01 Mixture and RMP

FC Training
Mixtures and RM Preparation

(J.V. Buritic)
JVB - 20/04/2010
FC Training April-May 2010 - Mixtures & RM Preparation
WHY?
The product properties will be the result of the used raw materials and the way they are prepared and put together.
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Mixtures
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Definition
A mixture can be defined as being the list of individual ingredients, expressed in weight %, used to manufacture the end product. The different ingredients are known as raw materials. From the type, quality and quantity of the RM used, will depend the final characteristics of the product.
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Raw Materials type

Three different types of raw materials are used in the FC technology: Fibres
Binders
Process Reinforcement
Auxiliary materials (Fillers)

Process Product performance Cost
Matrix cohesion Strength
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Raw Materials: Fibres

Fibres are used with two purposes: For the process: fibers must build a layer that acts like a filter over the sieve to help in the filtration of the slurry, improving the retention of the particles on the sieves. For the product: to reinforce the product improving the matrix performance to flexural and tension stresses.
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Raw Materials: Fibres - Cellulose

SUKP, HW, WPK, CPB Objective:
Process parameters:
As process fiber: to allow sheet formation on the machine, for which we need interlayer bonding, fiber flexibility, a fine fiber mesh on the sieves to reduce sieve losses As reinforcement fiber for the final product for which we need fiber length, fiber strength (zero span), fiber bonding with the matrix (fibrillation), fiber spreading in the matrix, fiber flexibility Refined > 50 SR for process fibre Slightly refined 22 < SR < 27 for Ca-Si products
FC Training April-May 2010 - Mixtures & RM Preparation 7
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Raw Materials: Fibres - Cellulose

Characteristics:
Fibre length (ELF - Kajaani) Coarseness or Diameter Tensile Strength (Zero Span tensile) Alkali-solubility Kappa Filtration speed (SR)
Tasman
Eucalyptus
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Raw Materials: Fibres Synthetic fibres

PVA, PP, PAN as reinforcement Fibrids (as process fibre) Objective:
Main reinforcement of the matrix
Process parameters:
Mixing time: mixing energy is to be controlled in order to avoid fibre damages Fibre orientation factor
Kinking due to raw materials preparation in FC plant (long/harsch mixing)
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Raw Materials: Fibres Synthetic fibres

Characteristics:
Tenacity (CN/dtex): tensile strength of the fibre Diameter (Titer) Length Dispersability: good fibre dispersion in order to be well embedded by cement and fillers Low solubility in warm water Alkali resistance Good resistance to high T (roof exposure) Oiling Agent
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Raw Materials: Binders

Binders: Hydraulic binders are used for the fiber cement process. Its main purpose is to build a compact resistant matrix where all raw materials are involved. The principle binder used is the cement. Silica in the Autoclaved technology is, together with the cement, the binder element in the mixture.
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Raw Materials: Binders - Cement

Physycal Data Composition
Specific surface area Particle size distribution

OPC or CEM I preferred Solubility coefficient C3A Setting time Thermography Compression and Flexural strength (7 & 28 days)
Reactivity
Mechanical Data
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Raw Materials: Binders - Silica

Physycal Data
Specific surface area Particle size distribution
KoB - M300 - Bl. 5330 cm/g KoB - M500 - Bl. 15660 cm/g 100 Manizales - Pulverizar - Bl. 3410 cm/g 90 Santiago - Migrin - Bl. 3910 cm/g Surabaya - Home grinding - Bl. 4280 cm/g 80
R200506669 PSDA of Quartz flour - by Mastersizer 2000 - dry disp. at 3 bar -
Composition
Volume-% particles smaller
SiO2 content Organic substances
70 60 50 40 30 20 10 0 0 1 10 100 1000
Particle size [ m ]
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Raw Materials: Auxiliary Materials

Auxiliary Materials: Auxiliary materials are all fiber cement matrix ingredients other than cement and fibers used in the mix with a specific purpose:
To help in the manufacturing process of the product. To improve the performance of the product. For cost reasons.
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Auxiliary Materials:
Calcium Carbonate (Ca CO3) Amorphous silica Aluminium Hydroxide Lime Perlite, Vermiculite Wollastonite, Mica Kaolin, Bentonite Pigments
Note: Polyelectrolite & Antifoam (process aids) are not considered as component in the RM mixture
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Raw Material Calcium Carbonate Amorphous silica Aluminium Hydroxide Lime Perlite Vermiculite Wollastonite Mica Kaolin Bentonite Pigments
Product Performance
Matrix stability Frost resistance Dimensional stability
Process
Cost
Low Blaine
Plasticity, Layer adhesion
Layer Homogeneity Low density, Fire resistance Low density, Fire resistance Fire resistance, Dimensional stability Dimensional stability, Fire resistance Impermeability Layer adhesion
Plasticity, Layer adhesion Plasticity
Visual aspect
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Raw Material Calcium Carbonate Amorphous silica Aluminium Hydroxide Lime Perlite Vermiculite Wollastonite Mica Kaolin Bentonite Pigments
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Physical properties PSD Blaine

