Basic Ideas :
1. Minimize the Waste from Production Line of Fiber Cement Process.
2. Minimize the Waste from Back Water / Decantation /Waste Water Tank
3. Basic Fundamental of Cement Reactivity to Water and Filler / Aggregrate.
Concepts :
1. Up grade from old process methode to new once ( countinues methode ).
2. Minimize to usage of utility - Electricity.
3. Minimize the raw material damages in the line process - low yeild
Action :
Still in my Project ..........( hope will be realised ....... )
Application :
On new machine / new project
Minggu, 28 November 2010
Minggu, 21 November 2010
MAK- Fiber is 3D-reinforcement solution
What is MAK-Fiber ?
MAK-Fiber is an Organic Synthetic Fiber was applied to Fiber Cement and Board Manufacture which binds with aggregate or filler in mixture components.
MAK-Fiber is creating a highly cohesive 3-dimentional network with enhanced mechanical performance and durability.
Why used MAK-Fiber ?
The use of MAK-Fiber in Fiber Cement or Board can or able to replace Asbestos fiber.
However, it has been clarified that asbestos remarkably injures human health, for example, it causes cancer of the lung and the use of asbestos has been therefore becoming to be legally restricted or prohibited in many countries.
Benefits with MAK-Fiber
Strength without brittleness
The strongly fiber – bound 3D structure and cohesive action of MAK-Fiber allow
+ Cementitious matrix tensile strength due to high fiber elastic modulus.
+ Crack and micro-crack preventive during curing time .
+ Effective bridge mechanism provided the use of fiber with the optimal aspect
ratio ( a very wide range of length-diameter ratios are available)
+ Chemical and mechanical adherence to the cementitious matrix
Thermal and Chemical resistance
MAK-Fiber recognized high resistance to most chemical and physical agents provides a durable reinforcement solution
+ Long term stability
+ Resistance to outdoor exposure ( no rust or UV alterations)
+ Resistance to biological agent ( growth of mildew, fungi,etc)
+ Resistance to cement alkalinity, acids and organic solvents
+ Thermal Resistance
Applications of MAK-Fiber
- Fiber Cement and Board Sheet Manufacture
To replace an asbestos fiber and substitution to cellulose fiber.
Can be applied to both Air Cure and Autoclave Process.
Improves to Strength, Flexibility and Bending of the Fiber Cement and Board
product.
Anti-uv and high temperature , cold resistance ability.
Recommended usage conditions of MAK-Fiber
Please contact to Frangky
MAK-Fiber is an Organic Synthetic Fiber was applied to Fiber Cement and Board Manufacture which binds with aggregate or filler in mixture components.
MAK-Fiber is creating a highly cohesive 3-dimentional network with enhanced mechanical performance and durability.
Why used MAK-Fiber ?
The use of MAK-Fiber in Fiber Cement or Board can or able to replace Asbestos fiber.
However, it has been clarified that asbestos remarkably injures human health, for example, it causes cancer of the lung and the use of asbestos has been therefore becoming to be legally restricted or prohibited in many countries.
Benefits with MAK-Fiber
Strength without brittleness
The strongly fiber – bound 3D structure and cohesive action of MAK-Fiber allow
+ Cementitious matrix tensile strength due to high fiber elastic modulus.
+ Crack and micro-crack preventive during curing time .
+ Effective bridge mechanism provided the use of fiber with the optimal aspect
ratio ( a very wide range of length-diameter ratios are available)
+ Chemical and mechanical adherence to the cementitious matrix
Thermal and Chemical resistance
MAK-Fiber recognized high resistance to most chemical and physical agents provides a durable reinforcement solution
+ Long term stability
+ Resistance to outdoor exposure ( no rust or UV alterations)
+ Resistance to biological agent ( growth of mildew, fungi,etc)
+ Resistance to cement alkalinity, acids and organic solvents
+ Thermal Resistance
Applications of MAK-Fiber
- Fiber Cement and Board Sheet Manufacture
To replace an asbestos fiber and substitution to cellulose fiber.
Can be applied to both Air Cure and Autoclave Process.
Improves to Strength, Flexibility and Bending of the Fiber Cement and Board
product.
Anti-uv and high temperature , cold resistance ability.
Recommended usage conditions of MAK-Fiber
Please contact to Frangky
Sabtu, 20 November 2010
FOCUSED BEAM REFLECTANCE MEASUREMENT
Introduction:
This introduction presents several uses of focused beam reflectance measurement (FBRM) as tool to measure flocculation. It includes information on the interaction of wet-end aids with the different pulp fractions, such as optimal polymer dosage and the resulting floc properties (floc size, strength, etc.) and all the filler in the process both making Fiber Cement Sheet and Paper Sheet.
Background :
Flocculation is a complex phenomenon that is extremely important in both Fiber Cement Sheet and Paper Sheet process.
