XAC NH UNG CONG NGHE SAN XUAT

GACH AT SET NUNG KHI XOA BO LO THU CONG,

CHUYEN OI CONG NGHE SAN XUAT
TS. LNG C LONG - Vien Trng Vien Vat lieu xay dng
Gch t st nung (SN) l loi vt liu xy
dng c t rt lu i. Nhiu ti liu nghin cu cho
rng gch SN xut hin khong nm 7000 -7500 trc
cng nguyn. Hin nay, ngay nhng nc tin tin
nh cc nc chu u v Nht Bn, ngi ta cng vn
sn xut v s dng gch SN. nc ta, gch t
SN (cn gi l gch ) cng c t rt sm. Ngi
ta tm thy gch trong trong nhng cng trnh c
cch y hng ngn nm. Nm 2011, c nc sn xut
khong trn 22 t vin gch . Theo d bo ca Vin
VLXD, nhu cu gch xy vo nm 2020 nc ta l
khong 42 t vin quy tiu chun.
Tuy l vt liu xy truyn thng, c nhiu u
im nhng t l sn xut v s dng gch trn th
gii ngy cng gim v cc l do: ngun nguyn liu cho
sn xut ngy cng cn kit, cng ngh sn xut gy
ra nhiu cht thi c hi, vic tip tc khai thc st cho
sn xut gch lm gim din tch trng lng thc,
nh hng nghim trng ti mi trng sinh thi,...Ngy
nay, ngi ta sng to ra nhiu loi vt liu thay th
gch vi nhng u im vt tri c v tnh nng k
thut, m thut v cng ngh sn xut, ng thi t nh
hng n mi trng sinh thi. l cc loi vt liu
khng nung khc nhau.
pht trin sn xut v s dng vt liu xy
khng nung (VLXKN) thay th gch SN, tit kim t
nng nghip, gp phn bo m an ninh lng thc quc
gia, gim kh thi gy hiu ng nh knh v nhim mi
trng, gim chi ph x l ph thi ca cc ngnh cng
nghip, tit kim than, em li hiu qu kinh t cho x hi,
ngy 28/4/2010, Th tng Chnh ph ban hnh quyt
nh s 567/Q-TTg ph duyt Chng trnh pht trin
vt liu xy khng nung n nm 2020. Theo , nm
2020, t l sn xut v s dng VLXKN thay th gch SN
nc ta s l 30-40% v tin ti xa b hon ton cc c
s sn xut gch SN bng l th cng.

Thc hin Quyt nh s 567/Q-TTg, nhiu a
phng trong c nc tch cc pht trin VLXKN v hn
ch sn xut v s dng gch SN. nhiu a phng,
vic sn xut gch SN bng l th cng c chm
dt t nm 2010, 2011 (v d: Hng Yn, Bc Ninh,...).
Trong qu trnh hn ch sn xut v s dng gch SN,
xa b cng ngh sn xut gch SN bng l th cng,
ny sinh mt s cch hiu khng ng v cc loi cng
ngh sn xut gch SN, gy kh khn cho vic qun l,
iu hnh ca c quan qun l Nh nc a phng,
c nguy c tip tc pht trin mt s loi cng ngh lc
hu, c tn gi mp m, khng r rng. Trong bi vit ny,
chng ti s phn tch mt s vn c bn lin quan n
cng ngh sn xut gch SN hin nay nc ta.
I. Mt s loi hnh cng ngh sn xut gch SN hin
nay Vit Nam:
Cng ngh sn xut gch SN c gi theo tn
ca l nung trong dy chuyn cng ngh. Hin nay,
nc ta c nhng loi cng ngh sn xut gch SN
chnh sau: cng ngh tuynel, cng ngh l hoffman (hay
cn gi l l vng), cng ngh l ng lin tc, cng ngh
l ng th cng.
1.1. Cng ngh sn xut gch SN bng l tuynel:
Cng ngh sn xut gch bng l tuynel l loi
cng ngh tin tin. Nhng thit b chnh trong dy chuyn
sn xut gm: my n p lin hp c ht chn khng,
my nho, my cn, hm sy lin hp, l nung gch l l
tuynel. L tuynel l mt hm (tuynel) thng, c vm l c
nh, h thng ca vo - ra hai u, h thng np nhin
liu, iu khin gi vm l v c ray a xe gong
vo, ra l. Theo chiu di l, c 3 vng (zn) chc nng c
nh: sy, nung v lm ngui. Vt liu nung di chuyn dc
thn l qua cc zn chc nng trn xe gong cn ngn la
ng yn (zn nung c nh mt vng xc nh ca l).