High Blaine Low Blaine D50 PSD Retention Mesh 325 (45m) Bulk density
Other
Composition
CaCO3 SiO2 Al(OH)3 Ca(OH)2
Other
PSD D50
Loose bulk density Loose bulk density Aspect ratio Buoyancy test Aspect ratio Buoyancy test
Asbestos free
Expansion capacity Exfoliation capacity
Kolinite Quartz Na Bentonite Swelling
Retention Mesh 325 (45m)

Iron oxides
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Mixture
How to put all of them together?
According to the product: Fibres
Auxiliary Materials
Application Characteristics
Manufacturing
Process Technology
Binders
Air-cured Autoclaved
Others:
Availability Cost Health
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Mixture According to the product

Following Application: According to the location in the buildings
Indoor: ceiling, panelling, flooring Outdoor: roofs and faades
According to the main function

Fire-protection boards (Promat) General purpose boards (Superboard EterBoard) Under roof boards Roof elements (corrug. sheets - slates multitiles) Faade elements & cladding
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Mixture According to the product
Following product characteristics: According to the density (& strength)

Low density: < 1.00 kg/dm Medium density: 1.00 1.40 kg/dm High density: 1.40 1.85 kg/dm
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Flat sheets: Application following density (KOB products)

1.75
Pictura Natura
Slates
1.80 0.60
Textura
Promatect-L
0.65
1.60
Glasal/Eflex/Tunnel Etercolor
1.60 0.80
1.60
1.55
Eterboard HD
Promatect-H Supalux
1.40 1.35 1.00 0.95
Eterspan
Cedral
Sidings Multiboard Coated 1.25
Operal
LD MD
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Low density
Eterboard MD (Superboard)
:
1.20
Hydropanel/ Bluclad
Eterbacker MD
~ 1.18
Fire board (Promat) Multipurpose, Panels (division) Faade (outdoor application)
Medium density : High density :
Density in g/cm
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HD
Mixture According to Manufacturing
Following manufacturing process: Forming machine:

Multilayer: Hatschek, Flow-on Monolithic: filter-press, extrusion, Magnani Injection process (fittings, flower pots) Hand-moulding: roof accessories
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Mixture According to Manufacturing

Following manufacturing technology: Air-cured (PVA reinforced)
The fiber cement matrix is cured at ambient conditions or in a curing tunnel (60 C, RH > 95%):
Cement clinker + Water Calciumsilicates + gel-like Ca-Silicate Hydrates + Lime
Autoclaved (cured at high T & Pressure)

(saturated steam):
The matrix, containing cement, silica (optionally lime) is cured at high temperature (up to 180C) and pressure
Quartz + Lime + Water Mix of fully and partially crystalline CaSilicate Hydrates* + residual quartz
Unpressed or Pressed (in stack press)

Mixture According to Product Application & Manufacturing technology

Roofing
Air-cured Autoclaved
Cladding & wall separations

Air-cured Ventilated faade Ceilings Decorative boards Autoclaved
Slates Corr. sheets Hand mould.
No
Ventilated faade Ceilings Multi-purpose Wet cells Render substrate Tile substrate Fire protection
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Mixture
Autoclaved Raw Material
Fibres Synthetic Cellulose (SUKP, HWP, CPB) Cellulose (WPK) Binders Cement (Cem I) Cement (Cem II) Silica Auxiliary Materials Calcium Carbonate Amorphous Silica Aluminium Hydroxide Lime Perlite Vermiculite Wollastonite Mica Kaolin Bentonite Pigments
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Air Cured
High density Faacde (outdoor application)
NO Process + Reinforcement NO Yes, low amount NO Yes, high amount NO NO Yes Yes NO NO Yes Yes Yes Yes Reinforcement Process Process Yes, high amount Yes, high amount NO Yes Yes NO NO NO NO NO NO Yes (IBM) Yes (IBM) Yes
Low density Fire protection

NO Process + Reinforcement NO Yes, low amount NO Yes, high amount NO NO Yes Yes Yes Yes Yes Yes
Medium density Multipurpose, panels