The flocculation is intermediate state between the raw materials and the final product in both Fiber cement and Paper Manufacture.
Functions of FBRM for Engineers/ scientists or operator :
- Identification of flocculation mechanism a real time in process
- Monitoring and control to deflocculation and reflocculation in the process
- Identify dissolved and colloidal material agglomeration of mixture material .
All the functions to enable the engineers, scientists or operator with all the information to enhance process performance and easy to handle or prepared particles to the next process.
Why , used a FBRM
- Can monitoring the particle size or floc size
- Can see all the process of Deflocculation and Reflocculation
- Can make / evaluation thru the picture (photo) time to time process
Added technology to Engineers/ Scientists or Operator:
- Real time to control the process i.e additive , filler, pulp, cement etc.
- Achievement to standardization of finish product.etc
Frangky Welly W
This introduction presents several uses of focused beam reflectance measurement (FBRM) as tool to measure flocculation. It includes information on the interaction of wet-end aids with the different pulp fractions, such as optimal polymer dosage and the resulting floc properties (floc size, strength, etc.) and all the filler in the process both making Fiber Cement Sheet and Paper Sheet.
Background :
Flocculation is a complex phenomenon that is extremely important in both Fiber Cement Sheet and Paper Sheet process.
The flocculation is intermediate state between the raw materials and the final product in both Fiber cement and Paper Manufacture.
Functions of FBRM for Engineers/ scientists or operator :
- Identification of flocculation mechanism a real time in process
- Monitoring and control to deflocculation and reflocculation in the process
- Identify dissolved and colloidal material agglomeration of mixture material .
All the functions to enable the engineers, scientists or operator with all the information to enhance process performance and easy to handle or prepared particles to the next process.
Why , used a FBRM
- Can monitoring the particle size or floc size
- Can see all the process of Deflocculation and Reflocculation
- Can make / evaluation thru the picture (photo) time to time process
Added technology to Engineers/ Scientists or Operator:
- Real time to control the process i.e additive , filler, pulp, cement etc.
- Achievement to standardization of finish product.etc
Frangky Welly W
Senin, 15 November 2010
How To Elimination or Protected Cellulose From Alkalinity of the Cement ?
Key words :
Cellulose is not permanently resistant to the alkalinity of the cement.
Sizing to the Cellulose Fiber.
Background :
In the Papermaking Process ( in the first started from china as early as AD 768 ) , why to sized the cellulose fiber ?
- To improve the water resistance of the paper surface
- To improve the Surface Strength
- To Improve printability of paper
Basic Fundamental:
Cellulose a complex carbohydrate, (C6H10O5)n, that is composed of glucose units, forms the main constituent of the cell wall in most plants, and is important in the manufacture of numerous products, such as paper, textiles, etc.
Cellulose is Hydrophilic (water-loving)
Hydrophilic literally translates as "water loving" or "water friend." Hydrophilic substances are attracted to, and dissolve well within, water.Hydrophilic is typically used to describe a property of a molecule, and refers to the likelihood of its bonding with the hydrogen molecule in water. A hydrophilic molecule is not just soluble in water but also in other polar solvents; it will dissolve less readily in oils and other hydrophobic solvents. Hydrophilic molecules are charge-polarized so that one end is positive and the other negative.A hydrophilic molecule or portion of a molecule is one that is typically charge-polarized and capable of hydrogen bonding, enabling it to dissolve more readily in water than in oil or other hydrophobic solvents. Hydrophilic and hydrophobic molecules are also known as polar molecules and nonpolar molecules, respectively. Some hydrophilic substances do not dissolve. This type of mixture is called a colloid. Soap, which is amphipathic, has a hydrophilic head and a hydrophobic tail, allowing it to dissolve in both waters and oils.
