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Artificial Broken Stone Production for Industrial and Civil Engineering: Technological Parameters
Available online at www.sciencedirect.com
ScienceDirect Procedia Engineering 111 (2015) 534 – 539
XXIV R-S-P seminar, Theoretical Foundation of Civil Engineering (24RSP) (TFoCE 2015)
Artificial broken stone production for industrial and civil engineering: technological parameters Sergey A. Mizuriaeva*, Sarsenbeck A. Montaevb, Azamat T. Taskaliev b a
Samara State University of Architecture and Civil Engineering (SSUACE), Molodogvardeyskaya St 194, Samara, 443001, Russia b West-Kazakhstan Agrarian-Technical University named after Zhangir khan, Zhangir-Khan St. 51, Uralsk, 090009, Kazakhstan
Abstract The paper presents the results of investigation according to which the optimal fraction composition of clay concrete from Taskala gaize is found out. Its physical and mechanical properties are taken into account. The optimal fraction for crushed clay concrete is as follows: 5-10mm, 10-20mm and 20-40mm. The paper describes the influence of various technological factors on physical and mechanical properties of artificial crushed rock made from gaize. The role of preliminary thermal treatment of clay concrete particles and fractions is also looked into. According the results of the investigation the optimum thermal treatment temperature is stated. It’s 200-3000°С for chert gaize and 400-4500°С for clay materials. © 2015 The Authors. Published by Elsevier B.V. © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license Peer-review under responsibility of organizing committee of the XXIV R-S-P seminar, Theoretical Foundation of Civil (http://creativecommons.org/licenses/by-nc-nd/4.0/). Engineering (24RSP) under responsibility of organizing committee of the XXIV R-S-P seminar, Theoretical Foundation of Civil Engineering (24RSP) Peer-review Keywords: Aggregate; Silicates; Gaize; Preparation; Resistibility; Density.
1. Introduction Modern construction is impossible without concrete application, concrete and reinforced-concrete constructions. It is a well-known fact that one of the main concrete components, which greatly influences concrete parameters, is an aggregate [1]. Traditionally, heavy-weight dense aggregate in the form of broken stone is advised to use for structural concrete, as it has higher strength in comparison with porous aggregate.
* Corresponding author. Tel.: +7-937-997-94-88. E-mail address: [email protected]
1877-7058 © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of organizing committee of the XXIV R-S-P seminar, Theoretical Foundation of Civil Engineering (24RSP)
doi:10.1016/j.proeng.2015.07.037
535
Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539
Nowadays, broken stone for high-strength concrete grade is produced of rock formation, deposited not in all regions of Kazakhstan Republic and Russia. That is the reason why broken stone is transported via railway to the regions that lack necessary rock formations. This fact causes problems of broken stone supply [2-6]: x Problem of timely broken stone supply. x High prices due to delivery cost rise. x High production cost of goods made of imported broken stone. Traditional dense broken stone has a number of disadvantages. Firstly, its average density is 2200-2500 kg/m3, that considerably loads constructions, secondly, its high thermal conductivity predetermines low heat-insulating parameters. There are several ways to solve this problem. 2. The analysis of chemical composition of the gaize It is effective to use various local materials and industrial wastes [7-11]. Results on the use of high-strength expanded clay aggregate used in structural stone arouse profound interest [12-16]. It should be noted that there is a big volume of research devoted to technologies of high-strength expanded clay aggregate production [17,18] and use of expanded-clay concrete for production of constructions for structural purposes [19-21]. However, use of highblowing raw-material for production of high-strength expanded clay aggregate seems to be irrational. Numerous and widely-spread formations of silica rock, potentially applicable for production of construction materials, are of great concern [22-26]. In connection therewith, research and tests were conducted, designed for optimal technological parameters of preparation and thermal processing of silica rock formation – gaize for getting natural stone using the ceramics technology. Experimental research was conducted, using the natural test-samples directly from the borrow pit of the gaize in Taskalin rock formation, located in the Western-Kazakhstan region. Chemical and mineral composition of silica rock formation - gaize of Taskalin rock formation, particularly, phase composition and crystal structure of original particles was analyzed during this research. The results of the research on chemical composition of the gaize are presented in Table 1. Table 1. Chemical composition of the gaize.