NO Process + Reinforcement NO Yes, low amount NO Yes, high amount NO NO Yes Yes NO NO Yes Yes Yes Yes (IBM) Yes
Roofing
Cladding & Wall separations

Reinforcement Process Process Yes, high amount Yes, high amount NO Yes Yes NO NO NO NO NO NO NO NO Yes
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Typical Mixtures
TYPICAL MIXTURE FOR CORRUGATED SHEETS (air-cured process) Raw Material (in wt.%) EBMO Synthetic fibre Refined Cellulose Cement Microsilica (CSF) Limestone Kaolin Bentonite Pigments Hardwaste
Thickness Density Breaking Load
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IBM 1.8 - 2.0 3.0 - 4.0 0 - 2.0 75 - 85 10 - 15 5 0-2 0-2 0-3

4.5 - 6.0 1.40 - 1.50 Class 6 2500 - 4100
PVA (HT) PVA (MT) SUKP WPK CEM I - II
1.8 - 2.0 2.8 - 3.4 74 - 88 5.8 - 6.5 0 - 15 0-1
Quality results for Profile 7 mm 6.5 - 6.7 gr/cm 1.50-1.55 requir. class C1-X average N/m 4400 - 4900
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Typical Mixtures
TYPICAL MIXTURE FOR SLATES (air-cured process) Raw Material (in wt.%) EBMO Synthetic fibre Refined Cellulose Cement Microsilica (CSF) Limestone Pigments
Thickness Density Strenght
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IBM 1.8 - 2.0 3.0 80.0 15.0 0.2

4.0 1.75 - 1.80 18 - 20
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PVA (HT) PVA (MT) SUKP CEM I - II
1.2 0.6 3.2 - 4.2 77 - 80 2.5 - 3.2 11 - 15 0.2
Quality results for Slates mm 4.0 gr/cm 1.9 N/mm 20

Typical Mixtures
TYPICAL MIXTURE for Medium Density Flat Sheets (IBM Division) Raw Material (in wt.%) High Quality SUKP SUKP + WPK (blend) PVA Cement OPC Quartz Limestone Al-Hydroxyde Na-Bentonite HGW Autoclaved
indoor/outdoor
Air-cured 3.0 - 4.0 1.5 - 1.8 75 - 80 15 - 20 0-3
7.0 - 8.0 35.0 52.0 4.0 0-1
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Typical Mixtures
Autoclaved Flat Sheet - KOB
Raw Material / Product Cellulose Cement Silica Perlite Vermiculite Mica Lime Wollastonite Pigments Alum. Hydroxide
Low Density
X X X X1 X2 X2 X X X
1: Promatect-H 1: New Promina 2: Masterboard 2: Supalux 0.90 - 0.95 1.20
Eterbacker-HD 1.60
Mica Mix
X X X
Lime Mix
X X X
Siding
X X X
Eflex
X X X
X X X X
Eterbacker-MD
X X X3 X
Eterboard-MD
X X
Siding Cedral Multiboard
non-pressed
Density (in gr/cm)
1.20
Eterboard-HD 3: Etercolor 1.60
1.25 - 1.30
Glasal 1.60
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pressed
Density (in gr/cm)
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Raw Material Preparation
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Filler 1 Filler 2 Filler 3
1.7
PVA debalers Cellulose treatment
Fillers
Cement
fibre mixer cement mixer
main mixer
Silica grinding
slurry chest
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to machine feeding
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Raw Material Fibres Synthetic Cellulose Binders Cement Silica Auxiliary Materials Calcium Carbonate Amorphous silica Aluminium Hydroxide Lime Perlite Vermiculite Wollastonite Mica Kaolin Bentonite Pigments
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Treatment required
YES NO Better if
Pulping & Refining CrVI reduction Grinding Grinding pH adjustment
Dispersed
Expansion Exfoliation

Swelling
Dispersed Dispersed
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Cellulose treatment
PULPING PROCESS
cellulose bales pulper Storage tank
Transport conveyor
pump
1.7
pump
Refiner
pump
Storage tanks
REFINING PROCESS
Cellulose treatment
Process fibre & reinforcement fibre
Different qualities (HQ-SUKP SUKP CPK WPK) Dosing in bales (dry): check water content ~ 15%
Desintegration: pulping process

In low consistency pulper (type Voith)
For virgin cellulose At 40 g/l (4.0 %)
In high consistency pulper (hlico-pulper)

