Foam Glass Production Research Articles

Parametric optimization of the thermal processing of foam glass on basis of heat transfer models

The foam glass is one of the most prospective materials in the market of vitro-crystalline building materials. To achieve optimal physical and technical parameters of foam glass, the development of technology that will regulate the processes of heat treatment of the raw material mixture to produce foam glass without reducing its performance is required. Foaming process is an important parameter in the foam glass technology. The temperature of the raw material mixture changes from the surface layers to the center of the backfill during foaming, the activation reaction of the gasifier thermal decomposition proceeds similarly, which can result in the material uneven air-entraining. Mathematical model presented in this paper makes modeling the distribution of temperature fields at the contact boundaries of the metal mold for foaming and the raw material mixture for the foam glass production as well as prediction of the further temperature changes in the raw material mixture, which is the key factor in the formation of a uniformly porous final product, possible.

Analysis of existing technological solutions of foam glass production

Introduction. Foam glass is often represented as a thermal insulation, a sound insulation and a sound absorbing material in the form of blocks (slabs), granules and shaped products. Cellular glass is characterized by durability, incombustibility, biostability and sufficient strength. Among the main properties, it is also possible to mark out low thermal conductivity of foam glass which makes it a promising thermal insulation material. Materials and methods. A complex of general scientific logical methods of research is used in this work. The complex is based on a theoretical analysis of technological solutions for the foam glass production described in the scientific and technical literature, patents as well as scientific papers. Results. Possible classifications of foam glass products are marked out; an authors’ classification is suggested depending on the field of foam glass application. The main foam glass properties are considered. The advantages and disadvantages of the foam glass charge mixture are identified in the course of analysis of possible raw components as well as their influence on the foam glass production technology and properties of the finished product are examined. Comparison of blowing agents is conducted depending on the foaming temperature and pore character that affect the field of material application. A comparative table of the foam glass production technologies is proposed, the merits and demerits of each technological solution are revealed as well as variants of the obtained products and needed equipment are considered. Conclusions. Allowing for the consumer demand for thermal insulation materials and strict requirements for them, it is most expedient to produce granulated foam glass with a wet method. The advantages of this technology are the accelerated grinding of glass in liquid media, lowering the foaming temperature, expanding the temperature range of structure formation, eliminating dust emission that permits reducing the finished product cost.

Resource-Saving Technologies in the Thermal Insulation-Structural Foam Glass Production

The modern building materials market places high demands on heat-insulating and heat-insulating structural materials. In this connection, the issues of developing high-quality building materials obtained on the resource-saving technologies basis allowing to solve two interrelated problems are topical. The first problem is the industrial waste generated and existing stocks disposal. The second is associated with a decrease in the traditional raw materials deficit [1]. These problems solution, combining rational technological solutions, is based on the scientific research achievements in this area, in particular in the foam glass production. The priority scientific research areas in the foam glass materials production are the developments related to the study, the new raw materials use and the production of foam glass mixture compositions on their basis, which provide, along with the necessary performance properties, high environmental safety requirements [2, 3].

Modeling of Macro-Physical Parameters of Foam Glass under Exposure of Cyclic Thermal Effects

The process of the raw materials mixture heat treatment in the foam glass production is of great importance in the formation of the finished product thermal characteristics. Selection of optimal temperature regimes at the stages when the process of glass particles melting is activated and thermal decomposition of the gasifier occurs is of particular importance. Otherwise, a situation when the gasifier has decomposed by mass on the layers close to the material surface at that the reaction has not been initiated at the raw materials mixture center may emerge. The problem can be solved by the uniform heating throughout the raw materials mixture entire volume. The fact that excessive heating can entail additional financial costs for manufacturers’ energy resources and as a result the cost of the material can be increased and affect its competitiveness among thermal insulation materials should be taken into account. A method for calculating temperature fields allowing to simulate the thermophysical heating process in the center of the material under study on the basis of its surface temperature indicators has been presented in the paper. Such an approach may make calculation of the rational time intervals for the raw material mixture heat treatment prior to the foaming stages and partially optimization of the production process possible.

The use of industrial waste and cullet for building foam glass

There is a huge raw material base for the production of foam glass. The aim of the work was to develop a technology for producing foam glass from cullet and industrial waste. Glass makes about 5% of municipal waste. Calcium carbonate which is the waste of ANP fertilizer production can be used as a foaming agent. The research task was to obtain effective heat-insulating and structural and heat insulating material with the corresponding physical and mechanical characteristics for low-rise and high-rise construction. The analysis of existing approaches to the production of foam glass was carried out in the course of the work, laboratory study of various mixtures composition was held and optimal mixtures of cullet and a foaming agent were proposed. Experiments showed that the density of foam glass made from different kinds of glass differs by up to 15%, which makes it possible to dispense with the expensive operation of sorting cullet.