K2O
0,431,39
1,394,8
0,030,97
0,150,78
1,132,85
Ignition loss
Na2O
0,24-17,9
SO3
0,10,62
CaO
TiO2
Al2O3 5,7612,95
Fe2O3
66,9883,5
MgO
Gaize
SiO2
Proportion of oxides (%wt) Raw material nomination
1,85-18,9
The analysis of the mineral composition of the gaize showed that in the majority of cases the gaizes contain glauconite (1-4%) in the form of rounded pale-green grains with aggregate polarization. Carbonate material looks as small (0,02-0,1 mm) foraminifer shells, which outfaces are made of thinly laminated calc-spar and infaces are made of fire opal. Besides that there are small balls of pelitomorphic calci-spar. Occasional spherical organic remnants (of diatoms, sponges) of low survival rate with hardly visible organogenic structure can also be seen. The size of silica framework is 0,07-0,12 mm. Brownish spots in the formation (apparently, clots of clay matter, impregnated finely dispersed with black iron oxide) are of small size and mostly are parallel to shaly lamination. Small singular voids are incrusted with chalcedony. Copperas stone grains exist as small impurities (0,04-0,07 mm). Data decoding of X-ray analysis of gaizes showed polymineral composition of the studied formations. Welldefined crystobalite reflex (408-410 picometers), complicated by tridymite reflex, is the peculiarity of these formations (427-430 picometers). A 500 kg batch of gaize was dispatched from the borrow pit on the tip lorry for the definition and systematization of naturally selected gaize clot sizes. Afterwards the selected batch went through particle analysis. The particle analysis results are shown in Table 2.
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Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539
Table 2. Results of particle analysis. Fraction sizes, mm
Fraction composition, %
more than 150
15
150 -100
15
100 - 50
20
40-20
30
20-10
15
10-5
3
Less than 5
2
The average open pit humidity of the test samples was 15,5%. 3. Analysis of physical-mechanical properties of the broken stone from the gaize of Taskalin rock formation after crushing Taking into consideration that silica rock formations in their natural state possess some extent of gum rigidity and the results of preliminary gaize test, getting the required fraction size was achieved through crushing [26-28]. Study of equipment regarding maximum output of the required fraction with the minimum formation of flour particles was carried out for the definition of the most rational ways of crushing. At the initial stage various crushing machines, produced by the leading companies of Russia, Ukraine, Germany and other countries, were analysed. As a result two types of crushing machines were chosen for division of gaize clots into necessary fractions. These are revolving pin and jaw crushers. The results of impact of crushing type on the properties of the broken stone are shown in Table 3. Table 3. Physical and mechanical properties of the broken stone from the gaize of Taskalin rock formation. Type of gaize crushing Revolving pin crusher
Jaw crusher
Fraction size, mm
Crushing resistance, MPa
Water absorption, %
Flour particles, %
5-10
3,4
31
3-4
10-20
3,6
30
2-3
20-40
3,8
29
1-2
5-10
3,2
31
5-7
10-20
3,5
30
4-6
20-40
3,7
29
3-5
Taking into consideration physical and mechanical properties of the gaize and the results of the preliminary lab tests revolving pin crusher was finally chosen as the most appropriate. The analysis of the experimental results showed that fraction strength of the gaizes during crushing with jaw crusher is 6-7% lower in comparison with the fractions, granulated by the revolving pin crusher. Besides that, it should be noted that while crushing gaize fractions by jaw crusher, formation of flour particles is 40-50 % more than while crushing by the revolving pin crusher. After crushing with the help of laboratory griddle the gaize broken stone was divided into three fractions: 5-10 mm, 10-20 mm, 20-40 mm, that were tested for the definition of the basic physical and mechanical properties. The test results are presented in Table 4.
