The leading manufacturer of abrasive materials, PrJSC "Zaporizhzhia Abrasive Plant", in search of options for expanding sales, has signed an agreement with the Lviv Polytechnic National University to conduct an independent study on the possibility of using our production waste in the construction sector.
For this purpose, the plant sent samples of silicon carbide materials, normal corundum, dry sludge and dusty material of gas purification filters for melting normal corundum, and also provided information on the prices of these materials - in order to also work out the issue of the feasibility of a particular application.
These days, the plant received an official report from Lviv Polytechnic on the results of the work. We asked the chief technologist of PrJSC "Zaporizhzhia Abrasive Plant" to comment on important nuances of the research conducted, recorded in this document.
It turned out that of all the samples of our materials sent, according to the results of the scientists' report, the most interesting and promising in terms of effective application is the fine-dispersed, dust-like material of electrostatic filters for gas purification of normal electrocorundum smelting, due to its properties, availability and low price.
According to the conclusions drawn on the basis of scientific research and analysis, an effective direction for the use of this material is its use in the production of mastics.
Mastic is a paste used for sealing, i.e. gluing, cementing, filling cracks, etc., to create a seamless waterproof coating.
Mastics are used in construction and repair works: in the arrangement and repair of roofs, foundations, various coatings, in the construction of bridges, tunnels, for hydro- and vapor barrier, as a protective material for structures and buildings from the effects of various atmospheric phenomena, etc.
The report of the national university based on the results of the research that we requested contains both a chemical analysis of our material, a description of the laboratory work that was carried out, and recommendations for areas of application. And we are ready to provide this report to our potential consumers for more detailed review if necessary.
Which filler in the production of mastic can be replaced with powdered material of normal corundum?
- It can replace any filler in the form of a finely dispersed powder used in the production of mastics: limestone, dolomite, brick and andesite mineral powders, dolomite flour, kaolin, talc, talcomagnesite, chalk, ground sand, natural marshalite, thermal power plant ash, cement.
What are the advantages of our powder material compared to other fillers?
The main advantages of fine-dispersed powder material of normal electrocorundum are its cheapness and availability against the background of improved indicators for use in the production of mastic.
How much do other fillers cost, for comparison?
For comparison, the cost of 1 ton of lime mineral powder, which is added as a filler in the production of mastics, is 2,000 hryvnias and above. The price of our dusty material today is 250 hryvnias per ton. This is 8 times cheaper, so the difference is significant. Today, fine-dispersed dusty material of normal electrocorundum is the cheapest material, any other is more expensive.
What percentage of filler is used to make mastic?
About 6%. The impact of such a component on the final cost of the product may seem insignificant to some, but if the scale of production is large, it is significant. Therefore, the use of our material, which is characterized by a low price, as a filler is economically profitable.
What indicators are improved by the use of fine-dispersed powdered material of normal electrocorundum?
The use of our powdered material, due to its physicochemical properties, significantly increases such an important indicator as heat resistance.
The structure of the coating in which our material is used is preserved at high temperatures, which is especially important against the backdrop of climate changes that have been observed recently, when it is getting hotter every year.
What is the main chemical composition of fine-dispersed normal corundum dust?
Al2O3 ≤ 35, SiO2 - 35-70, Fe2O3 ≤ 15, C ≤ 20
What is the particle size of this material?
The average particle size of the dusty material is 22.8 microns, the bulk density is 0.33 t/m3.
Have mastic formulations been developed using powdered normal corundum material?
Today, we have approximate mastic formulations using powdered normal corundum material, selected by scientists - these formulations are recorded in their report. If necessary, they are ready to engage in more in-depth developments for manufacturers, make detailed calculations, where and in what proportion to use, with the inclusion of data in the relevant regulatory documents (technical conditions, DSTU).
What volume of powdered normal corundum material can the plant supply to consumers?
Today, we have the opportunity to ship 300 tons of such material, which is in stock in big bags of 300-350 kg. The monthly volume that we can sell to consumers during the operation of one melting furnace is on average approximately 70 tons. In September, another furnace is being brought into operation, accordingly, this volume will increase approximately twice.
