raw material base

The least «capricious» and the most «noble» raw materials for TRIBOPRESS plants are the stone quarry screenings.
It’s evidentl that different quarries exploit different stones and different stones have different wastes more or less suitable for our plants.

1. Screenings of «soft» stone quarries

«Soft» stones for our technology are the stones with the strength of up to 500 kg/cm², however the most favourable are the stones with the strengthof  up to 300 kg/cm².

The most appropriate, as a basic raw material for TRIBOPRESS plants, are the screenings of the following «soft» stone quarries:

1. shellrock,
2. limestone,
3. dolomite,
4. tuff,
5. marble,
6. marl,
7. some types of gaize.

The screenings of the above mentioned stones are  perfect raw materials for TRIBOPRESS plants, in the following composition:

1. «soft» stone screenings – a product of primary processing of stone (85%),
2. cement – a product of  secondary processing of  stone (7%),
3. water – a universal agent of chemical reactions (8%).

Exploiting quarries of the above mentioned stones can be found practically everywhere and their screenings are a cheap and easily accessible raw material.

The preferable building materials based on the «soft» stone screenings are facing bricks in the supporting walls.

1. Screenings of the «hard» stone quarries

In the mountainous regions of the Earth there are large accumulations of hard volcanic rocks, such as granite, basalt, diorite, gabbrodiorite, siltstone and others as well as hard limestones and marbles, dolomitic limestones, etc.

«Hard» stones for our technology are the stones with the strength of more than 500 kg/cm².

Screenings of the above mentioned «hard» stones are a good raw material for TRIBOPRESS plants, always mixed with «soft» stone screenings in the following composition:

1. «hard» stone screenings – a product of primary processing of stone (51%),
2. «soft» stone screenings – a product of primary processing of stone (25%),
3. cement – a product of secondary processing of stone (12%),
4. water – a universal agent of chemical reactions (12%).

The necessity to use «hard» stone screenings relates to their huge accumulations due to the impossibility to utilize them by other technologies, except for the technology of TRIBOPRESS plants.

Naturally, the building materials based on the «hard» stone screenings, have a colossal strength (easily achieve 750 kg/cm² and higher) and their best transformation is the transformation into antiseismic bricks (outside and inside) and  sidewalk and road pavers, of the highest strength and erosive resistance.

1. Ceramic brick crushing and claydite screenings

Quite often,  ceramic brick production is accompanied by large quantities of low quality bricks accumulated in the form of ceramic crushing, and  claydite production – by large quantities of screenings.

After splitting small ceramic items are a good raw material for TRIBOPRESS plants, in the following composition:

1. small ceramic items  – a product of  primary + secondary processing (60%),
2. «soft» stone screening – a product of primary processing of stone (20%),
3. cement – a product of secondary processing of  stone (10%),
4. water –  a universal agent of chemical reactions (10%).

So, the screenings of claydite production are a good raw material as well.

The preferable building materials based on ceramic breakage and screenings are both facing bricks and  bricks for inner brickwork.

1. Rubble piles of destroyed iron concrete buildings

At the reconstruction of urban districts or after strong destructions there is a keen problem of how to use the ruins of buildings and constructions.

The most complicated thing is to separate iron reinforcements  and millwork from the rubble of big concrete slabs.

If we solve this problem and can crush concrete rubbles into the fractions of screenings, we can get a perfect raw material for TRIBOPRESS plants in the following composition:

1. splitted concrete – a product of primary and secondary processing of stone (85%),
2. cement – a product of the secondary processing of the stone (7%),
3. water – a universal agent of chemical reactions (8%).

This solution is unique as the production of new building materials from ground concrete or bricks can be made in  immediate proximity to the place of new construction.

1. Blast-furnace slags

The accumulation of blast-furnace slags on the territory of metalurgical industrial complexes quite often represents a real problem which requires an adequate and economically profitable solution.

Rather often blast-furnace slags contain up to 13-15% of residual iron. A preliminary cleaning of blast-furnace slags from residual iron on the special technological lines is required.

On the «tails» of the above mentioned technological lines TRIBOPRESS plants are installed.

When cleaned from the residual iron, the blast-furnace slag is an excellent raw material for TRIBOPRESS plants, in the following composition:

1. ground blast-furnace slag – a product of primary and secondary processing (87%),
2. cement – a product of secondary processing of stone (5%),
3. water – a universal agent of chemical reactions (8%).

The preferable building materials based on the purified blast-furnace slag are facing and inside bricks in the supporting walls as well as sidewalk and road pavers.

