Production of foam materials and production line to this end

FIELD: process engineering.

SUBSTANCE: invention relates to production of foam materials on the basis of asbestos, basalt, carbon, polyether or polyamide or any other inorganic and organic fibres to be used in aircraft and ship building, machine building, etc. This method comprises the steps that follow. Production of foam bilk from initial mix of fibres and feed of said foam bulk to conveyor belt. Foam bulk is dried in drying chambers at stepwise increase in temperature in successive zones. Foam bulk is annealed in the kiln to foam material and cut reset-size boards. Note here that drying and annealing comprises simultaneous effects of IR radiation and convective heat. Note here that drying stepwise temperature increase occurs at 60°C-170°C. Annealing is performed at 190-280°C. Foam bulk is fed through drying chambers and annealing kiln at the rate of 6-12 m/h. Invention proposes also the conveyor line to this end.

EFFECT: accelerated drying, higher quality of foam material, continuous production.

8 cl, 3 dwg

 

The invention relates to the production of foams, for example, on the basis of asbestos, basalt, carbon, polyester or polyamide, and other kinds of inorganic and organic fibers used in the field of aviation and shipbuilding, mechanical engineering and electronic industry.

A method of producing heat and sound insulation proabability plates, including obtaining promessi from the source of raw materials and heat treatment of Promesse by step effortlessly place a call to the rise of temperature promessi in the convective heat input as follows:

- in the first zone at 65±2°C Promass incubated for 120 min to achieve a moisture content 750-800% (from initial moisture 1100-1500%),

- in the second zone at 75±2°C Promass incubated for 120 min to achieve a moisture content 650-750%,

in the third zone at 85±2°C Promass incubated for 90 min to achieve a moisture content 550-650%,

in the fourth zone at 95±2°C Promass incubated for 90 min to achieve a moisture content between 450 and 550%,

- in the fifth zone at 105±2°C Promass incubated for 90 min to achieve a moisture content 350-450%,

in the sixth zone at 120±3°C Promass incubated for 120 min to achieve a moisture content 200-350%,

the seventh zone at 130±3°C Promass stand in accordance with the s 120 min to achieve a residual moisture content of 3-5%.with. The USSR №1661174).

The disadvantage of this method is the long process of heat treatment of promessi average of 12.5 hours, because of the inefficient way of heat.

Closest to the claimed method and adopted for the prototype is a method of foam production, including the production of promessi from the feedstock, convective drying promessi effortlessly place a call by stepwise raising the temperature and roasting promessi to obtain a foam, characterized in that Promass before entering on convective drying of previously dehydrated in vacuum at a pressure of 100-150 mm of hcpa. Art. within 30-120 seconds to achieve a moisture content of promessi 600-700%, convective drying promessi exercise regime: in the first zone at a temperature of 75±2°C until the moisture content of promessi 500-600%, in the second zone at a temperature of 85±2°C until the moisture content of promessi 400-500%, in the third zone at a temperature of 95±2°C until the moisture content of promessi 300-400% in the fourth zone at a temperature of 105±3°C until the moisture content of promessi 200-300%, in the fifth zone at a temperature of 115±3°C until the moisture content of promessi 100-200% in the sixth zone at a temperature of 130±5°C until the moisture content of promessi 1-3%, and the firing of promessi conduct when exposed to infrared radiation at 230-250°C in ECENA 10-30 minutes

As a source of raw materials use of magnesium hydrosilicate fibrous structure, the fibers of basalt, polyester or polyamide, wetting agent, surfactant, and water (patent RF №2098392).

The disadvantage of this method is the length of the drying process (11 hours) and the heterogeneity of the structure of the obtained foam thickness on the bottom and top surfaces of the crust is formed, which strongly affects the electronic and mechanical parameters of the final product.

Known conveyor line for the production of foams containing a foam generator, a continuous grid resting on the rollers and carrying the substrate, the drying unit and the actuator, in which the generator is made of several consecutive chambers increasing in volume from the previous to the subsequent, and the drying unit is made in the form of magneto electric furnace whose walls are made of materials with different electrical and physical properties, and the windings of the inductors are made sectional sofas with different number of turns in the sections and between the sections of the windings in the walls of the chambers are made of the slotted holes with steam venting pipes.

