technology:Fibres

ProcessReinforcement

BindersMatrix cohesionStrength

Auxiliary materials (Fillers)ProcessProduct performanceCost


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Raw Materials: Fibres

Fibres are used with two purposes:

For the process:fibers must build a layerthat acts like a filter over the sieve to helpin the filtration of the slurry, improving theretention of the particles on the sieves.

For the product:to reinforce the product

improving the matrix performance toflexural and tension stresses.


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Raw Materials: Fibres - Cellulose

SUKP, HW, WPK, CPBObjective:

As process fiber:to allow sheet formation on themachine, for which we need interlayer bonding, fiber

flexibility, a fine fiber mesh on the sieves to reducesieve lossesAs reinforcement fiberfor the final product for

which we need fiber length, fiber strength (zerospan), fiber bonding with the matrix (fibrillation),

fiber spreading in the matrix, fiber flexibilityProcess parameters:

Refined > 50 SR for process fibreSlightly refined 22 < SR < 27 for Ca-Si products



Characteristics:Fibre length (ELF - Kajaani)

Coarseness or Diameter

Tensile Strength (Zero Span tensile)

Alkali-solubility

Kappa

Filtration speed (SR)

Tasman Eucalyptus

Raw Materials: Fibres - Cellulose



PVA, PP, PAN as reinforcement

Fibrids (as process fibre)

Objective:

Main reinforcement of the matrixProcess parameters:

Mixing time: mixing energy is to be controlled inorder to avoid fibre damages

Fibre orientation factor

Raw Materials: Fibres Synthetic fibres

Kinking due to raw materials preparationin FC plant (long/harsch mixing)


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Raw Materials: Binders

Binders:

Hydraulic binders are used for the fibercement process. Its main purpose is to build

a compact resistant matrix where all rawmaterials are involved. The principle binderused is the cement.

Silica in the Autoclaved technology is,

together with the cement, the binderelement in the mixture.



Raw Materials: Binders - Cement

Physycal DataSpecific surface areaParticle size distribution

CompositionOPC or CEM I preferredSolubility coefficientC3A

Reactivity

Setting timeThermography

Mechanical DataCompression and Flexural strength (7 & 28 days)



Raw Materials: Binders - Silica

Physycal DataSpecific surface area

Particle size distribution

CompositionSiO2content

Organic substances

R200506669 PSDA of Quartz flour

- by Mastersizer 2000 - dry disp. at 3 bar -

0

10

20

30

40

50

60

70

80

90

100

0 1 10 100 1000

Particle size [ m ]

Vo

lume-%p

articlessmalle

KoB - M300 - Bl. 5330 cm/g

KoB - M500 - Bl. 15660 cm/g

Manizales - Pulverizar - Bl. 3410 cm/g

Santiago - Migrin - Bl. 3910 cm/g

Surabaya - Home grinding - Bl. 4280 cm/g


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Auxiliary Materials: Calcium Carbonate (Ca CO3)

Amorphous silica

Aluminium Hydroxide Lime

Perlite, Vermiculite

Wollastonite, Mica

Kaolin, Bentonite Pigments

Note:Polyelectrolite & Antifoam (process aids) are not considered as

component in the RM mixture

Raw Materials: Auxiliary Materials


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Raw Material Product Performance Process Cost

Calcium Carbonate Matrix stability Low Blaine

Amorphous silica Frost resistance Plasticity, Layer adhesion

Aluminium Hydroxide Dimensional stability

Lime Layer Homogeneity

Perlite Low density, Fire resistance

Vermiculite Low density, Fire resistance

WollastoniteFire resistance, Dimensional

stabilityLayer adhesion

MicaDimensional stability, Fire

resistance

Kaolin Impermeability Plasticity, Layer adhesion

Bentonite Plasticity

Pigments Visual aspect


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PSD Blaine Other

Calcium CarbonateHigh Blaine

Low BlaineCaCO3

Amorphous silica D50 Bulk density SiO2

Aluminium Hydroxide PSD Al(OH)3

LimeRetention Mesh

325 (45m)Ca(OH)2

PerliteLoose bulk

density

Expansion

capacity

VermiculiteLoose bulk

densityAsbestos free

Exfoliation

capacity

WollastoniteAspect ratio

Buoyancy testMica PSD

Aspect ratio

Buoyancy test

Kaolin D50Kolinite

Quartz

Bentonite Na Bentonite Swelling

PigmentsRetention Mesh

325 (45m)Iron oxides

Physical propertiesComposition OtherRaw Material


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Mixture

How to put all of them together?