An approximate rule of thumb for hydrophilicity of organic compounds is that solubility of a molecule in water is more than 1 mass % if there is at least one neutral hydrophile group per 5 carbons, or at least one electrically charged hydrophile group per 7 carbons
History
As the process of sizing had and has the intent of making the paper suitable for printing, it would seem slightly ironic that some processes of sizing would make printing paper a problem for the continued existence of that paper and those who would preserve them. Sizing processes started early on in the papermaking processes, with historians citing that items, such as starch, were early sizing agents used on paper. Dade Hunter in papermaking through Eighteen Centuries corroborates this by writing, “The Chinese used starch as a size for paper as early as A.D. 768 and its use continued until the fourteenth century when animal glue was substituted.” The early modern paper mills Europe, which produced paper for printing and other uses, the sizing agent of choice was gelatin, as Susan Swartzburg writes in Preserving Library Materials, “Various substances have been used for sizing through the ages, from gypsum to animal gelatin.” Hunter describes the process of sizing in these paper mills in the following:The drying completed, the old papermakers dipped their paper into an animal size that had been made from the parings of hides, which they procured from the parchment-makers. It was necessary to size that paper so that it would be impervious to ink, but sizing was more needed in writing than in printing papers. Many books of the fifteenth century were printed upon paper that had not been sized, this extra treatment not being essential for a type impression. The sizing was accomplished by a worker holding a number of sheets by the aid of two wooden sticks, and dipping the paper into the warm gelatinous liquid. The sheets were then pressed to extract the superfluous gelatine. This crude method of sizing the paper was extremely wasteful as many sheets were torn and bruised beyond use. The sizing room of the early paper mills, was, for this reason, known as the ‘slaughter-house.’With the advent of the mass production of paper, the type of size used for paper production also changed. As Swartzburg writes, “By 1850 rosin size had come into use. Unfortunately, it produces a chemical action that hastens the decomposition of even the finest papers.” In the field of library preservation it is known “that acid hydrolysis of cellulose and related carbo-hydrates is one of the key factors responsible for the degradation of paper during ageing.” Some recent professional work has focused on the specific in the degradation involved in the deterioration of paper that has had a rosin sizing process, and what amount of rosin affects the deterioration process, in addition to work on developing permanent paper and sizing agents that will not eventually destroy the paper. An issue on the periphery to the preservation of paper and sizing, is washing, which is described by V. Daniels and J. Kosek as, “The removal of discolouration in water is principally effected by the dissolution of water-soluble material; this is usually done by immersing paper in water. In such a process, surface level items applied to the paper, such as size in early paper making processes as seen above, have the possibility of being removed from the paper, which might have some item specific interest in a special collections library. With later processes in paper making being more akin to “engine sizing,” as H. Hardman and E. J. Cole describe it, “Engine sizing, with is part of the manufacturing process, has the ingredients added to the furnish or stock prior to sheet formation, the concern for the removal of size is less, and as such, most literature focuses on the more pressing issue of preserving acidic papers and similar issues.
Implementation on Fiber Cement making
Cellulose Fiber Sized in Fiber Cement Process :
Chemically treating cellulose fibers to impart the fibers with hydrophobicity and/or durability, and making cellulose fiber reinforced cement composite materials using the Chemical / Additive treated cellulose fibers which the cellulose fibers are treated or sized with specialty chemicals that impart the fibers with higher hydrophobicity by partially or completely blocking the hydrophilic groups of the fibers.
This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption have advantage reduced rate of water absorption, lower water migration, lower water permeability so the final products made from these materials have improved freeze-thaw resistance, reduced efflorescence, reduced dissolution and re-deposition of water-soluble matrix components in natural weathering.
Using fiber sizing almost to improve other product properties to the physical and mechanical of final product.
More information : sent to my Email
Frangky Welly W
Cellulose is not permanently resistant to the alkalinity of the cement.
Sizing to the Cellulose Fiber.
Background :
In the Papermaking Process ( in the first started from china as early as AD 768 ) , why to sized the cellulose fiber ?
- To improve the water resistance of the paper surface
- To improve the Surface Strength
- To Improve printability of paper
Basic Fundamental:
Cellulose a complex carbohydrate, (C6H10O5)n, that is composed of glucose units, forms the main constituent of the cell wall in most plants, and is important in the manufacture of numerous products, such as paper, textiles, etc.
Cellulose is Hydrophilic (water-loving)
Hydrophilic literally translates as "water loving" or "water friend." Hydrophilic substances are attracted to, and dissolve well within, water.Hydrophilic is typically used to describe a property of a molecule, and refers to the likelihood of its bonding with the hydrogen molecule in water. A hydrophilic molecule is not just soluble in water but also in other polar solvents; it will dissolve less readily in oils and other hydrophobic solvents. Hydrophilic molecules are charge-polarized so that one end is positive and the other negative.A hydrophilic molecule or portion of a molecule is one that is typically charge-polarized and capable of hydrogen bonding, enabling it to dissolve more readily in water than in oil or other hydrophobic solvents. Hydrophilic and hydrophobic molecules are also known as polar molecules and nonpolar molecules, respectively. Some hydrophilic substances do not dissolve. This type of mixture is called a colloid. Soap, which is amphipathic, has a hydrophilic head and a hydrophobic tail, allowing it to dissolve in both waters and oils.
