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Introduction. One of the urgent tasks of the wall ceramics industry at present is the production of large-format ceramic stones with compressive strength of 10–15 MPa and thermal conductivity less than 0.12 W/(m·оС), while the market cost per 1 m3 should be competitive with gas-concrete blocks and be in the range of 5–6 thousand rubles per 1 m3. This problem can be solved by developing modern energy-efficient production technology and using opoko-like rocks and coal processing wastes as the main raw material as fuel and burnout additive.Materials and Methods. The opoka-like rocks — opokas from the deposits of southern Russia — Nagolnovskoye, Bakanskoye, Shakhtinskoye, Avilo-Fyodorovskoye, and coal cake produced by Pyramida LLC were used for research. The study of chemical and mineral composition was carried out by standard methods on prepared samples. The study of ceramic and technological properties (plasticity, molding moisture, degree of crushing, air and fire shrinkage, compressive strength, water absorption) of raw materials was carried out according to generally accepted methods on samples precrushed to a certain grain composition, since opokas, depending on the type, do not soak or slowly soak in water.Results. Pre-firing technological properties of opokas and their differences from traditional clay raw materials soaked in water were confirmed: increased molding moisture, small air shrinkage, low sensitivity to drying. The dependence of density and strength of samples on the degree of pulverization of opoka, firing temperature and the amount of carbon cake in the raw material mixture has been established. The influence of coal preparation wastes and their optimal amount on physical and mechanical properties of fired samples has been determined. The introduction of carbon cake allows to exclude the use of gas for firing or minimize its introduction. On the basis of the obtained results a simplified technological scheme for the production of large-format stones with minimum production cost has been developed.Discussion and Conclusion. The proposed technological scheme consists of two units of the main mass preparation equipment, molding of products is carried out by semi-rigid extrusion, drying of products is carried out directly on kiln cars, and for firing coal cake is used, which is introduced into the raw mix. These factors and technological methods allow to obtain products with low thermal conductivity, but with strength 3–5 times higher than that of aerated concrete blocks of similar density. The prime cost of ceramic stones will amount to 3–3.5 thousand rubles per 1 m3 of products. Rostov region, possessing opoka-like rocks and unclaimed reserves of technogenic coal raw materials, can become a center of production of large-format ceramic stones with low cost and provide the south and central part of the country with highquality wall materials.
Introduction. One of the urgent tasks of the wall ceramics industry at present is the production of large-format ceramic stones with compressive strength of 10–15 MPa and thermal conductivity less than 0.12 W/(m·оС), while the market cost per 1 m3 should be competitive with gas-concrete blocks and be in the range of 5–6 thousand rubles per 1 m3. This problem can be solved by developing modern energy-efficient production technology and using opoko-like rocks and coal processing wastes as the main raw material as fuel and burnout additive.Materials and Methods. The opoka-like rocks — opokas from the deposits of southern Russia — Nagolnovskoye, Bakanskoye, Shakhtinskoye, Avilo-Fyodorovskoye, and coal cake produced by Pyramida LLC were used for research. The study of chemical and mineral composition was carried out by standard methods on prepared samples. The study of ceramic and technological properties (plasticity, molding moisture, degree of crushing, air and fire shrinkage, compressive strength, water absorption) of raw materials was carried out according to generally accepted methods on samples precrushed to a certain grain composition, since opokas, depending on the type, do not soak or slowly soak in water.Results. Pre-firing technological properties of opokas and their differences from traditional clay raw materials soaked in water were confirmed: increased molding moisture, small air shrinkage, low sensitivity to drying. The dependence of density and strength of samples on the degree of pulverization of opoka, firing temperature and the amount of carbon cake in the raw material mixture has been established. The influence of coal preparation wastes and their optimal amount on physical and mechanical properties of fired samples has been determined. The introduction of carbon cake allows to exclude the use of gas for firing or minimize its introduction. On the basis of the obtained results a simplified technological scheme for the production of large-format stones with minimum production cost has been developed.Discussion and Conclusion. The proposed technological scheme consists of two units of the main mass preparation equipment, molding of products is carried out by semi-rigid extrusion, drying of products is carried out directly on kiln cars, and for firing coal cake is used, which is introduced into the raw mix. These factors and technological methods allow to obtain products with low thermal conductivity, but with strength 3–5 times higher than that of aerated concrete blocks of similar density. The prime cost of ceramic stones will amount to 3–3.5 thousand rubles per 1 m3 of products. Rostov region, possessing opoka-like rocks and unclaimed reserves of technogenic coal raw materials, can become a center of production of large-format ceramic stones with low cost and provide the south and central part of the country with highquality wall materials.
Currently, the amount of man-made waste worldwide is steadily increasing. It is, therefore, necessary to constantly look for effective ways of utilization and recycling. It is also necessary to reduce the use of non-renewable resources and reduce the impact on the environment. The use of coal industry waste is currently quite insignificant, amounting to some 10% of the total volume. The work aimed to study the properties of raw materials and study the processes of structure formation during the forming, drying, and firing of composite ceramic produced using overburden rock and additives. The work’s relevance lies in the need to solve environmental, economic, and technological problems related to the utilization of coal mining waste. Experiments of the past prove the possibility of using the waste coal industry as additives in the production of building materials. The article presents the results of studies of the chemical, mineralogical, and granulometric composition of overburden rock in coal mining. Peculiarities of structure formation during the forming, drying, and firing of ceramic composites based on optimal fractional compositions from coal-mine overburden were revealed. Organic and chemical additives were used for the correction of technological properties and improvement of the quality of finished composite products. The physical and mechanical indices of the obtained composite ceramic samples were determined, the analysis of which revealed that the use of highly mineralized carbonaceous rocks as solid additives provided a 2–2.5-fold increase in the strength of the product, 5.6% reduction in water absorption, and an increase in the product frost resistance by 20–25 cycles. The aluminum oxychloride influence on the physical and mechanical indices of the obtained composite articles was reflected in a reduction in their water absorption from 8.2 to 7.0%, a 10–12% increase in strength in compression, and an increase in freeze–thaw resistance by 30–35 cycles. Research results proved that the composition and properties of coal-mine overburden rock are close to those of conventional clays. With special technological preparation, they can be used for the production of composite ceramic products. This will significantly reduce the cost of bricks, to make up for the shortage of high-grade clay raw materials and improve the environmental situation. Nevertheless, further research into the use of coal-mine overburdens in the composite ceramic material technology is warranted.
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