Sn lng gch tuynel nc ta hin nay chim khong
60% - 65% tng sn lng gch SN.
Cng ngh sn xut gch nung bng l tuynel c
nhng u im sau:
Quy m sn xut ln, lin tc;
iu chnh c nhit nung bng cch tng gim
lng than qua l tra than;
Mc c gii ha cao, nng sut cao;

>> VN HM NAY
S 1
2012
NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012 1S
Ch ng sn xut, do c hm sy lin hp nn tn dng
c ti a lng nhit khi nung sn phm;
Sch, gii quyt c vn mi trng sinh thi, gim
pht thi kh CO
2
, hn ch nhim mi trng;
C th nung a dng cc sn phm nh gch ngi, gch
p lt, gch th, c bit l nhng sn phm c rng
t 16 - 60%;
Mc tiu hao nguyn liu st gim t 15 40% (ty thuc
vo rng ca sn phm), than cm 6 gim t 20 35%,
nng sut lao ng tng gp 2 3 ln so vi sn xut gch
c trong l th cng.
1.2. Cng ngh sn xut gch nung bng l vng Hoff-
man (l vng):
L vng c dng mt hm (tuynel) hnh vnh khn
khp kn, c: vm l; cc ca ra - vo sn phm bn
cnh hm; h thng van khi v knh khi trc tm theo
chiu di hnh vnh khn. Theo chu vi l, khng c cc
vng chc nng c nh. Cc vng sy, nung v lm ngui
di chuyn vng quanh chu vi l. Thng thng mi l c
12 n 36 bung. Mi bung c mt li ra - vo kch thc
khong 1,2m x 1,3 m. Vt liu nung c xp trc tip vo
l, trn nn l v nm c nh trong l t khi cn dng
mc n khi c nung thnh gch, cn ngn la di
chuyn lin tc vng quanh l (zn nung di chuyn lin tc
theo chu vi l). Nh vy, phng thc sn xut ca loi
l ny l lin tc nhng ch nhit li gin on i vi
vng nung. i vi tng khoang l, ch nhit ng ca
l tng t nh l ng th cng hoc l ng lin tc. Do
ch kh ng hc trong l l ngn la chy quanh theo
vng l nn ngn la chy c th cn phi s dng
ng khi cao, khong 60m to lc ht hoc s dng
qut ht cng sut ln. Gn y, mt s c s u t xy
dng mt loi l gi l l Hoffman ci tin. y l mt bin
th ca l Hoffman. Loi l ny c nguyn l cu to nh l
Hoffman nhng c mt s ci tin v h thng knh khi,
van khi v vm l. Vm l ca l Hoffman ci tin c th
l loi di ng hoc n gin hn, c th khng c vm xy
m ch ph pha trn bng mt lp x than. V bn cht, y
l l Hoffman (l vng).
L Hoffman (l vng) c chi ph nhit nung ln,
do phi chi ph nhit cho tng l, vm l, nn l mi
ln ngn la i qua. Ni cch khc, zn nung c hnh
thnh theo chu k chuyn ng ca ngn la nn mi ln
mt vng l chuyn thnh zn nung u phi chi ph nhit
t nng vng t nhit mi trng ln n nhit
zn nung, nhit nung gch mc, nhit cn bng vi
nhit tn tht ra mi trng (i vi l tuynel - v zn nung
c nh nn ch cn cung cp nhit cn bng vi lng
nhit tn tht ra mi trng v nhit nung gch mc). Vic
xp mc vo l v d gch ra l u c thc hin trong
thn l nn iu kin lm vic ca ngi lao ng rt
nhim (nng v bi). Tuy nhin, do chi ph xy dng l
Hoffman ci tin rt thp nn mt s ch u t la
chn loi l ny.