537
Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539 Table 4. Physical and mechanical properties of the gaize of Taskalin rock formation divided into fractions. Fraction size, mm
Packed density, kg/m3
Water absorption, %
Crushing resistance, MPa
Thermal conductivity, W/mK
5-10
640
27
3,5
0,08
10-20
625
26
3,9
0,08
20-40
590
25
4,1
0,07
Analysis of dependence of compressive strength and packed density of the objects under research on the rate of firing temperature rise Preliminary thermal preparation of the samples is technologically important for the production of artificial broken stone of the silica rock formation, as the end-use properties and quality of the obtained production depend on the parameters of thermal preparation. Basic technological parameters of thermal preparation are intake temperature of thermal processing and its durability. The basic criteria for getting quality products is the optimal temperature definition under the condition of fast firing. Under production conditions activated process of firing takes place in rotary furnaces [29, 30]. During experimental research broken stone of the gaize was placed into laboratory rotary electric furnace and was thermally processed under various temperatures according to specially designed mode. The initial temperature of thermal preparation for silica formation gaize was 100 0С. Such temperatures as 1000С, 2000С and 3000С were taken for the definition of the optimal thermal preparation temperature for silica formation gaize. These temperature indexes were taken into account with the prior defined physical and mechanical properties of raw materials, as well as chemical and mineral composition. Method of optimal temperature of thermal preparation determination consisted of the following stages: gaize broken stone samples were preliminary heated to the mentioned temperatures with the speed of temperature rise 100-1500С per hour. These samples were sustained for one hour under the mentioned temperatures and were exposed to dramatic temperature rise to 950-10500С. The optimal thermal preparation temperature was the temperature that allowed to fire the samples avoiding breakages and cracks. The results of experimental research allowed to identify the optimal thermal preparation temperature of the object under research. The optimal rate of temperature rise for the gaize of silica rock formation was 200-3000С per hour. Gaizes were also exposed to fast firing at the rate of temperature rise 200 0 - 3000С per hour in order to identify the optimal temperature of firing for silica rock fractions. The results of strength indexes and packed density of the sintered fractions allowed to determine the maximum temperature of firing. The results of the experimental research are showed in Table 5. Table 5. Dependence of compressive strength and packed density of the objects under research on the rate of firing temperature rise. Object name
Rate of temperature rise, 0
С per hour 200
Silica rock formation gaize
Maximum firing temperature, 0
С
950 r 20
300 200 300
1050 r 20
Compression strength,
Packed density,
МPa
kg/m3
51
735
54
740
65
750
68
760
The results of the research show that the rate of temperature rise and maximum firing temperature produce a strong impact upon the technological and physical-mechanical properties of the finished units. The fast firing at 2003000С allows to get the required compressive strength and packed density. It should be noted that there were no considerable variations in property indexes under above mentioned temperature ranges of fast firing. The compressive strength of thermally processed samples under 950-10500С is 51-68 MPa, and the packed density is
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about 735-760 kg/m3. According to the National State Standard 22263 “Broken stone and sand of silica rock formation”, artificial broken stone of gaize has strength corresponding to the line mark П350, and its packed density corresponds to line mark 700-800. 