Plastic and nonmetallic article shaping or treating: processes – Including step of generating heat by friction
Patent
1993-04-28
1998-11-03
Speer, Timothy
Plastic and nonmetallic article shaping or treating: processes
Including step of generating heat by friction
264 66, 264 71, F27B 904
Patent
active
058303944
DESCRIPTION:
BRIEF SUMMARY
The invention relates to the manufacture of building materials and may be used for making wall and other building products, e.g., brick and wall panels, preferably out of clayey raw materials. It can also be used for preparing batch mixtures, mortars and for other uses.
STATE OF THE ART
Most valuable building products from the point of view operational characteristics and architectural and aesthetic properties are ceramic brick or stones of clayey raw materials which are produced by preparing a raw material molding green body, drying it at 100.degree. to 150.degree. C. during 2 to 4 days, and firing at 900.degree. to 1100.degree. C. during 2 to 3 days. For producing, lining brick, either monomineral clays or loams have to be used, or clayey raw material should be homogenized and stirred which calls for high energy consumption with rather bulky production equipment. Inclusions of limestone or dolomite of a size larger than 1 to 2 mm in an amount exceeding 1 to 3% in this process are inadmissible as they result in destruction of fired bricks upon wetting. Long duration of firing is necessary to ensure curing of the brick during several hours under conditions where the brick surface is heated to a temperature not above the upper limit of the sintering range and the points most distant from the surrface of the brick are heated to at least the lower limit of the sintering range. The long time periods for temperature rise and temperature decrease during firing are necessary to avoid defects. These features result in a protracted production cycle lasting for at least 10 to 15 days, high thermal energy consumption for drying and firing, high material usage and cost of production equipment and as a result high brick cost.
Lower duration of production processes is characteristic of processes making use of the hydraulic hardening mechanism instead of pyrosilicate hardening. The main of these processes are as follows.
Processes of making silica brick, stones, and silica-concrete blocks involves forming green body from humidified mixture of quartz sand and lime, generally without adding other binders; autoclaving the resulting green body under saturated steam pressure of 0.8 to 1.6 MPa at 175.degree. to 200.degree. C. during 7 to 12 hours. These processes are characterized by the need to prepare lime in lime kilns, the need to use sand without harmful inclusions, e.g., clayey inclusions. In the majority of applications quartz sand is to be ground completely or in part. These processes are accompanied by dust. In addition to said features, these processes are characterized by necessity of employment the autoclaves and steam of high parameters. These lime-silica products have low aesthetic value deteriorating during operation. This is why constructions made from silica brick are either painted or lined. In silica brick, similarly to ceramic brick, cohesion with mortar deceases with an increase of frost-resistance, and vice versa since these parameters depend on accessible porosity on the product surface.
Building products are also manufactured on the basis of cement binders, e.g., Portland cement. Cement-based products are capable for hardening both under autoclaving and at normal temperature. However, preparing cement is associated with high fuel consumption for firing raw meal at temperatures about 1500.degree. C. and with high energy requirements for fine grinding both carbonate and clayey raw materials and very strong clinker as firing product. Production and application of cement are associated with a strong dust lading of air. Production equipment is characterized by a high material usage, especially for the construction of lined kilns. Cement-based products are also of a low aesthetic value if used without supplementary finishing.
In addition to said processes, known in the art are other processes involving the use of compositions or components containing clayey raw materials or products of their processing: presence of lime only under autoclaving conditions and are inactive at normal temperature; components of
REFERENCES:
patent: 1131463 (1915-03-01), Berry
patent: 3316334 (1967-04-01), Walen
patent: 3434855 (1969-03-01), Webb
Bazhenov, Yu M., "Concrete Making Practice", Yysshaya Shkola Pubishers, Moscow, 1978, p. 56.
Peregudov, V.V. et al., "Thermal Processes. . . ", Stroyizdat Publishers, Moscow, 1983, pp. 263, 271, 272, 276, 286, 287, 356.
Butt, Yu. M. et al., "General Practice of Silicate Production", Stroyizdat Pub. Moscow, 1976, pp. 94, 140, 229.
Onatski, S.P., "Production of Expanded Clay Aggregate," Publishing House for Literature on Construction Problems, Moscow, 1971, pp. 88, 109, 179, 208, 209, 217-219.
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