For virgin or recuperated pulp At 110 130 g/l Separation of contaminants through screen
Pulping process
Water dosing
Pulp feeding
Clear process water for pulp preparation: - Consistency : 4% (40 g/l) - Pulping time: 20 30 min - Total cycle time: 30 40 min
Process Controls: - Concentration - Dispersability
to sock chest
Low consitency pulper

Pulping process
LH1
WATER DOSING TANK Cap. +/- 20m3

6" 4"
FL1 - flowmeter
6"
6"
VM1 P0 - M0 Flow: +/- 180 m3/h Head: +/- 1.2..1.4 bars Power: 15 kW
4" VM2
6" VM4
6"
FL2 - flowmeter
2"
4"
VM5
HELICO PULPER
Vp2
VM3
Vp5
HELICO PULPER Cap. 5000 Litres

M10 -110kW
DUMPING POIRE
DUMPING POIRE M11- 30kW
Vp3
- Clear process water for pulp preparation:

- Consistency : 110 130 g/l - Pulping time: 20 - 40 min - Total cycle time: 30 50 min
Vp6
16"
6"
6"
10"
Vp8
P2 - M2 Flow: +/- 220m3/H Head: +/-1 - 1.5 Bars Power: 22 kW
Contaminants
High consitency pulper

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Turbine
Pulper Dumping poire
High consitency pulper

Cellulose treatment plant
Pulper feeding
Cellulose bales
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Refining process
What is refining?
Is the mechanical alteration of fibres which is obtained by forcing a flow of pulp through grooved rotating discs.
Refining of cellulose is commonly divided into four primary

effects:
Increased fiber flexibility due to internal fibrillation or delamination. External fibrillation of the fiber surface, Fines formation and fiber shortening.
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Refining process
Evolution of the fibre through refining
unrefined rigid fibres flexible fibre
higher specific surface,

Refining process
Why to refine the cellulose?
To obtain the most suitable fibre morphology for the Hatschek process (sieve retention):
Increase the specific surface of the fibre Ensure a proper distribution of the fibre in the matrix Maintain a compromise between degree of fibrillation (SR) and fibre length (L-AVG)
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Refining process
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Refining process
Variables affecting refining:
Type of pulp Rotational & peripheral speed: hydration/fibrillation mode Consistency: around 40 g/l No-load power Net specific energy Refining intensity: Specific Edge Load (SEL) Flow through the refiner inlet & outlet pressure Refiner plate pattern:
Pumping vs retention mode
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Bar size: groove depth, bar width, groove width Bar angle
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Refining process: ABC

ABC: Automatic Batch Control (Hydra cycle) In that configuration, refining is realized per batch and cycled x times through the refiner. Allow higher flexibility, but:
Variability from batch to batch Output affected by operation conditions: - filling/emptying the recycling tank - opening of disk refiner Solution: independent feeding pump and cst level in recycling tank
to production line
V3
from pulper Recycling tank Flowmeter
V2
Virgen Unrefined pulp Storage tank Magnetic separator
Virgen Refined pulp Storage tank
Level VM33 Level VM30
V1
Refiner feeding pump
4"
Refiner
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Refining process: Continous refining

Direct pump recirculation: In that configuration, part of the cellulose is passing only once through the refiner and part is passing several times.
Advantages: - simplified installation but need automatic proportional valves - less quality variation - increased output
Flowmeter F2 to production line
Flowmeter F1
Virgen Unrefined pulp Storage tank Magnetic separator
Virgen Refined pulp Storage tank
Level VM33 Level

4"
VM30
VM33
Refiner feeding pump
4"
Refiner
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Storage & dosing of cellulose

Special attention has to be given to storage & dosing of cellulose since concentration variations in the stock chest will affect the product characteristics
Eliminate all uncontrolled addition of water (pumps seals agitators rinsing) Process parameters to be checked regularly
Pulp concentration ( x times /shift) SR ( x times / shift)
Fibre length (on a weekly base)
Stock chests & agitators to be designed as per well defined characteristics.

Storage & dosing of cellulose

Stock chest
Important to maintain a good agitation in the tanks: - D / h ratio - designed agitators: kW rpm Diam
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Synthetic fibre Preparation