4. Conclusion Consequently, there is a real possibility of getting artificial broken stone out of gaize of silica rock formation, using the technology of fast firing. These results of experiment are important today and can be helpful for the industrial development of broken stone production technology, using silica rock formation – gaizes of Kazakhstan Republic and Russia. The resulted material (broken stone) possesses enough low density, high strength and good insulating properties. The research was conducted as a grant project of the Ministry of education and sciences in Kazakhstan Republic. References [1] D.A. Panfilov, The methodology for calculating deflections of reinforced concrete beams exposed to short duration uniform loading (based on nonlinear deformation model) / D.A. Panfilov, A.A. Pischulev//Procedia Engineering, XXIII R-S-P Seminar, Theoretical Foundation of Civil Engineering (23RSP) (TFoCE 2014) ISSN: 18777058,–Vol.. 91, – 2014, – 188–193рр. doi:10.1016/j.proeng.2014.12.044. [2] D.A. Panfilov, The review of the existing deformation curves of concrete during compression in national and foreign normative documents, Industrial and civil engineering – M., 2014, № 3, pp. 80-84. (in Russian) [3] D.A. Panfilov, V.G. Murashkin, An advanced method of calculating the total deflections of flexural reinforced concrete elements with allowance for discrete cracking for normal and high-strength concrete, Izvestiya OrelGTY. Stroitelstvo. Transport.Orel 2011,№6, pp.30–42. (in Russian) [4] D.A. Panfilov, Experiment research of deflections of reinforced concrete elements made from normal and high-strength concrete, Beton i zhelezobeton, Moscow, 2011, №6, pp. 8-12. (in Russian) [5] D.A. Panfilov, Application of program complexes for the specified calculation of deflections of reinforced concrete elements, G.V. Murashkin, V.G. Murashkin, D.A. Panfilov, International Journal for Computational Civil and Structural Engineering,Volume 8, Issue 4, 2012, рp. 89-95. (in Russian) [6] D.A. Panfilov, Research of influence of distance between cracks on deflections of the bending reinforced concrete elements exposed to short duration uniform loading, VolgGASU Bulletin. Series: Construction and architecture, Volgograd, 2013, Part II, №31(50), pp. 388-391. (in Russian) [7] D.A. Panfilov, Researches of deflections of the bending reinforced concrete beams at equally distributed loading, Modern problems of calculation and design of reinforced concrete designs of multi-storied buildings: the collection of research papers of the International research conference devoted to the 100 anniversary of P.F. Drozdov (October 15th, 2013), Moscow state construction university, Moscow, 2013, pp. 175-179. (in Russian) [8] D.A. Panfilov, Calculation and comparison of the general deflection of the bent reinforced concrete elements for various techniques and computer systems, Problems of modern concrete and reinforced concrete: research papers of the 3d international symposium, BelNIIS, Minsk, 2011, V1, pp.275-287. (in Russian) [9] Panfilov D. A., An Improved Technique of Calculating Deflections of Flexural Reinforced Concrete Elements Made of Conventional and High-Strength Concrete, Journal of Civil Engineering and Architecture, ISSN 1934-7359, USA. –Feb.2013, –Volume 7, –No.2 (Serial No.63), –pp.125-131. (in Russian) [10] D.A. Panfilov, Calculation of deflections of reinforced concrete elements for Eurocode 2 technique, Traditions and innovations in construction and architecture. Electronic resource: materials of the 70 th Russian research and engineering conference on the results of research work of 2012. Samara, 2013, pp. 311-314. (in Russian) [11] D.A. Panfilov, Modeling of a reinforced concrete beam by method of a finite element taking into account concrete creep, Traditions and innovations in construction and architecture. Materials of the 70 th jubilee Russian research and engineering conference on the results of research work of 2012. Samara, 2013, pp.307-308. (in Russian) [12] D.A. Panfilov, Review of method of calculation of width of cracking disclosure of the bent reinforced concrete elements in native and foreign standard documents, Science of 21st century/ SGTU, Saratov, 2011, №3, pp.57-65. (in Russian) [13] D.A. Panfilov, Considerations of features of reinforced concrete, calculating exception of the propagating rupture, Bulletin of construction sciemces department/Russian academy of architecture and construction sciences, M. Orel-Kursk, 2011, № 15, pp. 127-130. (in Russian) [14] D.A. Panfilov, Modeling of the intense deformed condition of the stressed reinforced concrete elements on the basis of discrete approach taking into account the nonlinear deformation curve and concrete creep, Traditions and innovations in construction and architecture. Materials of the 69 th Russian research and engineering conference on the results of research work of 2011. Samara state university of architecture and civil engineering, 2012, pp. 311-315. (in Russian) [15] G.V. Murashkin, V.G. Murashkin, Modeling of the deformation concrete chart, Izvestiya OrelGTY, Stroitel’stvo i transport, 2007, №2-14, pp. 86-88.
Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539 [16] A.V. Kozlov, Calculation of the bent reinforced concrete elements with application of deformation curve, TulGU Bulletin. Series Technology, mechanics and durability of construction materials, buildings and constructions. Issue 2, Tula, TulGU, 2010. [17] A.A. Pishulev, Flexural concrete elements with similar strength properties of concrete compressed zone, Beton i zhelezobeton, 2010, № 2, pp. 23-26. [18] G.V. Murashkin, A.A. Pishulev, Using deformation models to determine the bearing capacity of reinforced concrete flexural members with corrosion damages of concrete compressed zone, Izvestiya OrelGTY, Stroitel`stvo i rekonstuktsiya, 2009, №6, pp. 36-42. [19] Yu.V. Zhyltsov, Pilot studies of distance between cracks in it is central tensile elements, Traditions and innovations in construction and architecture. Materials of the 70 th Russian research and engineering conference on the results of research work of 2012. Samara state university of architecture and civil engineering, 2012, pp. 308-310. (in Russian) [20] G.A. Smolyago, The issue of ultimate concrete elongation, Beton i zhelezobeton, 2002, №6, pp. 6-9. [21] P. T.Wang, S. P.Shah, A. E. Naaman, High-Strength Concrete in Ultimate Strength Design, Journal of the Structural Division, ASCE, V. 104, No. ST11, 1978, pp. 1761-1773. [22] SP 63.13330.2012, Concrete and reinforced concrete structures. Basic principles. Revised edition SP 52-101-2003. Ministry of Regional Development of Russia. M.,2011, p. 161. [23] Guide to SP 52-101-2003, Guide on concrete and reinforced concrete structures design made from heavy concrete without reinforcement prestress. M., 2005, p. 217. [24] Eurocode 2, prEN 1992-1 (Final draft), Design of concrete structures, Part 1: General rules and rules for buildings. Brussels, 2001. p. 54. [25] FIB Model Code 2010,Vol.2, Final Draft, fib bulletin 56, 2010 – 293p.
539
ScienceDirect Procedia Engineering 111 (2015) 534 – 539
XXIV R-S-P seminar, Theoretical Foundation of Civil Engineering (24RSP) (TFoCE 2015)
Artificial broken stone production for industrial and civil engineering: technological parameters Sergey A. Mizuriaeva*, Sarsenbeck A. Montaevb, Azamat T. Taskaliev b a
Samara State University of Architecture and Civil Engineering (SSUACE), Molodogvardeyskaya St 194, Samara, 443001, Russia b West-Kazakhstan Agrarian-Technical University named after Zhangir khan, Zhangir-Khan St. 51, Uralsk, 090009, Kazakhstan
Abstract The paper presents the results of investigation according to which the optimal fraction composition of clay concrete from Taskala gaize is found out. Its physical and mechanical properties are taken into account. The optimal fraction for crushed clay concrete is as follows: 5-10mm, 10-20mm and 20-40mm. The paper describes the influence of various technological factors on physical and mechanical properties of artificial crushed rock made from gaize. The role of preliminary thermal treatment of clay concrete particles and fractions is also looked into. According the results of the investigation the optimum thermal treatment temperature is stated. It’s 200-3000°С for chert gaize and 400-4500°С for clay materials. © 2015 The Authors. Published by Elsevier B.V. © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license Peer-review under responsibility of organizing committee of the XXIV R-S-P seminar, Theoretical Foundation of Civil (http://creativecommons.org/licenses/by-nc-nd/4.0/). Engineering (24RSP) under responsibility of organizing committee of the XXIV R-S-P seminar, Theoretical Foundation of Civil Engineering (24RSP) Peer-review Keywords: Aggregate; Silicates; Gaize; Preparation; Resistibility; Density.
1. Introduction Modern construction is impossible without concrete application, concrete and reinforced-concrete constructions. It is a well-known fact that one of the main concrete components, which greatly influences concrete parameters, is an aggregate [1]. Traditionally, heavy-weight dense aggregate in the form of broken stone is advised to use for structural concrete, as it has higher strength in comparison with porous aggregate.
* Corresponding author. Tel.: +7-937-997-94-88. E-mail address: [email protected]
1877-7058 © 2015 The Authors. Published by Elsevier Ltd. This is an open access article under the CC BY-NC-ND license
(http://creativecommons.org/licenses/by-nc-nd/4.0/). Peer-review under responsibility of organizing committee of the XXIV R-S-P seminar, Theoretical Foundation of Civil Engineering (24RSP)
doi:10.1016/j.proeng.2015.07.037
535
Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539
Nowadays, broken stone for high-strength concrete grade is produced of rock formation, deposited not in all regions of Kazakhstan Republic and Russia. That is the reason why broken stone is transported via railway to the regions that lack necessary rock formations. This fact causes problems of broken stone supply [2-6]: x Problem of timely broken stone supply. x High prices due to delivery cost rise. x High production cost of goods made of imported broken stone. Traditional dense broken stone has a number of disadvantages. Firstly, its average density is 2200-2500 kg/m3, that considerably loads constructions, secondly, its high thermal conductivity predetermines low heat-insulating parameters. There are several ways to solve this problem. 2. The analysis of chemical composition of the gaize It is effective to use various local materials and industrial wastes [7-11]. Results on the use of high-strength expanded clay aggregate used in structural stone arouse profound interest [12-16]. It should be noted that there is a big volume of research devoted to technologies of high-strength expanded clay aggregate production [17,18] and use of expanded-clay concrete for production of constructions for structural purposes [19-21]. However, use of highblowing raw-material for production of high-strength expanded clay aggregate seems to be irrational. Numerous and widely-spread formations of silica rock, potentially applicable for production of construction materials, are of great concern [22-26]. In connection therewith, research and tests were conducted, designed for optimal technological parameters of preparation and thermal processing of silica rock formation – gaize for getting natural stone using the ceramics technology. Experimental research was conducted, using the natural test-samples directly from the borrow pit of the gaize in Taskalin rock formation, located in the Western-Kazakhstan region. Chemical and mineral composition of silica rock formation - gaize of Taskalin rock formation, particularly, phase composition and crystal structure of original particles was analyzed during this research. The results of the research on chemical composition of the gaize are presented in Table 1. Table 1. Chemical composition of the gaize.