Binders

Fibres

Auxiliary

Materials

According to the product: Application

Characteristics

Manufacturing Process

Technology Air-cured

Autoclaved

Others: Availability

Cost

Health


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Following Application:

According to the location in the buildingsIndoor: ceiling, panelling, flooring

Outdoor: roofs and faadesAccording to the main function

Fire-protection boards (Promat)

General purpose boards (Superboard EterBoard)

Under roof boardsRoof elements (corrug. sheets - slates multitiles)

Faade elements & cladding

Mixture According to the product


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Following product characteristics:

According to the density (& strength)Low density: < 1.00 kg/dm

Medium density: 1.00 1.40 kg/dm

High density: 1.40 1.85 kg/dm

Mixture According to the product


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Promatect-L

Promatect-H

0.95

0.80

0.650.60

1.00

1.20

1.40

1.60

1.80

Low density : Fire board (Promat)

Medium density : Multipurpose, Panels (division)

High density : Faade (outdoor application)

LD

MD

HD

Hydropanel/ Bluclad

~ 1.18Eterbacker MD

Cedral

OperalSidings

1.35

1.25Multiboard Coated

Glasal/Eflex/Tunnel

NaturaPictura

1.75

1.60

Etercolor1.60

Eterboard HD1.55

Density in g/cm

Flat sheets: Application following density (KOB products)

Eterspan

Supalux

Eterboard MD(Superboard)

Textura

Slates


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Following manufacturing process:

Forming machine:Multilayer: Hatschek, Flow-on

Monolithic: filter-press, extrusion, Magnani

Injection process (fittings, flower pots)

Hand-moulding: roof accessories

Mixture According to Manufacturing


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Following manufacturing technology:

Air-cured (PVA reinforced) The fiber cement matrix is cured at ambient conditions

or in a curing tunnel(60 C, RH > 95%):Cement clinker + Water Calciumsilicates + gel-like Ca-SilicateHydrates + Lime

Autoclaved (cured at high T & Pressure) The matrix, containing cement, silica (optionally lime) is

cured at high temperature (up to 180C) and pressure(saturated steam):Quartz + Lime + Water Mix of fully and partially crystalline Ca-

Silicate Hydrates* + residual quartz

Unpressed or Pressed (in stack press)

Mixture According to Manufacturing


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Roofing

Air-cured

Slates

Corr. sheets

Hand mould.

Autoclaved Air-cured Autoclaved

NoVentilated faade

Ceilings

Decorative boards

Ventilated faade

Ceilings

Multi-purpose

Wet cells

Render substrateTile substrate

Fire protection

Mixture According to Product Application& Manufacturing technology

Cladding &

wall separations


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Mixture

Low density Medium density High density

Fire protectionMultipurpose,

panels

Faacde (outdoor

application)

Fibres

Synthetic NO NO NO Reinforcement Reinforcement

Cellulose (SUKP, HWP, CPB)Process +

Reinforcement

Process +

Reinforcement

Process +

ReinforcementProcess Process

Cellulose (WPK) NO NO NO Process Process

Binders

Cement (Cem I) Yes, low amount Yes, low amount Yes, low amount Yes, high amount Yes, high amount

Cement (Cem II) NO NO NO Yes, high amount Yes, high amount

Silica Yes, high amount Yes, high amount Yes, high amount NO NO

Auxiliary Materials

Calcium Carbonate NO NO NO Yes Yes

Amorphous Silica NO NO NO Yes Yes

Aluminium Hydroxide Yes Yes Yes NO NOLime Yes Yes Yes NO NO

Perlite Yes NO NO NO NO

Vermiculite Yes NO NO NO NO

Wollastonite Yes Yes Yes NO NO

Mica Yes Yes Yes NO NO

Kaolin Yes Yes Yes (IBM) NO

Bentonite Yes (IBM) Yes (IBM) NO

Pigments Yes Yes Yes Yes

Raw Material

Air Cured

RoofingCladding & Wall

separations

Autoclaved


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Typical Mixtures

Quality results for Profile 7Thickness mm 6.5 - 6.7 4.5 - 6.0Density gr/cm 1.50-1.55 1.40 - 1.50Breaking Load requir. class C1-X Class 6

avera e N/m 4400 - 4900 2500 - 4100

TYPICAL MIXTURE FOR CORRUGATED SHEETS

(air-cured process)Raw Material (in wt.%) EBMO IBM

Synthetic fibre PVA (HT) 1.8 - 2.0PVA (MT) 1.8 - 2.0

Refined CelluloseSUKP

2.8 - 3.4 3.0 - 4.0WPK 0 - 2.0Cement CEM I - II 74 - 88 75 - 85Microsilica (CSF) 5.8 - 6.5Limestone 0 - 15 10 - 15Kaolin 5Bentonite 0 - 2Pi ments 0 - 1 0 - 2Hardwaste 0 - 3