PVA debalers
Filler 2
No special treatment is required in the factory since the fibre is received ready for use. Supplied in bales (compacted) or in bags. -Accurate weighing is required -Mix with filler (or cellulose) to disperse and pump -Mixing energy has to be limited in order not to damage the fibre: special impeller to reduce shear forces. -Use antistatic material to avoid sticking
Caution: once de-compacted, the fibres can occupy up to 10 times their volume
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Filler plant
Fillers are generally handled in bulk or in bags (or big bags).
Filler 1
Filler 2 Filler 3
RM in powder can behave in different way according to their morphology and physical characteristics: - Ground sand (silica) will flow like water, - Humidity content may change totally the handling conditions (> 2% H20 for CaCO3) - Needle-shaped powder (Wollastonite) or fibrous material (HGW) will bridge in the silos or hoppers. - Some fillers tends to agglomerates and need special intensive mixer to disperse properly (Kaolin, amorphous silica, pigments) - High shear mixers may be requested for process reasons (Bentonite)
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Filler plant Big bag feeding
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Filler plant big bag feeding
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Filler plant - feeding
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Filler plant - feeding
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Mixing process
Obtain an homogeneous mixture of the different RM within a certain accuracy and time (min > 10% machine max. output)
Depending of layout, different configuration can be selected: from 1 3 mixers

Mixing cycle: 8 12 min (5 to 8 mix/hrs) Typical concentration of mixers:
Cement mixer: 500 800 g/l Fillers: 200 500 g/l Final mixer: 250 350 g/l
Mixing process
Ekato mixer design
shaft baffles
s1 s2
traditional turbines
h1
h 2 d 2 d1
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Ekato turbine
Mixing process
Mixing sequence: Fibre mixer: water + filler (CSF Kaolin - ) + PVA (reduce mixing speed) Cement mixer: water + cement Final mixer
note: cement mixer not always needed
Water + cellulose + fibre mixer + fillers waiting time + cement

mixing time (2 min) before releasing to slurry chest.
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RMP: 3 mixers configuration

Cement Silo
Water Cell
PVA Debaler
Fill er 1
Cement Mixer
Fill er 2
Fiber Mixer
Main Mixer
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RMP: 2 main mixers configuration

water Cement silo water
MP1
MP2
MP3
Cel. loop Cell
MP3
MP2
MP1
Main Mixer n1
Main Mixer n2
Slurry chest
RMP: 1 main mixer configuration

Cement Silo Water
Loop Al(OH)3 Loop Silica Loop Bentonite Loop Cellulose
RM 1 Vol 4m
RM 2 Vol 2,1m
RM 3 Vol ,25m
RM 4 Vol 1m
RM 5 Vol ,25m
Main Mixer n1 Useful Vol 8m
Slurry Chest Useful Vol 12m
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Thank you for your attention
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01 Mixture and RMP

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01 Mixture and RMP

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FC Training

Mixtures and RM Preparation

FC Training April-May 2010 - Mixtures & RM Preparation

FC Training April-May 2010 - Mixtures & RM Preparation

FC Training April-May 2010 - Mixtures & RM Preparation

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials type

Auxiliary materials (Fillers)

Matrix cohesion Strength

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Fibres

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Fibres - Cellulose

Raw Materials: Fibres - Cellulose

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Fibres Synthetic fibres

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Fibres Synthetic fibres

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Binders

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Binders - Cement

Specific surface area Particle size distribution

Raw Materials: Binders - Silica

R200506669 PSDA of Quartz flour - by Mastersizer 2000 - dry disp. at 3 bar -

SiO2 content Organic substances

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Auxiliary Materials

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Auxiliary Materials

Raw Materials: Auxiliary Materials

Plasticity, Layer adhesion

Plasticity, Layer adhesion Plasticity

FC Training April-May 2010 - Mixtures & RM Preparation

Raw Materials: Auxiliary Materials

Physical properties PSD Blaine

Expansion capacity Exfoliation capacity

Kolinite Quartz Na Bentonite Swelling

Retention Mesh 325 (45m)

FC Training April-May 2010 - Mixtures & RM Preparation

Mixture According to the product

According to the main function

FC Training April-May 2010 - Mixtures & RM Preparation

Mixture According to the product

Following product characteristics: According to the density (& strength)

FC Training April-May 2010 - Mixtures & RM Preparation

Flat sheets: Application following density (KOB products)

Fire board (Promat) Multipurpose, Panels (division) Faade (outdoor application)

Medium density : High density :

FC Training April-May 2010 - Mixtures & RM Preparation

Mixture According to Manufacturing

Following manufacturing process: Forming machine:

FC Training April-May 2010 - Mixtures & RM Preparation

Mixture According to Manufacturing

Autoclaved (cured at high T & Pressure)

Unpressed or Pressed (in stack press)

Mixture According to Product Application & Manufacturing technology

Cladding & wall separations

Slates Corr. sheets Hand mould.

FC Training April-May 2010 - Mixtures & RM Preparation

Low density Fire protection

Medium density Multipurpose, panels

Cladding & Wall separations