An approximate rule of thumb for hydrophilicity of organic compounds is that solubility of a molecule in water is more than 1 mass % if there is at least one neutral hydrophile group per 5 carbons, or at least one electrically charged hydrophile group per 7 carbons
History
As the process of sizing had and has the intent of making the paper suitable for printing, it would seem slightly ironic that some processes of sizing would make printing paper a problem for the continued existence of that paper and those who would preserve them. Sizing processes started early on in the papermaking processes, with historians citing that items, such as starch, were early sizing agents used on paper. Dade Hunter in papermaking through Eighteen Centuries corroborates this by writing, “The Chinese used starch as a size for paper as early as A.D. 768 and its use continued until the fourteenth century when animal glue was substituted.” The early modern paper mills Europe, which produced paper for printing and other uses, the sizing agent of choice was gelatin, as Susan Swartzburg writes in Preserving Library Materials, “Various substances have been used for sizing through the ages, from gypsum to animal gelatin.” Hunter describes the process of sizing in these paper mills in the following:The drying completed, the old papermakers dipped their paper into an animal size that had been made from the parings of hides, which they procured from the parchment-makers. It was necessary to size that paper so that it would be impervious to ink, but sizing was more needed in writing than in printing papers. Many books of the fifteenth century were printed upon paper that had not been sized, this extra treatment not being essential for a type impression. The sizing was accomplished by a worker holding a number of sheets by the aid of two wooden sticks, and dipping the paper into the warm gelatinous liquid. The sheets were then pressed to extract the superfluous gelatine. This crude method of sizing the paper was extremely wasteful as many sheets were torn and bruised beyond use. The sizing room of the early paper mills, was, for this reason, known as the ‘slaughter-house.’With the advent of the mass production of paper, the type of size used for paper production also changed. As Swartzburg writes, “By 1850 rosin size had come into use. Unfortunately, it produces a chemical action that hastens the decomposition of even the finest papers.” In the field of library preservation it is known “that acid hydrolysis of cellulose and related carbo-hydrates is one of the key factors responsible for the degradation of paper during ageing.” Some recent professional work has focused on the specific in the degradation involved in the deterioration of paper that has had a rosin sizing process, and what amount of rosin affects the deterioration process, in addition to work on developing permanent paper and sizing agents that will not eventually destroy the paper. An issue on the periphery to the preservation of paper and sizing, is washing, which is described by V. Daniels and J. Kosek as, “The removal of discolouration in water is principally effected by the dissolution of water-soluble material; this is usually done by immersing paper in water. In such a process, surface level items applied to the paper, such as size in early paper making processes as seen above, have the possibility of being removed from the paper, which might have some item specific interest in a special collections library. With later processes in paper making being more akin to “engine sizing,” as H. Hardman and E. J. Cole describe it, “Engine sizing, with is part of the manufacturing process, has the ingredients added to the furnish or stock prior to sheet formation, the concern for the removal of size is less, and as such, most literature focuses on the more pressing issue of preserving acidic papers and similar issues.
Implementation on Fiber Cement making
Cellulose Fiber Sized in Fiber Cement Process :
Chemically treating cellulose fibers to impart the fibers with hydrophobicity and/or durability, and making cellulose fiber reinforced cement composite materials using the Chemical / Additive treated cellulose fibers which the cellulose fibers are treated or sized with specialty chemicals that impart the fibers with higher hydrophobicity by partially or completely blocking the hydrophilic groups of the fibers.
This technology advantageously provides fiber cement building materials with the desirable characteristics of reduced water absorption have advantage reduced rate of water absorption, lower water migration, lower water permeability so the final products made from these materials have improved freeze-thaw resistance, reduced efflorescence, reduced dissolution and re-deposition of water-soluble matrix components in natural weathering.
Using fiber sizing almost to improve other product properties to the physical and mechanical of final product.
More information : sent to my Email
Frangky Welly W
Minggu, 14 November 2010
Non Asbestos ?” It’s Not Only Economical But a Better Products”
Summary
Fibre cement sheets are most economic for roofing and wall building.
Various production technologies are :
1. The sieve cylinder process ( paper mill machine – Cylinder Mould) – Modified
and patent by Hatschek
Where thin fibre cement layers are formed on a felt
– Flat and Corrugated Sheet – Good Strength
2. The flow on process ( paper mill machine – Fourdrinier Type )
Is much simpler uses cheaper fibres and needs less investment
- Flat and Corrugated Sheet - Lower Strength than cylinder process
3. Air Cure / Autoclave curing
Provides dimensional stability and next day ready to sales because both of the stability
and process of aggregate in the mixture sheet was done which in 8-10 hours comparing with
air curing needed 28 days to get ready all the stability of the sheet.
4. New technique to process Non Asbestos Fiber Cement .
The process are improvement of traditional techniques.
The price is availability related to raw material.
Using existing equipment and the low investment of utilize / support equipment.
Why Non Asbestos Fiber Cement Product ????
http:// www.osha.gov/SLTC/asbestos
1. Sieve cylinder process
This process with operations almost everywhere on the globe.
Mechanisms ;
- A very thin slurry of water, binder and fibres is mixed and is introduced into each one
of the sieve cylinder vats.
- The rotating sieve cylinder collects a thin layer of 0.2 to 0.35 mm of the solid materials
whilst most of the excess water passes through the wire mesh of the sieve cylinder.
- The thin layer "emerges" from the slurry and is further dewatered and compressed by
the couch roller as it is transferred to a felt.
- The thin layers of all the various sieve cylinders are collected on the felt which runs with
a speed of approx. 60 - 130 m/ over dewatering vacuum boxes to the accumulating size
roller.