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Typical Mixtures

TYPICAL MIXTURE for Medium Density Flat Sheets

(IBM Division)

Autoclaved

indoor/outdoor

High Quality SUKP 7.0 - 8.0SUKP + WPK (blend) 3.0 - 4.0PVA 1.5 - 1.8Cement OPC 35.0 75 - 80Quartz 52.0

Limestone 15 - 20Al-H drox de 4.0Na-Bentonite 0 - 1HGW 0 - 3

Raw Material (in wt.%) Air-cured


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Eterbacker-HD Eterboard-HD Glasal

3: Etercolor

Density (in gr/cm) 1.60 1.60 1.60

pressed

Typical Mixtures

Autoclaved Flat Sheet - KOB

Raw Material / Product Low Density Mica Mix Lime Mix Siding Eflex

Cellulose X X X X X

Cement X X X X XSilica X X X X X

Perlite X1Vermiculite X2Mica X2 XLime X X XWollastonite X X X XPigments X3Alum. Hydroxide X X X X X

1: Promatect-H Eterbacker-MD Eterboard-MD Siding Cedral1: New Promina Multiboard

2: Masterboard

2: Supalux

Density (in gr/cm) 0.90 - 0.95 1.20 1.20 1.25 - 1.30

non-pressed


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Raw Material Preparation


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Raw Material Preparation

1.7

Cellulose treatment

Silica grinding

FillersPVA debalers

Filler 1

Filler 2

Filler 3

Cement

main mixer

fibre mixer

cement mixer

slurry chest

to machine feeding
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Pulp feeding

Low consitency pulper

Clear process water for pulp

preparation:

-Consistency : 4% (40 g/l)

-Pulping time: 2030 min

-Total cycle time: 3040 min

to sock chest

Process Controls:

-Concentration

-Dispersability

Pulping processWater dosing


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6"

HELICO PULPER

DUMPING POIRE

16 "

Cap. 5000 Litres

M1 0-110kW

M11- 30kW

10"

Vp5

Vp6

Vp2

Vp3

WATER

DOSING

Cap. +/- 20m3

TANK

6"6"FL1- flowmeter

FL2- flowmeter

4" P0 - M0

Flow: +/- 180 m3/h

Head: +/- 1.2..1.4 bars

Power: 15 kW

Vp8

Flow: +/- 220m3/H

Head: +/-1 - 1.5 Bars

Power: 22 kW

P2 - M2

6"

6"

6"6"4"

2"

4"

LH1

VM1

VM2

VM3

VM4

VM5

High consitency pulper

-Clear process water for pulp

preparation:

-Consistency : 110130 g/l

-Pulping time: 20 - 40 min

-Total cycle time: 3050 min

ontaminants

DUMPING POIRE

HELI O PULPER

Pulping process


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High consitency pulper

Turbine

Pulper

Dumping poire


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Cellulose bales

Cellulose treatment plant

Pulper feeding


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Refining process

What is refining? Is the mechanical alteration of fibres which is obtained by forcing a

flow of pulp through grooved rotating discs.

Refining of cellulose is commonly divided into four primary

effects: Increased fiber flexibilitydue to internal fibrillation or delamination. External fibrillationof the fiber surface, Finesformation and fiber shortening.


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Evolution of the fibre through refining

flexible fibre

higher specific surface,

unrefined rigid fibres

Refining process


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Refining process

Why to refine the cellulose?