Physical-Chemical Studies of Gaizes as Alternative Raw Materials for the Production of Foam Glass and Foam Materials

Data from physical and chemical studies of gaizes are presented—chemical, phase, and granulometric compositions, degree of crystallinity, and thermal stability in the temperature interval 90 – 1000°C. It is shown that the silica in the studied gaizes exhibits heightened reactivity and the gaizes have low crystallinity and high dispersity, which promotes activation of structural-chemical transformations in gaizes when they are heated.

A Comparative Life Cycle Assessment of Typical Foam Glass Production

Foam glass is a new insulation building materials and plays an important role in building energy efficiency for its many excellent performances, such as small thermal conductivity, low coefficient of thermal expansion and high mechanical strength. Generally, the manufacturing process of foam glass mainly can be classified into two typical processes, the waste glass recycling process and glass melting process. In this paper, the process-oriented life cycle assessment is used to quantitative analyze and evaluate the environmental load, such as energy consumption and pollutant emission of the two typical processes. The results show that the environmental load of the glass melting process takes place in two stages of the foaming and annealing, and the raw material extraction, while the waste glass recycling process mainly come from foaming and annealing. Regarding the energy consumption of foam glass, waste glass process is lower 22.4% than the glass melting process, while carbon emissions is lower 24.8%, and the comprehensive environmental impact is lower 40%. Therefore, the findings will guide and promote the new technology application for the energy saving and green technology applications in foam glass industry.

Peculiarities of the use of siliceous raw materials of the Russian Far East in the integrated pipeline protection

Modern trends in the development of Russian oil and gas infrastructure are examined. The important role of the Far East in the transportation and export of oil is revealed. The main threats in the operation of pipelines are described. The integrated protection technology of pipeline surfaces is proposed. The structure and properties of local silicate raw material – diatomite – are studied. The technology of obtaining glass enamel coating is designed to protect the internal surface of the pipe. The phase composition, microstructure and properties of the coating are compared with analogues. The technology of foam glass production is designed to protect the external surface of the pipe. The foaming processes are studied; the properties and structure of the material are examined. The optimum ratio of raw materials is revealed. Recommendations on the application of the developed technology for integrated pipeline protection are given.

Foam Glass Production from Waste Glass by Compression

The authors have identified the impact of the glass mixture briquetting process parameters (milling method, dispersibility, particle size distribution, particle form and compression parameters) on the performance characteristics and the physical and chemical properties of foam glass. It was demonstrated that briquette density increasing contributes to achieving a lower average density of foam glass. It was proven that briquettes produced from multifractional powders are characterized by a higher density than those produced from powders with a limited range of particle size distribution.

Filter Medias from Granulated Foam-glass, Properties Investigated for Water Treatment Possibilities

Inorganic material – granulated foam-glass produced from glass breakage in small porous granule shape. Foam-glass is gotten by connecting thoroughly grounded glass with foamers, later this composition is heated in the furnace in especially high temperature and is turned into various diameter greyish granules. Granulated foam-glass is a unique ecological material of which inner structure pores are arranged in such a way that air is trapped inside. Foam-glass production technology is one of the most advanced since the product is made from secondary raw materials, not leaving any third row waste. From granule surface images it can be seen that granule surface has pores and voids, some of these pores are closed, others are connected with granule’s inner pores, all pore walls are smooth, and the wall material is vitrified. Pores and voids are arranged chaotically in smaller granules, bigger granules inner space structure is tidy, bigger part is occupied by correctly arranged bigger pores and space between them is filled with smaller pores. Granules are composed of amorphous phase, in mineralogical composition can emit one material cristobalite. In the work were researched two fraction granules: 0/2 and 2/4 as well as determined 0/4 fraction granular-metric composition. Researched and determined main physical granule properties and properties related to water effect to the material, shown in micro-structural granule surface and inner structure images. According to explored properties it can be noted that granules can be adapted in water cleaning technologies.

Mathematical Modeling of the Technological Stages of Porous Glass Production (Review)

Directions for using mathematical modeling in the last 15 years to improve the technological processes in the production of foam glass are reviewed. The works of leading scientists in this field are presented. The main positions, assumptions, areas of application, and uses of the mathematical models created are presented. The general rules in using the homogeneous and discrete approaches to solving the problems of mathematical modeling are indicated.

Single-stage technogy for granulated foam glass production based on the composition of tripoli and technogical microsilica

The possibility of foam glass production by means of one-stage technology based on the natural tripoli and technogenic silica is determined. 45 % sodium hydroxide solution is used for the synthesis of foam glass. The addition of microsilica as an extra component in an amount of 10 to 50 wt. % in batch component increases the strength of the obtained material to 4 MPa and reduces foaming temperature from 870 to 830 °C. The increased mechanical strength of the material is due to the residual quartz dissolution and cristobalite crystallization. The samples obtained from batch with 30 wt. % microsilica have maximum strength.