- The size roller accumulates layer after layer until the programmed number of
revolutions and the required sheet thickness is reached and the automatic cut-off
mechanism cuts through the layers.
- The sheet thickness is double-checked by high-precision laser control. The sheet drops
onto the take-off conveyor.
- Should the thickness differ from the preset thickness the slurry density and/or the felt
speed is adjusted.
- The sheet needs to be cut to exact size and runs through a cutting system with rotating
knives or even better through a high precision cutting press where the sheet can be cut
to any irregular Shape.
- Until this production step the sheet is still flat or to be corrugated.
Flat sheets
Are preferably compressed to improve their strength and, if required, to receive an embossed surface in
form of stone texture or wood grain. Flat sheets are best and most economically compressed in a
stacking system press with a specific pressure of 50 - 300 kg/cm² (700 - 4000 psi)
Sheets may also be embossed directly on the forming roller without additional pressing or in a roller press with minimal pressing.
Corrugated sheets
Are corrugated with a suction corrugators while on the cross conveyor bridge. The corrugators picks up the flat sheet by suction after cutting and during the cross motion contracts and corrugates the sheet to exact shape. The sheet is placed onto a corrugated steel mould.
Type to making corrugated;
- Uncompressed sheets are stacked with the steel mould as a mixed pile. Compressed sheets
run on a corrugated perforated process steel mould through a single sheet press.
- The compressed corrugated sheets are stacked on the usual corrugated steel moulds to
form a mixed pile. The empty perforated process steel mould remains in the closed press
cycle. It is washed and returned to the corrugator for immediate repeated press use.
Sheets precuring, curing and finishing
After a defined precuring time ( depending on the cement to be used) - the sheets are hard enough for
further handling. They are then demoulded and palletized for 2 to 4 weeks' aircuring, or high-pressure
steam cured in autoclaves for about 12 hours.
What are the benefits of the sieve cylinder system?
There must be many benefits as it is the mostly used process!
- High strength due to many individual layers
- The many layers allow good and easy moulding (corrugated, hand moulding)
- Easy to operate
Are there any disadvantages?
- Large water surplus (which is recycled)
- Requires suitables fibres to run the process
- Risk of delamination (minor)
2 Flow-on sheet production
The flow-on sheeting plant is similar to the sheeting plant using the sieve cylinder machine.
The difference is how the layer is formed on the felt: The slurry is much thicker, i. e. the solid content is higher and the slurry flows directly onto the felt via a distributor mechanism ( head box in Paper machine )
This distributor mechanism is either ;
a) A large box similar to the sieve cylinder vat where the felt is forming the wall of the vat and
the layer is drawn to the felt by a vacuum box
or
b) A distributor box ( head box ) on top of the felt which forms a thin layer in the gap between
the felt and the distributor box and is dewatered by means of both foil blade and vacuum box
.
What are the benefits Flow On?
- The sheeting machine is much simpler.
- There is only little excess water which saves a sophisticated water recuperating system.
- The slurry can be composed by any available raw materials and fibres.
- There is no need for process related tricks to keep the binders and fibres together ( still have
and more easily ).
- There is a reasonably good ratio of fibre distribution in DM (Direct machine) or CM ( Cross
machine ) direction.
Are there any disadvantages Flow On?
_ The slightly lower strength of the sheets as there are less layers and the strength is approx.
90 - 95 % of the sieve cylinder system.
- The higher risk of delamination due to the thicker layers, especially for corrugated sheets
- Risk of different density in the sheet
- The lower production capacity (similar to a 2 sieve cylinder machine) because of the need for a
longer dewatering time of this layer and the difficulty of forming more than one layer on the
felt.
- The flow-on system is successfully used for flat but rarely for good corrugated sheets.
Note : To minimize the disadvantages of flow on machine must do the any
modification and combined with additive - modified by Frangky Welly )
3 Curing
The curing process are
- Aircuring
Aircuring is the conventional cement hardening similar to all other cement-based products
After 8 - 12 hours the sheet is hard enough for further handling but needs another 28 days to
reach its full strength.
Benefit: - no extra investment
Disadvantages: - reduced dimensional stability - i. e. shrinkage
- 3-4 weeks curing time, needs high working capital ( ware house area )
- Autoclaving
Autoclaving creates a completely different hydrated material, i.e. "high temperature calcium
silicate hydrate" of a superior crystal structure.
In fact the aircuring system forms already a semi-crystallized silicate hydrate, but the high
temperature in the autoclaves forms various crystal structures - preferably the tobermorite
structure - which give the sheet unique properties and opens a market for new applications.
Cement is mixed with fine silica in the ratio of approx. 40-45 % cement and 50 -55 % SiO2.
Precuring is aircuring as described before but final curing is in the autoclave. At approx.