1.3. Cng ngh sn xut gch SN bng l ng nung
lin tc:
L lin tc kiu ng c xut s t Trung Quc,
c du nhp vo Vit Nam t nm 2001. L lin tc
kiu ng khi ng mt ln, c th vn hnh lin tc
trong sut qu trnh sn xut. L lin tc kiu ng c
bung t t theo chiu thng ng, gch di chuyn t
trn xung di. Mc c gii ho tng i cao, gim
c lao ng nng nhc; tit kim nhin liu n 45%
so vi l th cng truyn thng, gim thiu nhim mi
trng. Quy m sn xut v vn u t ph hp vi nng
lc ca cc doanh nghip va v nh. T nm 2002 n
nay, l ng nung lin tc thay th cho cc l th cng
ci thin c cht lng gch, gim nhim mi
trng, gim bt mt s khu lao ng nng nhc cho
ngi lao ng, nng sut v cht lng sn phm c
nng ln. Cng ngh ny cng c ci tin ph hp
vi cc doanh nghip va v nh nn c kh nhiu tnh
pht trin thay th cho gch nung th cng. Vi cng
ngh ny, cc tnh pha Nam sn xut c gch c
rng ti 50%, mc tiu hao nhin liu thp hn l tuynel
v mi trng c ci thin nhiu. Tuy nhin, nhn v
chin lc lu di th vic pht trin l ny vn cha ph
hp ch trng cng nghip ha, hin i ha ca ngnh
VLXD, sn xut theo hnh thc ny vn mang tnh nh l,
gy kh khn cho cng tc qun l trung ng v a
phng. y c th coi l gii php trc mt, c th p
dng cho nhng a phng thiu t, cho nhng huyn
min ni c iu kin kh khn v giao thng, cho vic
thay th cc cm l th cng lc hu (nhng c s khng
c vn pht trin l tuynel).
1.4. Cng ngh sn xut gch nung bng l th cng
truyn thng:
L th cng truyn thng c s dng ph bin
Vit Nam t lu i. y l loi hnh cng ngh sn
xut n gin, lc hu nht. Hin nay sn lng gch
SN c sn xut bng l ng th cng chim khong
35 - 40% tng sn lng gch SN. c im ni bt
ca loi hnh sn xut th cng l thit b my mc, nh
xng rt n gin. Cng tc gia cng, to hnh ch yu
c thc hin bng cc loi my n lento loi EG2
hoc EG5 khng c chn khng. Kh nhiu h t nhn
mt s a phng sn xut gch hon ton th cng.
Cc quy trnh k thut trong sn xut khng c thc
hin, khun mu to hnh sn phm khng m bo v
kch thc, cha ph hp vi co nguyn liu, nn kch
>> VN HM NAY
14 NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012
thc sn phm thng thiu ht, mu m sn phm n
iu. Gch mc sau khi to hnh c phi trn cng th
cng khng c mi che, sau c nung trong l gin
on. Nhn chung, cng ngh sn xut ch yu l th cng,
hao ph nguyn, nhin liu ln, gy nhim mi trng,
cht lng gch cn hn ch, c bit l v kch thc,
hnh dng. C th lit k hng lot nhc im ca cng
ngh sn xut gch SN bng l th cng nh sau:
Nung gin on, khng c h thng kim tra nhit , th
t l kim tra nhit bng kinh nghim;
Tn tht nhit nng ln, pht thi kh CO
2
nhiu, gy
nhim mi trng cao;
Qu trnh nung ko di, kh nng tn dng nhit km,
nhit tch trong v l ln;
Cht lng gch thp, khng ng u, mu m n
iu, ph thuc nhiu vo kinh nghim ca ngi t l, t
l gch ph phm cao (trn 10%);
Nng sut lao ng thp, iu kin lao ng nng nhc.
gim nhim mi trng, hin nay, mt s
a phng ci tin b phn ng khi ca l nung theo
hng: nng cao ng khi pht tn kh thi ra mt
vng rng hn, gim nng nhim khu vc gn l
nung; dng nc vi hp th bt kh CO
2
v SO
2

chn ng khi hoc trn thm mt lng nh vi vo
nhin liu hp th bt kh SO
2
ngay trong vng nung
(gii php ny cng c s dng cho l tuynel). Tuy
nhin, vic u t h thng x l thng khng y ,
khng vn hnh h thng u t (u t mang tnh i
ph) nn khng gim thiu c cc kh c. Ton b quy
trnh cng ngh sn xut c bn vn khng c g thay i.
iu kin lao ng ca ngi lao ng vn rt km v
cht lng sn phm vn thp, khng n nh v cc chi
ph vn cao.