K2O
0,431,39
1,394,8
0,030,97
0,150,78
1,132,85
Ignition loss
Na2O
0,24-17,9
SO3
0,10,62
CaO
TiO2
Al2O3 5,7612,95
Fe2O3
66,9883,5
MgO
Gaize
SiO2
Proportion of oxides (%wt) Raw material nomination
1,85-18,9
The analysis of the mineral composition of the gaize showed that in the majority of cases the gaizes contain glauconite (1-4%) in the form of rounded pale-green grains with aggregate polarization. Carbonate material looks as small (0,02-0,1 mm) foraminifer shells, which outfaces are made of thinly laminated calc-spar and infaces are made of fire opal. Besides that there are small balls of pelitomorphic calci-spar. Occasional spherical organic remnants (of diatoms, sponges) of low survival rate with hardly visible organogenic structure can also be seen. The size of silica framework is 0,07-0,12 mm. Brownish spots in the formation (apparently, clots of clay matter, impregnated finely dispersed with black iron oxide) are of small size and mostly are parallel to shaly lamination. Small singular voids are incrusted with chalcedony. Copperas stone grains exist as small impurities (0,04-0,07 mm). Data decoding of X-ray analysis of gaizes showed polymineral composition of the studied formations. Welldefined crystobalite reflex (408-410 picometers), complicated by tridymite reflex, is the peculiarity of these formations (427-430 picometers). A 500 kg batch of gaize was dispatched from the borrow pit on the tip lorry for the definition and systematization of naturally selected gaize clot sizes. Afterwards the selected batch went through particle analysis. The particle analysis results are shown in Table 2.
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Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539
Table 2. Results of particle analysis. Fraction sizes, mm
Fraction composition, %
more than 150
15
150 -100
15
100 - 50
20
40-20
30
20-10
15
10-5
3
Less than 5
2
The average open pit humidity of the test samples was 15,5%. 3. Analysis of physical-mechanical properties of the broken stone from the gaize of Taskalin rock formation after crushing Taking into consideration that silica rock formations in their natural state possess some extent of gum rigidity and the results of preliminary gaize test, getting the required fraction size was achieved through crushing [26-28]. Study of equipment regarding maximum output of the required fraction with the minimum formation of flour particles was carried out for the definition of the most rational ways of crushing. At the initial stage various crushing machines, produced by the leading companies of Russia, Ukraine, Germany and other countries, were analysed. As a result two types of crushing machines were chosen for division of gaize clots into necessary fractions. These are revolving pin and jaw crushers. The results of impact of crushing type on the properties of the broken stone are shown in Table 3. Table 3. Physical and mechanical properties of the broken stone from the gaize of Taskalin rock formation. Type of gaize crushing Revolving pin crusher
Jaw crusher
Fraction size, mm
Crushing resistance, MPa
Water absorption, %
Flour particles, %
5-10
3,4
31
3-4
10-20
3,6
30
2-3
20-40
3,8
29
1-2
5-10
3,2
31
5-7
10-20
3,5
30
4-6
20-40
3,7
29
3-5
Taking into consideration physical and mechanical properties of the gaize and the results of the preliminary lab tests revolving pin crusher was finally chosen as the most appropriate. The analysis of the experimental results showed that fraction strength of the gaizes during crushing with jaw crusher is 6-7% lower in comparison with the fractions, granulated by the revolving pin crusher. Besides that, it should be noted that while crushing gaize fractions by jaw crusher, formation of flour particles is 40-50 % more than while crushing by the revolving pin crusher. After crushing with the help of laboratory griddle the gaize broken stone was divided into three fractions: 5-10 mm, 10-20 mm, 20-40 mm, that were tested for the definition of the basic physical and mechanical properties. The test results are presented in Table 4.