180 -185 °C and at saturated steam corresponding to 12 bar (170 - 180 PSI) calcium silicate
hydrate is formed. The crystal structure provides highly preferred properties to the sheet,
especially to the flat sheet.
Why Using Autoclave ?
Benefits:
- extreme dimensional stability
- Less material cost as cement is partly substituted by silica sand
- Immediate final curing, i.e. the sheet can be sold within 24 hours after production
- Reduction of working capital.
Disdavantages:
- Increased investment - depending on the process.
- sand grinding (could in some cases be replaced by using silica powder)
- Autoclaves and accessories
- Steam boiler
4 The New technique to process Non Asbestos Fiber Cement
WHY ???
“ It’s Not Only Economical But a Better Products
Fibre cement sheets are most economic for roofing and wall building.
Various production technologies are :
1. The sieve cylinder process ( paper mill machine – Cylinder Mould) – Modified
and patent by Hatschek
Where thin fibre cement layers are formed on a felt
– Flat and Corrugated Sheet – Good Strength
2. The flow on process ( paper mill machine – Fourdrinier Type )
Is much simpler uses cheaper fibres and needs less investment
- Flat and Corrugated Sheet - Lower Strength than cylinder process
3. Air Cure / Autoclave curing
Provides dimensional stability and next day ready to sales because both of the stability
and process of aggregate in the mixture sheet was done which in 8-10 hours comparing with
air curing needed 28 days to get ready all the stability of the sheet.
4. New technique to process Non Asbestos Fiber Cement .
The process are improvement of traditional techniques.
The price is availability related to raw material.
Using existing equipment and the low investment of utilize / support equipment.
Why Non Asbestos Fiber Cement Product ????
http:// www.osha.gov/SLTC/asbestos
1. Sieve cylinder process
This process with operations almost everywhere on the globe.
Mechanisms ;
- A very thin slurry of water, binder and fibres is mixed and is introduced into each one
of the sieve cylinder vats.
- The rotating sieve cylinder collects a thin layer of 0.2 to 0.35 mm of the solid materials
whilst most of the excess water passes through the wire mesh of the sieve cylinder.
- The thin layer "emerges" from the slurry and is further dewatered and compressed by
the couch roller as it is transferred to a felt.
- The thin layers of all the various sieve cylinders are collected on the felt which runs with
a speed of approx. 60 - 130 m/ over dewatering vacuum boxes to the accumulating size
roller.
- The size roller accumulates layer after layer until the programmed number of
revolutions and the required sheet thickness is reached and the automatic cut-off
mechanism cuts through the layers.
- The sheet thickness is double-checked by high-precision laser control. The sheet drops
onto the take-off conveyor.
- Should the thickness differ from the preset thickness the slurry density and/or the felt
speed is adjusted.
- The sheet needs to be cut to exact size and runs through a cutting system with rotating
knives or even better through a high precision cutting press where the sheet can be cut
to any irregular Shape.
- Until this production step the sheet is still flat or to be corrugated.
Flat sheets
Are preferably compressed to improve their strength and, if required, to receive an embossed surface in
form of stone texture or wood grain. Flat sheets are best and most economically compressed in a
stacking system press with a specific pressure of 50 - 300 kg/cm² (700 - 4000 psi)
Sheets may also be embossed directly on the forming roller without additional pressing or in a roller press with minimal pressing.
Corrugated sheets
Are corrugated with a suction corrugators while on the cross conveyor bridge. The corrugators picks up the flat sheet by suction after cutting and during the cross motion contracts and corrugates the sheet to exact shape. The sheet is placed onto a corrugated steel mould.
Type to making corrugated;
- Uncompressed sheets are stacked with the steel mould as a mixed pile. Compressed sheets
run on a corrugated perforated process steel mould through a single sheet press.
- The compressed corrugated sheets are stacked on the usual corrugated steel moulds to
form a mixed pile. The empty perforated process steel mould remains in the closed press
cycle. It is washed and returned to the corrugator for immediate repeated press use.
Sheets precuring, curing and finishing
After a defined precuring time ( depending on the cement to be used) - the sheets are hard enough for
further handling. They are then demoulded and palletized for 2 to 4 weeks' aircuring, or high-pressure
steam cured in autoclaves for about 12 hours.
What are the benefits of the sieve cylinder system?
There must be many benefits as it is the mostly used process!
- High strength due to many individual layers
- The many layers allow good and easy moulding (corrugated, hand moulding)
- Easy to operate
Are there any disadvantages?
- Large water surplus (which is recycled)
- Requires suitables fibres to run the process
- Risk of delamination (minor)
2 Flow-on sheet production
The flow-on sheeting plant is similar to the sheeting plant using the sieve cylinder machine.