To avoid spreading promessi outside the grid before it is installed formulating equipped with supporting rollers with ribs to give the substrate to ritabrata form (and.with. The USSR №1139720).

The disadvantage of this invention is the complex structure of the foam generator, not providing a regulated supply promessi on the conveyor, and unreliable work of formulates that do not provide guaranteed trough-like shape of the substrate in the process of the spill on her promessi. In the finished products in the form of sheets (mats) does not have the required geometrical dimensions, which degrades the quality of the material and increases the amount of waste.

It is also known a device for heat treatment of heat and sound insulation proabability plates containing a closed conveyor in the form of a grid, a device for supplying promessi on the conveyor, sectional drying chamber, the ventilation system supply, suction and delivery ducts, in which the walls of the drying chamber made in the form of distribution boxes with holes located in the inner wall in two rows on each side, the total area of which is the cross-sectional area of the drying chamber, while mesh conveyor is installed with a clearance from the inner wall, and suction ducts previous sections of the drying chamber connected to the inlet ducts of the subsequent sections and located in a sound-proof casing to the ceiling part of the drying chamber.with. The USSR №1661174).

what dostatkom this device is the ventilation system supply and construction of the drying chamber designed for continuous drying process is 12.5 hours. Low conveying capacity and high energy consumption significantly increase the cost of the foam.

Closest to the technical essence and the achieved result is a conveyor line for the production of foams based on inorganic and organic fibers containing a foam generator, a conveyor mounted on the frame with a continuous mesh belt supported on rollers, a substrate located on the surface of the continuous mesh belt feeder substrate in continuous mesh belt, the drying chamber of the kiln and the actuator, characterized in that it further provided with a device for creating a vacuum, which is located under the conveyor before drying chambers and connected with a reservoir for collecting the water removed from promessi, and with the foam generator

Conveyor line prototype includes 6 drying chambers in which the temperature is maintained at from 75°C to 130°C with an interval of 10°C. the Drying is carried out due to the convective heat and kiln temperature is maintained 230-250°C by exposure to infrared radiation (RF patent No. 2098728).

The disadvantage of this conveyor line is that it is not rednaznachena for continuous operation, has a low productivity - drying process takes around 11 hours.

The dehydrator of promessi comprising a vacuum device, a negative impact on the geometry of the manufactured material and respectively.

The technical challenge is to develop a method of foam production, allowing to reduce the duration of the drying process promessi, to improve the quality of the produced foam and conveyor line, designed for continuous operation with high performance.

To solve this problem is proposed a method of foam production, including the production of promessi from the source mixture based fibers, promessi on conveyor conveyor line, drying Promesse by passing it through a drying chamber effortlessly place a call with speed rise temperature, calcination promessi in the furnace to obtain the foam and cutting it on a plate of a given size, wherein the drying and firing of promessi carried out by simultaneous exposure to infrared and convective heat source, effortlessly place a call stepwise rise of temperature of drying is carried out with a 60°C to 170°C, and roasting promessi carried out at a temperature from 190°C to 280°C, and the passage of promessi through the drying chamber and kiln carry out with what korostil 6-12 m/hour.

Impact on Promass infrared heat source provide the top and convection from below.

The use of combination schemes of heating by simultaneous exposure to Promass infrared and convective heat allows for speed promessi 6-12 m/hour to provide optimal drying, i.e. maintaining the drying temperature from 60°C to 170°C with an accuracy of ±2°C and high intensity drying.

Low initial drying temperature 60°C excludes the formation of a crust on the surface of the foam, so it has high mechanical and electronic properties.

The speed promessi on the conveyor is 6-12 m/h, which can significantly reduce the drying time and consequently increase the volume of production in comparison with the prototype for the same period of time.

This method enables the manufacture of a foam-based fibers (asbestos, basalt, carbon fiber, polyester and polyamide, and others), with heat and sound insulation and stealth properties.

The original components for the manufacture of promessi are fibers, wetting agent, water-repelling liquid and water.

The proposed method of manufacture is as follows.