1. Burnt coal wastes  of mining and processing complexes

The accumulations of gob piles on the territory of mining and processing complexes frequently become a real problem requiring an adequate and economically profitable solution.

For the technology of TRIBOPRESS plants it is necessary to use old, completely burnt coal refuse (red dog).

After crushing, small coal wastes items are a good raw material for TRIBOPRESS plants, in the following composition:

1. small coal wastes items – a product of primary and secondary processing (60%),
2. «soft» stone screenings - a product of primary processing of stone (20%),
3. cement – a product of secondary processing of stone (10%),
4. water – a universal agent of chemical reactions (10%).

The preferable building materials based on the coal refuse are both facing bricks and  bricks for inside brickwork.

1. Solid ash-slag wastes of the Thermal Power Plants.

The most efficient heat carrier for Thermal Power stations is coal. Its heating value exceeds the heating value of natural gas more than twice .

Coal Thermal Power plants have mainly the following wastes:

1. СО – carbonic oxide – gaseous product of incomplete carbon combustion;
2. СО2 – carbonic dioxide - gaseous product of complete carbon combustion;
3. volatiles – light products of combustion of the dirts with a small quantity of carbon;
4. solid ash-slag wastes – products of combustion of dirts not containing carbon.

As a rule solid ash-slag wastes contain such substances as SiO2 , Al2O3 , CaO , MgO , K2O , Na2O and others. Among the «others», sulfur and its compounds are sometimes present.

The main part (more than 90%) of it falls at silicon dioxide (SiO2) – more than 65% and aluminium dioxide (Al2O3) – more than 25%, i.e. at the substances  quite appropriate for the technology of TRIBOPRESS plants.

After the coal combustion in the furnace of the electric plant, solid ash-slag wastes are ground up to the granulometry of screenings and are supplied in pipes by water to the precipitation tanks. The precipitation tanks are artificially dug in the ground «tanks», in this case - «slag tanks».

The polluted by many impuruties water gradually oozes into the soil mixing with ground waters and raising their level and the artificial ground reservoirs remain forever filled with ash wastes in the form of fine black screenings, dusting and poisoning the atmosphere, soil and rivers.

It is a real ecological catastrophe for the environment.

What is the scope of the caused ecological damage?

Let’s speak only about the solid ash wastes.

Now there are Thermal Power plants which every year «consume» from one to three hectares of fertile lands by the above mentioned «slag tanks», throwing into them from 200.000 up to 600.000 tons of solid ash wastes in the form of screenings.

What is the production cost of this storage for a Thermal Power plant?

According to the evaluations of the special state institutions of some countries, the cost of such a «disposal» of solid ash  wastes is about 60 euros/ton. 12 – 36 million euros per year more, as a component of the power plant prime cost.

What should be done? Electric power is vital and coal is the best heat carrier for power plants. Is there any way out? If there is any, for example in the form of controversial atomic power plants, but it would be in many years. What should we do now? How can we utilize (completely) these enormous quantities of ecologically damaging and economically expensive wastes?

The problem of utilizing  the solid ash wastes of the power plants is solved by the technology of TRIBOPRESS plants.

The cost of transformation of one ton of solid ash wastes into bricks is 20 euros.

The cost of the «disposal» of one ton of solid ash wastes is 60 euros.

So, to transform each ton of solid ash wastes in our bricks is 40 euros cheaper than to dig them in.

Thus, if on the output of the solid ash-slag wastes we install a TRIBOPRESS plant:

1. bricks for inside brickwork are produced (+ profit 10-30 million euros/year);
2. power production cost recedes  (+ profit 8 – 24 million euros/year);
3. never more it will be necessary to dig and fill the precipitation tanks - «slag tanks»;
4. ecological influence of the plant on the environment markedly improves.

After crushing, solid ash-slag wastes of the coal combustion are good raw materials for TRIBOPRESS plants, in the following composition:

1. solid ash-slag wastes – a product of primary + secondary processing (70%),
2. «soft» stone screenings – a product of  primary processing of stone (20%),
3. cement – a product of secondary processing of stone (5%),
4. water – a universal agent of chemical reactions (5%).

A natural building material based on the solid ash-slag wastes from coal combustion are bricks for inside brickwork.

The raw material base for TRIBOPRESS plants is endless, varied and  accessible, and their technology is ecologically clean as it produces neither solid nor liquid nor gaseous wastes, and as its raw material it uses wastes from other types of production: stone quarries, large brick plants and claydite plants, mining and processing and metallurgical industrial complexes, thermal power stations, coal thermal plants and mineral wastes from many other plants.

materias primas