The difference is how the layer is formed on the felt: The slurry is much thicker, i. e. the solid content is higher and the slurry flows directly onto the felt via a distributor mechanism ( head box in Paper machine )
This distributor mechanism is either ;
a) A large box similar to the sieve cylinder vat where the felt is forming the wall of the vat and
the layer is drawn to the felt by a vacuum box
or
b) A distributor box ( head box ) on top of the felt which forms a thin layer in the gap between
the felt and the distributor box and is dewatered by means of both foil blade and vacuum box
.
What are the benefits Flow On?
- The sheeting machine is much simpler.
- There is only little excess water which saves a sophisticated water recuperating system.
- The slurry can be composed by any available raw materials and fibres.
- There is no need for process related tricks to keep the binders and fibres together ( still have
and more easily ).
- There is a reasonably good ratio of fibre distribution in DM (Direct machine) or CM ( Cross
machine ) direction.
Are there any disadvantages Flow On?
_ The slightly lower strength of the sheets as there are less layers and the strength is approx.
90 - 95 % of the sieve cylinder system.
- The higher risk of delamination due to the thicker layers, especially for corrugated sheets
- Risk of different density in the sheet
- The lower production capacity (similar to a 2 sieve cylinder machine) because of the need for a
longer dewatering time of this layer and the difficulty of forming more than one layer on the
felt.
- The flow-on system is successfully used for flat but rarely for good corrugated sheets.
Note : To minimize the disadvantages of flow on machine must do the any
modification and combined with additive - modified by Frangky Welly )
3 Curing
The curing process are
- Aircuring
Aircuring is the conventional cement hardening similar to all other cement-based products
After 8 - 12 hours the sheet is hard enough for further handling but needs another 28 days to
reach its full strength.
Benefit: - no extra investment
Disadvantages: - reduced dimensional stability - i. e. shrinkage
- 3-4 weeks curing time, needs high working capital ( ware house area )
- Autoclaving
Autoclaving creates a completely different hydrated material, i.e. "high temperature calcium
silicate hydrate" of a superior crystal structure.
In fact the aircuring system forms already a semi-crystallized silicate hydrate, but the high
temperature in the autoclaves forms various crystal structures - preferably the tobermorite
structure - which give the sheet unique properties and opens a market for new applications.
Cement is mixed with fine silica in the ratio of approx. 40-45 % cement and 50 -55 % SiO2.
Precuring is aircuring as described before but final curing is in the autoclave. At approx.
180 -185 °C and at saturated steam corresponding to 12 bar (170 - 180 PSI) calcium silicate
hydrate is formed. The crystal structure provides highly preferred properties to the sheet,
especially to the flat sheet.
Why Using Autoclave ?
Benefits:
- extreme dimensional stability
- Less material cost as cement is partly substituted by silica sand
- Immediate final curing, i.e. the sheet can be sold within 24 hours after production
- Reduction of working capital.
Disdavantages:
- Increased investment - depending on the process.
- sand grinding (could in some cases be replaced by using silica powder)
- Autoclaves and accessories
- Steam boiler
4 The New technique to process Non Asbestos Fiber Cement
WHY ???
“ It’s Not Only Economical But a Better Products
http://www.osha.gov/SLTC/asbestos
4.2. What are the raw materials typically used?
4. 2.1 Fibres
The most critical material as they may dictated the price and quality of the sheet.
- Cellulose fibres bleached or unbleached
. as reinforcement for the sheet
. as the process fibre to help the process work in connection with other man-made fibres
Cellulose (for aircured process) is not permanently resistant to the alkalinity of the cement. Therefore small quantities of components which retard the alkalinity of the cement are added.
The cellulose alone is used in a process with autoclave-curing where a calcium silicate hydrate is formed which has a low alkaline matrix.
Cellulose can be blended with long lasting man-made fibres like PVA (Poly-Vinyl-Alcohol) or Copolymer- AN / Organic syntetic fiber ( MAK- Fiber ) depending on the required physical properties of the fibre cement products.
Note:
MAK- Fiber is suitable for both the air cured process and for the autoclave process
More information regarding this MAK- Fiber please contact to Frangky Welly W ( frangww@yahoo.com)
4. 2.2 Binders
- Portland cement
Is the most commonly used cement
- other preferred cement types are low alkaline cements like slag cement using steel furnace
slag.
- Other options for special sheets could be:
- Gypsum or anhydrite
- Lime-based binders
4.2.3 Siliceous Compounds
The siliceous compound SiO2 is unavoidable in the autoclave curing process where SiO2 with CaO and H2O forms calcium silicate hydrate.
Other siliceous compounds are added in small quantities to affect and determine the physical properties of the fibre cement products:
- Silica fume
- Amorphous silicates
- Perlite , expanded ( to get low density of product )
- Vermiculite, expanded
- Mica
- Bentonite
- Kaolin / Clay
- Slag
4.2.4 Others / Additive
- Water
- Flocculant
- Bonding Aid
- Defoamer
Note : Both Flocculant and Bonding Aid ( Floren series - by MAK )
4.3 Equipment
- Using existing Equipment
- Modification on Close Loop line and additing the feeding line for chemicals application and all
chemicals preparation equipment.