537
Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539 Table 4. Physical and mechanical properties of the gaize of Taskalin rock formation divided into fractions. Fraction size, mm
Packed density, kg/m3
Water absorption, %
Crushing resistance, MPa
Thermal conductivity, W/mK
5-10
640
27
3,5
0,08
10-20
625
26
3,9
0,08
20-40
590
25
4,1
0,07
Analysis of dependence of compressive strength and packed density of the objects under research on the rate of firing temperature rise Preliminary thermal preparation of the samples is technologically important for the production of artificial broken stone of the silica rock formation, as the end-use properties and quality of the obtained production depend on the parameters of thermal preparation. Basic technological parameters of thermal preparation are intake temperature of thermal processing and its durability. The basic criteria for getting quality products is the optimal temperature definition under the condition of fast firing. Under production conditions activated process of firing takes place in rotary furnaces [29, 30]. During experimental research broken stone of the gaize was placed into laboratory rotary electric furnace and was thermally processed under various temperatures according to specially designed mode. The initial temperature of thermal preparation for silica formation gaize was 100 0С. Such temperatures as 1000С, 2000С and 3000С were taken for the definition of the optimal thermal preparation temperature for silica formation gaize. These temperature indexes were taken into account with the prior defined physical and mechanical properties of raw materials, as well as chemical and mineral composition. Method of optimal temperature of thermal preparation determination consisted of the following stages: gaize broken stone samples were preliminary heated to the mentioned temperatures with the speed of temperature rise 100-1500С per hour. These samples were sustained for one hour under the mentioned temperatures and were exposed to dramatic temperature rise to 950-10500С. The optimal thermal preparation temperature was the temperature that allowed to fire the samples avoiding breakages and cracks. The results of experimental research allowed to identify the optimal thermal preparation temperature of the object under research. The optimal rate of temperature rise for the gaize of silica rock formation was 200-3000С per hour. Gaizes were also exposed to fast firing at the rate of temperature rise 200 0 - 3000С per hour in order to identify the optimal temperature of firing for silica rock fractions. The results of strength indexes and packed density of the sintered fractions allowed to determine the maximum temperature of firing. The results of the experimental research are showed in Table 5. Table 5. Dependence of compressive strength and packed density of the objects under research on the rate of firing temperature rise. Object name
Rate of temperature rise, 0
С per hour 200
Silica rock formation gaize
Maximum firing temperature, 0
С
950 r 20
300 200 300
1050 r 20
Compression strength,
Packed density,
МPa
kg/m3
51
735
54
740
65
750
68
760
The results of the research show that the rate of temperature rise and maximum firing temperature produce a strong impact upon the technological and physical-mechanical properties of the finished units. The fast firing at 2003000С allows to get the required compressive strength and packed density. It should be noted that there were no considerable variations in property indexes under above mentioned temperature ranges of fast firing. The compressive strength of thermally processed samples under 950-10500С is 51-68 MPa, and the packed density is
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Sergey A. Mizuriaev et al. / Procedia Engineering 111 (2015) 534 – 539
about 735-760 kg/m3. According to the National State Standard 22263 “Broken stone and sand of silica rock formation”, artificial broken stone of gaize has strength corresponding to the line mark П350, and its packed density corresponds to line mark 700-800. 4. Conclusion Consequently, there is a real possibility of getting artificial broken stone out of gaize of silica rock formation, using the technology of fast firing. These results of experiment are important today and can be helpful for the industrial development of broken stone production technology, using silica rock formation – gaizes of Kazakhstan Republic and Russia. The resulted material (broken stone) possesses enough low density, high strength and good insulating properties. The research was conducted as a grant project of the Ministry of education and sciences in Kazakhstan Republic. References [1] D.A. 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