To obtain the most suitable fibre morphology for theHatschek process (sieve retention):

Increase the specific surface of the fibre

Ensure a proper distribution of the fibre in the matrix

Maintain a compromise between degree of fibrillation

(SR) and fibre length (L-AVG)


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Refining process: ABC

ABC: Automatic Batch Control (Hydra cycle)In that configuration, refining is realized per batch and cycled x times throughthe refiner. Allow higher flexibility, but:Variability from batch to batchOutput affected by operation conditions: - filling/emptying the recycling tank

- opening of disk refiner

Solution: independent feeding pump and cst level in recycling tank

Level

Virgen

Unrefined pulp

Storage tank

V1

P

VM33

Flowmeter

Recycling tank

Magnetic

separator

Refiner feeding

pump Refiner

Level

Virgen

Refined pulp

Storage tank

4"

VM30

to production line

from pulper

V2V3


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Level

VirgenUnrefined pulpStorage tank

4"

VM33

P

VM33

FlowmeterF1

Magneticseparator

Refiner feedingpump Refiner

Level

VirgenRefined pulp

Storage tank

4"

VM30

to production line

FlowmeterF2

Refining process: Continous refining

Direct pump recirculation:In that configuration, part of the cellulose is passing only once through the refinerand part is passing several times.Advantages: - simplified installation but need automatic proportional valves

- less quality variation- increased output


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Storage & dosing of cellulose

Special attention has to be given to storage & dosingof cellulose since concentration variations in the stockchest will affect the product characteristics

Eliminate all uncontrolled addition of water (pumps seals

agitators rinsing)Process parameters to be checked regularly

Pulp concentration ( x times /shift)

SR ( x times / shift)

Fibre length (on a weekly base)

Stock chests & agitators to be designed as per welldefined characteristics.


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Stock chest

Storage & dosing of cellulose

Important to maintain a good agitation inthe tanks:

- D / h ratio

- designed agitators: kW rpm Diam


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Synthetic fibre Preparation

PVA debalers

Filler 2

No special treatment is required in thefactory since the fibre is received readyfor use. Supplied in bales (compacted) orin bags.

-Accurate weighing is required-Mix with filler (or cellulose) to disperseand pump

-Mixing energy has to be limited in ordernot to damage the fibre: special impeller

to reduce shear forces.-Use antistatic material to avoid sticking

Caution: once de-compacted, the fibrescan occupy up to 10 times their volume
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Filler plant

Filler 1

Filler 2

Filler 3

Fillers are generally handled in bulk or inbags (or big bags).

RM in powder can behave in different wayaccording to their morphology and physicalcharacteristics:- Ground sand (silica) will flow like water,

- Humidity content may change totally thehandling conditions (> 2% H20 for CaCO3)

- Needle-shaped powder (Wollastonite) orfibrous material (HGW) will bridge in thesilos or hoppers.

- Some fillers tends to agglomerates andneed special intensive mixer to disperseproperly (Kaolin, amorphous silica,pigments)

- High shear mixers may be requested forprocess reasons (Bentonite)
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Filler plant big bag feeding


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Filler plant - feeding


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Filler plant - feeding


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Mixing process

Obtain an homogeneous mixture of the differentRM within a certain accuracy and time (min > 10%machine max. output)

Depending of layout, different configuration canbe selected: from 1 3 mixers

Mixing cycle: 8 12 min (5 to 8 mix/hrs)

Typical concentration of mixers:

Cement mixer: 500 800 g/lFillers: 200 500 g/l

Final mixer: 250 350 g/l


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s1

s2

h1

h2

d1

d2

baffles

shaft

Mixing process

Ekato turbine

traditional turbines

Ekato mixer design


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Mixing process

Mixing sequence: Fibre mixer: water + filler (CSF Kaolin - )

+ PVA (reduce mixing speed)

Cement mixer: water + cementnote: cement mixer not always needed

Final mixer Water + cellulose + fibre mixer+ fillers

waiting time+ cementmixing time (2 min) before releasing toslurry chest.


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RMP: 3 mixers configuration

Cement

Mixer

CementSilo

Fiber

Mixer

Fill

er

1

Main Mixer

Fill

er

2

Water

PVA

Debaler

Cell

RMP: 2 main mixers configuration


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Main Mixer

n1

Slurry chest

Cell

Cement

silo

Cel. loop

water

MP1MP1

MP2 MP3MP3 MP2

water

Main Mixer

n2

RMP: 2 main mixers configuration


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RMP: 1 main mixer configuration

Main Mixer n1

Useful Vol 8m

RM 4

Vol

1m

RM 3

Vol

,25m

RM 2

Vol

2,1m

Slurry Chest

Useful Vol 12m

RM 1

Vol 4m

RM 5

Vol

,25m

Cement Silo

Water

Loop Al(OH)3

Loop Silica

Loop Bentonite

Loop Cellulose


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Thank you for yourattention

01 mixture and rmp

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