Note :
How to Up Grading Your Product ?
I will support and guidance to do it
Frangky Welly W
Kamis, 11 November 2010
The Next Process and Improvement to Making Fiber Cement
Fiber Cement maker in the manufacture just doing the " Working Cycle Routinity" and following the last SOP including the whole step in the process mechanisme.
In this situation to get more added value to the products of fiber cement , I want to share some new technology " How to making the high or good quality fiber cement products "
Rules : M O C
Mechanical :
- Hatschek Machine
- Flow On Machine
- Support Mechanical and Spart Part
- New Technology
Operational :
- SOP
- Man Power skill
- Controlling - Visual
- Monitoring
Chemicals ( additives)
- Formation and Flocc Aid
- Strength / Bonding Aid
Some information to sharing :
* Optimalisation Flocculant in making Fiber Cement
- Background Information
- Methology of Flocculation
- Flocculation influence to molecular weight
- Effect of Flocculation on bending strength
- In line Flocculation Monitoring
* The Dual System Flocculation programme
- What is the dual system Flocculation programme
. Dual Component Systems
. Dual Mechanisme
. Dual mechanisme Selection
- How does the Dual System program works
. Mechanisme Process
. Polymer Mechanisme
- Coagulant
- Flocculant
- Impact of share
*Furnish Components on Processing Fiber cement
- Fiber ( natural / syntetic )
. Inorganic
. Organic
- Filler
. Clay - Kaolin - hydrous Clays
. Calcium Carbonate
. Silica / Silica Fume
etc
More information please contact to my Email.
Frangky Welly W
In this situation to get more added value to the products of fiber cement , I want to share some new technology " How to making the high or good quality fiber cement products "
Rules : M O C
Mechanical :
- Hatschek Machine
- Flow On Machine
- Support Mechanical and Spart Part
- New Technology
Operational :
- SOP
- Man Power skill
- Controlling - Visual
- Monitoring
Chemicals ( additives)
- Formation and Flocc Aid
- Strength / Bonding Aid
Some information to sharing :
* Optimalisation Flocculant in making Fiber Cement
- Background Information
- Methology of Flocculation
- Flocculation influence to molecular weight
- Effect of Flocculation on bending strength
- In line Flocculation Monitoring
* The Dual System Flocculation programme
- What is the dual system Flocculation programme
. Dual Component Systems
. Dual Mechanisme
. Dual mechanisme Selection
- How does the Dual System program works
. Mechanisme Process
. Polymer Mechanisme
- Coagulant
- Flocculant
- Impact of share
*Furnish Components on Processing Fiber cement
- Fiber ( natural / syntetic )
. Inorganic
. Organic
- Filler
. Clay - Kaolin - hydrous Clays
. Calcium Carbonate
. Silica / Silica Fume
etc
More information please contact to my Email.
Frangky Welly W
Jumat, 05 November 2010
Offer to buy Jeffrey asbestos assets approved
Montreal Gazette November 1, 2010
A Canadian-led investor group confirmed Monday its offer to buy 100 per cent of privately held Jeffrey Inc. and its asbestos mining assets near Danville, Que. All Jeffrey shareholders, including the miners' co-operative, have approved its offer.
The closing is due by year-end and work on converting the existing open-pit mine to an underground operation can then start.
The group, including investors from India, a major market for Canadian asbestos, will finance the underground project to produce 225,000 short tons of chrysotile fibre annually. It undertakes to protect workers' health and to sell only to qualified customers. The project will secure 500 jobs.
The new investors will not be involved in the day-to-day running of the new mine, said Jeffry Inc.'s main shareholder Bernard Coulombe. The identities of the investors were not disclosed.
© Copyright (c) The Montreal Gazette
Read more: http://www.montrealgazette.com/health/Offer+Jeffrey+asbestos+assets+approved/3760938/story.html#ixzz14Soci4It
A Canadian-led investor group confirmed Monday its offer to buy 100 per cent of privately held Jeffrey Inc. and its asbestos mining assets near Danville, Que. All Jeffrey shareholders, including the miners' co-operative, have approved its offer.
The closing is due by year-end and work on converting the existing open-pit mine to an underground operation can then start.
The group, including investors from India, a major market for Canadian asbestos, will finance the underground project to produce 225,000 short tons of chrysotile fibre annually. It undertakes to protect workers' health and to sell only to qualified customers. The project will secure 500 jobs.
The new investors will not be involved in the day-to-day running of the new mine, said Jeffry Inc.'s main shareholder Bernard Coulombe. The identities of the investors were not disclosed.
© Copyright (c) The Montreal Gazette
Read more: http://www.montrealgazette.com/health/Offer+Jeffrey+asbestos+assets+approved/3760938/story.html#ixzz14Soci4It
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