Trong bng 1. Nu nhng c im c bn ca
cc loi cng ngh sn xut gch SN ch yu nc
ta hin nay:
Bng 1: Nhng c im ch yu ca cc loi cng ngh
sn xut gch t st nung.
c im ch yu
Cng ngh sn xut
L Tuynel L ng lin tc L Vng (Hoffman) L th cng
Quy m sn xut Va v ln Nh v va Va v ln Nh v va
Cng on to hnh
thng thng
My nho n p lin
hp, ct gch t ng
My nho n p lin
hp, ct gch t ng
My nho n p lin
hp, ct gch t ng
My n p, ct
gch th cng
Cng on phi,
sy mc
Hm sy, nh knh Phi t nhin
Phi t nhin,
hm sy
Phi t nhin
Cng on nung
Lin tc,
zn nung c nh
Lin tc,
zn nung c nh
L vn hnh lin tc,
zn nung thay i, gin
on theo khoang l
Gin on
Tiu hao nhin liu
TB (kg than/ 1000
vin gch QTC)
100 - 120 100 - 80 120 - 140 180 - 220
Vn chuyn ra vo l Xe gong
Vo l: Vn thng
Ra l: h thng vtme,
thy lc
Vo - ra: th cng Vo - ra: th cng
Mi trng xp d Nhit thng Nng, bi Nng v bi cao Nng v bi cao
nhim mi trng
Pht tn rng, c
th x l trit
Pht tn tng
i rng, kh x l
Pht tn rng,
kh x l
Pht tn tp
trung, kh x l
Chng loi
sm phm
Ph hp vi
sn phm mng,
gch rng
Nung c c
gch c v rng
Nung c gch c
(min Bc) v gch
rng (min Nam)
Nung c gch
c (min Bc)
v gch rng
(min Nam)
S 1
2012
NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012 15
II. Cn nhn dng ng v cng ngh u t
theo xu hng tin tin, ph hp vi ch trng
ca Nh nc:
Hin nay, do phi xa b cng ngh sn xut
gch SN bng l ng th cng nn mt s ch l gch
mun chuyn i sang cng ngh khc khng b cm vi
mc chi ph thp, ph hp vi iu kin ca mnh.
p ng nhu cu ca cc ch l gch th cng, trn th
trng xut hin mt s tn gi cng ngh mi, i khi
gy lng tng, kh hiu cho ngi dn v cc c quan
qun l nh nc a phng. C th nu mt vi loi
cng ngh thuc dng ny, nh sau:
L th cng ci tin (c ni gi l l p vung): Thc
cht y vn l l th cng. Loi l ny ch khc l th
cng mt im duy nht l cu to ng khi v x l
khi. Tuy nhin, vic x l khi khng c thc hin
thng xuyn nn hiu qu mi trng rt thp. c
im ca loi l ny c phn tch k mc 1.4
ca bi vit ny.
L Hoffman ci tin: Thc cht y vn l loi l Hoff-
man. S ci tin ch yu c ngha i vi ch u t
v chi ph u t thp hn so vi l Hoffman c in. c
im ca loi l ny c phn tch k mc 1.2 ca
bi vit ny.
Cng ngh Hoffman - tuynel ci tin: y l cch
gi mp m, kh chp nhn. Thc cht ca cng ngh
ny l l Hoffman ci tin. Trong dy chuyn cng
ngh ny, ngi ta c s dng hm sy tuynel. Tuy
nhin, hm sy tuynel c xy tch ri l vng (l
Hoffman). y l cch lch lut, i vi nhng a
phng khng ng h vic u t cng ngh l vng
(l Hoffman). Nu khng xem xt k, c th c quan
qun l d nhm hm sy tuynel vi cng ngh sn
xut gch SN tuynel.
Ngoi nhng bin tng trn, mt s a
phng, cc ch u t cn thu cc cng ty t vn
nh, thiu chuyn nghip lp d n, thit k cc d
n mang tn D n u t cng ngh sn xut gch
tuynel nhng ni dung k thut li khng phi l cng
ngh tuynel m l: hoffman ci tin hoc hoffman - tuy-
nel ci tin...Mt s t cn b lm cng tc qun l Nh
nc cc a phng nghe c cc thng tin rt hp
dn v l th cng ci tin, l p vung lng tng
trong vic iu hnh, qun l.
Chng ti hy vng rng, bi vit ny s gip bn
c c thm mt s thng tin c th hn nhn dng
ng v cng ngh u t sn xut theo xu hng
tin tin, ph hp vi ch trng ca Nh nc trong
vic sn xut gch SN Vit Nam hin nay./.

M hnh l Tuynel
M hnh l vng Hoffman
M hnh l ng lin tc
M hnh l gch th cng
>> VN HM NAY
16 NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012