The Effectiveness Of The Use Of The Zabaykalsky Territory Zeolite Row Materials For The Manufacture Of Heat-Insulating Materials In Road Construction

The use of many of insulation materials for construction of road pavement may be limited in areas with severe climatic conditions. One promising solution to this problem is the use of foam glass. Foam glass is safe and durable material with high thermal insulation properties and has many advantages over other types of materials. Processes of low temperature foaming of chemical and mechanical modified zeolite raw materials Holinskoe deposit were researched. The conditions for manufacturing of heat-insulating materials with density 250 kg/m 3 were define. That confirms the possibility of using zeolite raw materials in road pavement as thermal insulation material. In the production of new foam glass can be used raw materials with content of zeolites less than 50 %. That solves the problem of non-waste production of deposits with a corresponding increase their efficiency and reduce the technogenic load on the environment.

Analysis of the Environmental Impact of Foam Glass

Foam glass was widely used as a green energy saving material with good performances of light, thermal insulation and sound absorption. Using waste glass as raw material for foam glass production, can not only turn waste into treasure and reduce resource consumption, but also protect the environment. In this article, the foam glass which produced in Jiaxing, China was studied based on the method of life cycle assessment (LCA), and the resources, the energy consumption and the emission of pollutants at the same time were evaluated. The results show that the characterization value of GWP is the largest. The foaming stage is the main contributor which accounts for 79.7%. Similarly, the foaming stage is the major contributor to AP, POCP, EP and HTP .The characterization value of ADP is the smallest. The foaming stage and annealing stage is the main contributor to ADP which account for 43.0%, 49.7% respectively. It has been found that the foaming stage makes the most contribution to the environmental impact. AP, GWP, POCP and EP of the foaming stage are extremely prominent compared to other stages. The authors used the methods of equal weight coefficient and AHP to weight the single indicator. The results show that the environment impact caused by the foaming stage is the largest, then grinding stage and cutting stage follow behind. The environment impact caused by the transportation stage is the smallest.

Water and waterglass mixtures for foam glass production

The present study investigates the use of sodium waterglass as an environmental friendly foaming agent to create fine porous foam glasses. The reactivity of the foaming agent was determined using thermogravimetrical measurements and difference scanning calorimeter analysis. The porosity of the foam glasses was measured and the pore morphology was evaluated using scanning electron microscopy. Phase formation caused by the addition of waterglass was studied using X-ray diffraction. Furthermore, thermal conductivity and splitting tensile strength of the materials were measured. Foaming by using only waterglass as foaming agent is possible. As a result, fine porous foam glasses with closed pores of 4nm to 800µm in diameter and mechanical strengths of 1.7N/mm2 could be obtained. Conventional foam glasses which are available on the market have bigger pore sizes up to 3mm and achieve lower strength. For this reason the produced foam glass can be used as a promising light weight construction material.

Structural and Textural Characteristics of a Heat-Efficient Composite Material Based on Clays with Different Mineralogical Composition

The introduction of wastes from the production of foam glass into clay-containing mixtures promotes the formation of a strong porous fragmentary structure in a composite material. The influence of textural and structural characteristics of composites on their physical and mechanical properties is examined.

The scientific and technological aspects of foam glass production

Cellular silicate glass and foam glass-ceramic materials are of considerable interest from scientific and practical perspectives due to their unique performance properties. It is shown that the previous powder technology was based on the sulfate mechanism of gas formation which had inherent disadvantages. Reasons are given for an opportunity to use quite a different, i.e., hydrated, mechanism of gas formation. The data concerning the peculiarities of the obtained cellular material are given. The peculiarities of hydrated technology are discussed.

Diatomites in Granular Foam-Glass Technology

The present status of research on the production of foam-glass from siliceous rock by the one-step scheme is examined. The main technological principles of the experimental production of granular foam-glass based on diatomites are formulated. The production process is described and the main properties of the 5 – 10 mm fraction as compared with the normative requirements are presented.

Generation Review on the Production Line Development of Foam Glass at Home and Abroad

According to domestic and international history of foam glass, the foam glass development situation of the United States, France, Japan, the former Soviet Union and China was specifically introduced. Moreover ,the foam-glass-production-lines history was divided by generations and the production-lines characteristics each generation was presented in detail. Compared with the production scale ,investments and unit production cost of foam glass production line on different generations ,we could find that building high-generation production lines, increasing productivity, improving quality, reducing costs and enhancing competitiveness will be the development trend of foam glass industry in the future.

On the Interrelation of Surface Tension and Viscosity for Glass Melts

The interrelation of the surface tension and viscosity of glass melts is examined from the physical-chemical and technological standpoints. The corresponding relations and experimental results are presented. The interrelation of the surface tension and viscosity is also examined for technological processes: glassmaking, interaction of molten glass with refractories, formation of different types of glass articles, thermal polishing and edge melting of articles and foaming during the production of foam glass.