Given the formulation of the original components of the raw mix of loaded and in the foam generator: first fiber, then the water, wetting SW and repellent silicone. The mixing was carried out before the preparation of the volume promessi equal to the volume of the foam generator. Then Promass portions served on a conveyor conveyor line with a continuous mesh tape, where she speeds of 6-12 m/h is passed through the drying chambers 12 with a stepped effortlessly place a call by raising the temperature from 60°C to 170°C with a step of 10°C and through the kiln, where he maintained a temperature of from 190°C to 280°C depending on the composition of the initial mixture, the desired thickness and mechanical properties of the produced foam.

In kilns and furnaces due to the presence in the upper part of the tubular infrared heaters, and in the lower part of tubular heaters convection type promessa was subjected to intense heat from the integrated effect of the two sources of heat, resulting in the process of drying and firing when the length of the conveyor line 36 m and the feed speed of promessi, for example, 10 m/h was realized in the period of 3.6 hours instead of 11 hours, as the prototype.

Next was carried out by cutting made of foam plates of a given size.

To solve the technical problem is also offered conveyor line for the production of foams containing a device for the manufacture and supply Promesse, the conveyor, the plant on the frame with a continuous mesh tape a substrate located on the surface of the continuous mesh belt feeder substrate in continuous mesh belt, drying and kiln, a reservoir for collecting removed from promessi moisture, coupled with a device for the manufacture of promessi, and the actuator, characterized in that the device for the manufacture and supply conveyor promessi includes at least two of the foam generator with a screw mixers and placed them under a pressurized tank dispenser with sliding shutter with electric, continuous mesh belt relies on cross holders of the conveyor, the upper part of each of the drying chamber and furnaces are installed tubular infrared heaters, and at the bottom posted by tubular heaters convection type.

Tubular heaters convection type, placed under continuous mesh belt conveyor, equipped with personal protective screens, the ingress removed from promessi moisture in heaters.

A reservoir for collecting removed from promessi moisture is located beneath the conveyor from area of spill promessi to zone kiln.

Drying and kiln contain devices to maintain and control the temperature at a given level.

Device for podderjana and temperature control include control devices and thermocouples, individual for tubular electric heaters, convective type and tubular infrared heaters.

The presence of the proposed conveyor line at least two of the foam and pressurized tank dispenser for periodic and dosed feed promessi on the conveyor ensures continuous operation of the pipeline.

The placement of multiple tubular infrared heaters and tubular heaters convection type respectively in the upper and lower parts of each of the drying chamber and kiln can significantly increase the drying speed and thus reduce the time of manufacture of the foam almost in 2 times.

Depending on the thickness and composition of the produced material is calculated speed of the conveyor line and the required number of kilns and heaters.

Personal protective screens on tubular heaters convection type needed to exclude periodic stops of the conveyor due to obstruction of the heaters located under the conveyor.

The tank, located under the conveyor, allows you to collect and through the heat recovery device to reuse almost all of the removed liquid part of promessi.

The invention is illustrated by drawings, to the verge presents:

In Fig.1 - General view of the conveyor line for foam production.

In Fig.2 is a top view.

In Fig.3 - drying chamber (a) cross section; b) longitudinal section.

Conveyor line for foam production contains two foam generator 1, which is placed under a pressurized tank dispenser with 2 slide gate 3, the conveyor 4, mounted on the frame 5 with a continuous mesh belt 6, based on cross holders 7 of the conveyor 4, the substrate 8, fence 9, the leading drum 10, a driven drum 11, an actuator 12, the feeder substrate (of glass) 13, the drying chamber 14, kiln 15, a reservoir for collecting the removed moisture 16 and device for the recovery of the removed moisture 17 which is connected to the generator 1. Device for cutting custom foam contains a receiving table 18, the longitudinal and transverse to the blade 19 with electric buffet removing finished plates 20, the ventilation system 21, the control device and maintain the temperature of 22.

Conveyor line includes twelve drying chambers 14, each of which is coated with a layer of insulation 23 and comprises nine infrared tube heaters 24 above promessas, and nine tubular heaters 25 convective type located under the mesh conveyor belt and Conn is the R top individual screens 26.

Conveyor line works as follows.

