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RESEARCH AND DEVELOPMENT

    In recent years, Svoboda a syn s.r.o. company has developed a specialized plant focused on research and development of new technologies of processing energy by-products and selected types of industrial waste in construction industry.

    The subject to be solved in an independent research project concerned the technology of producing artificial aggregates from sintered fly ash, which was widened into a new innovative element aimed at production of artificial sintered aggregates from coal tailings. This problematics has been successfully resolved in a complex range, starting with a selection of suitable raw materials and development of technological methods of producing artificial aggregates, up to the final sampling of concrete.

    A completely new innovative theme being solved in the Research and Development department is a progressive technology of thermal treatment of fly ash with a high content of residual combustible substances. The thermal treatment is performed in a special annealing furnace where the output products are specially treated ashes primarily intended to be used as a quality Pozzolanic admixture for production of concrete.


The subject of the Research and Development project is an innovative process focused on selected methods of processing secondary raw materials and industrial waste.



Technology tests of artificial sintered aggregate production are mainly targeted at processing of power station and heat station ashes, or raw material mixtures containing also other raw material ingredients. The production technology of artificial sintered aggregate from coal tailings is being solved as an independent sub-problem. Coal tailings usually contain the necessary amount of combustible material for the self-burning process of charging stock on the sintering grate.

Vertical furnace
In the first stage of the implementation of technology tests of producing artificial sintered aggregate, protocol sampling is carried out and basic material qualities of raw material are specified in the laboratory of research centre and consequently laboratory burnings of artificial aggregates in vertical sintering furnace are performed. The aim of these tests is to determine optimal composition of raw material mixture, identify essential parameters of self-burning process of charging stock and determine approximately the quality of produced artificial aggregate. The design of vertical sampling furnace allows implementation of the burning process of the charging stock in high layers up to 120cm.

Horizontal furnace
Technology tests of sintered aggregates in a horizontal furnace are made on the bases of experience gained from preparatory burnings in a vertical furnace. When performing these tests the aggregate is produced in a bigger volume necessary for complex sampling of concrete.

Carousel sintering grate
In selected cases, sample burnings on sintering grate are made within technology tests of artificial aggregate production. When performing these tests, basic conditions for mass production of artificial aggregate from verified raw material entries are created. These produced aggregates quite clearly express parameters of the final product and offer further data for suggestion of suitable machine set for the purpose of future production.

New technology of thermal treatment of fly ash
with high content of residual combustible substances
The development of a brand new technology of fly ash thermal treatment with high content of residual combustible substances, performed using the principle of burning of the raw material input with its own content of burnable items is targeted mainly at processing of thermal treated fly ash when producing concrete at main concrete plants. It is also possible to process the thermal treated fly ash as a basic raw material for Aeroconcrete production. A particularly effective way for mass use of thermal treated fly ash is the production of artificial sintered aggregates, where the raw material entry with optimal content of combustible elements could be prepared as a mixture of thermal treated ash and the original non treated ash. In this case, the use of correcting combustibles can be completely eliminated. This method significantly reduces capital and operating costs associated with the production of artificial aggregates from sintered fly ash.

The fly ash thermal treatment tests are performed in a sample annealing furnace, mostly in such conditions, where the optimal annealing temperature ranges from 700 – 800 °C. The verified fly ash samples intended for thermal treatment usually contain residual combustible items in ranges from 12 – 22% of a substance.

A part of the test machine assembly is a special hose filter enabling to separate ash from the exhaust hot flue gasses. This device can be operated reliably even at high temperatures up to 800°C.

Production of pelletize fly ash granulates
Mixed fly ash stabilizers for construction purposes

CONTACT

Ing. Michal Batelka – Head of Research and development department
tel.: +420 531 029 319/619
mob.: +420 725 128 962
e-mail: michal.batelka@sasbrno.cz