The dispersion of the foam containing, for example, asbestos fiber, carburized fiber, water repellent and water is supplied to the foam generator 1, which is the formation of the source promessi. Through the gate at the bottom of the foam generator 1 promessa results in a pressure tank-hopper 2, from which through the sliding gate 3 with the drive Promass portions served on a substrate 8, which by means of the feeder 13 pre-stack on a continuous mesh belt conveyor 6 4. Continuous operation of the conveyor line is provided by loading promessi of two foam generators 1.

The required thickness of promessi height adjustable restrictive strap 9, the side walls of promessi are formed in the substrate 8, which is supported by uprights cross holders 7 of the conveyor 4.

Promessa moves on the conveyor with the speed of 6-12 m/h through twelve drying chambers 14, where promessi moisture is completely removed. Then promessa enters the kiln 15, which ends the process of the formation of foam. After firing the foam served in a device for cutting into slabs of a given size.

Thus, the proposed invention allows to provide a continuous process for the production of foams in the core is ve inorganic and organic fibers, to reduce the drying time of 1.8-3 times, to improve the quality of the foam and the volume of production per unit time.

1. The method of foam production, including the production of promessi from the source mixture based fibers, promessi on conveyor conveyor line, drying Promesse by passing it through a drying chamber effortlessly place a call with speed rise temperature, calcination promessi in the furnace to obtain the foam and cutting it on a plate of a given size, wherein the drying and firing of promessi carried out by simultaneous exposure to infrared and convective heat source, effortlessly place a call stepwise rise of temperature of drying is carried out with a 60°C to 170°C and calcination promessi carried out at a temperature from 190°C to 280°C, the passage of promessi through the drying chamber and kiln carried out with a speed of 6 to 12 m/h.

2. The method according to p. 1, characterized in that the impact on Promass infrared heat source provide the top and convection from below.

3. Conveyor line for the production of foams containing a device for the manufacture and supply Promesse, a conveyor mounted on the frame with a continuous mesh tape, a substrate located on the surface of the continuous mesh belt feeder substrate on continuous netcatalena, drying and kiln, a reservoir for collecting removed from promessi moisture, coupled with a device for the manufacture of promessi, and the actuator, characterized in that the device for the manufacture and supply conveyor promessi includes at least two of the foam generator with a screw mixers and placed them under a pressurized tank dispenser with sliding shutter with electric, continuous mesh belt relies on cross holders of the conveyor, the upper part of each of the drying chamber and furnaces are installed tubular infrared heaters, and at the bottom posted by tubular heaters convection type.

4. Conveyor line under item 3, characterized in that the tubular heaters convection type, placed under continuous mesh belt conveyor, equipped with personal protective screens.

5. Conveyor line under item 3, characterized in that the collecting tank removed from promessi moisture is located beneath the conveyor from area of spill promessi to zone kiln.

6. Conveyor line under item 3, characterized in that the drying chamber and the kiln contain devices to maintain and control the temperature at a given level.

7. Conveyor line under item 3, characterized in that the conveyor speed is 6-12 m/h

8. To kvaerna line p. 6, wherein the device for maintaining and controlling the temperature at a given level include control devices and thermocouples for individual tubular electric heaters, convective type and tubular infrared heaters.



 

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2 tbl

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1 ex, 1 tbl

Filler for concrete // 2528809

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2 ex, 1 tbl

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1 tbl, 3 ex

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1 tbl, 3 ex

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1 tbl, 3 ex

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4 cl, 1 dwg, 1 tbl

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2 cl, 1 ex, 1 tbl

FIELD: construction.

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5 cl, 4 dwg

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FIELD: construction.

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1 dwg

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2 cl

FIELD: construction.

SUBSTANCE: invention relates to the field of construction, namely, to structures for electric heating of a concrete mix in construction conditions. The electric heating hopper of cyclic action is made as installed with the angle of inclination 70…75° to the bottom by steel plate electrodes having horizontal strip cuts with height of 8…10 mm, arranged along the height of the electrode via 5…6 cm.

EFFECT: invention will make it possible to provide for increased evenness of heating of a concrete mix, to reduce duration of heating of a concrete mix, to reduce power consumption.

1 dwg

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