PRODUCTION OF FOAMED SAND USING NEAR INFRARED

Abstract

A method for producing a bulk material consisting substantially of foamed or blown mineral or oxide particles by thermal treatment of a bulk material of basic particles, characterized in that the thermal treatment includes transport of a transversely conveyed or horizontal layer or of a free flow of the bulk material through a radiation field, the substantial active component of which lies in the near infrared range (NIR), and which has a power density of at least 50 kW/m2.

Claims

1. A method for producing a bulk material essentially from foamed or blown mineral or oxidic particles by thermal treatment of a bed of basic particles, the method comprising: transporting a transversely conveyed or horizontal layer or a trickle stream of the bed of the basic particles through a radiation field of radiation whose essential active component is in a near infrared, NIR, range and which has a power density of at least 50 kW/m.sup.2 for thermally treating the basic particles.

2. The method according to claim 1, wherein the basic particles are a sand with a high water glass content, a grain size in the range of 50-500 m, and a water glass content of at least 40%.

3. The method according to claim 2, wherein the bulk material of foamed or blown sand particles at an end of the thermal treatment, without a separation step, comprises a proportion of at least 60% of perlite particles with at least one of a substantially closed surface or a particle size is in a range of 0.3 mm-2 mm.

4. The method according to claim 1, further comprising using halogen lamps to generate the NIR radiation field, radiation of which is focused on the layer or trickle stream of the bulk material.

5. The method according to claim 4, further comprising actively irradiating the layer or trickle stream of the bulk material from a main surface and a portion of the radiation passing through is reflected back into the layer or trickle stream.

6. The method according to claim 1, further comprising exposing the layer or trickle stream to the NIR radiation field for a period of time in the range between 0.5 and 20 s.

7. The method according to claim 1, further comprising adjusting a maximum temperature in the layer or in the trickle stream to a temperature in a range between 600 and 1500 C.

8. The method according to claim 1, wherein a power density of the NIR radiation field on a surface of the layer or trickle stream is above 300 kW/m.sup.2.

9. The method according to claim 1, wherein a layer thickness of the layer or the trickle stream is in range between 2 mm and 30 mm.

10. The method according to claim 1, further comprising transporting the bulk material through the NIR radiation field which includes several heating areas with different power density.

11. The method according to claim 1, further comprising, in addition to the transport through the radiation field with NIR radiation, carrying out at least one further thermal treatment step on the thermally treated basic particles.

12. The method according to claim 11, further comprising transporting the layer of the bed of basic particles horizontally or transversely through the radiation field with near infrared radiation and thereby thermally pretreating the bed of basic particles, and then subjecting the thermally pretreated bed to an after-treatment in an induction furnace or a second radiation field with infrared radiation.

13. The method according to claim 12, wherein the subsequent treatment step is carried out in a multi-zone furnace, the heating zones of which have a temperature which rises from an inlet to an outlet thereof.

14. The method according to claim 13, wherein a temperature of the first heating zone is set in a range between 950 and 1050 C., a temperature in a second heating zone is set in a range between 1050 C. and 1150 C., and a temperature in a third heating zone is set in a range between 1150 C. and 1250 C.

15. The method according to claim 11, further comprising after the thermal treatment, carrying out a rapid cooling of the bulk material.

16. The method according to claim 1, further comprising a separation step of separating the foamed or blown particles from non-foamed or non-blown basic particles based on different specific weight thereof.

17. The method according to claim 16, wherein further comprising carrying out the separation step together with the thermal treatment or a cooling step in one and the same plant part.

18. An arrangement for carrying out the method according to claim 1, comprising a flat arrangement of NIR halogen radiators for generating the NIR radiation field and a conveying device for transporting the layer or trickle stream of the bed of basic particles through the radiation field.

19. The arrangement according to claim 18, wherein the NIR radiation field comprises several heating areas with separate controls for setting different power densities.

20. The arrangement according to claim 18, wherein the transport device comprises a vibrating table, belt conveyor or drum conveyor, wherein for the drum conveyor the flat arrangement of NIR halogen emitters is curved to match a peripheral surface of the drum conveyor.

21. The arrangement according to claim 18, further comprising a multi-zone furnace with an inductive or infrared heating system, which is at least one of arranged in a transport direction of the bed downstream of the NIR radiation field or is oriented vertically.

22. The arrangement according to claim 21, further comprising a cooling device for rapid cooling of the thermally treated bulk material, which comprises an actively cooled cooling surface on which the bulk material impinges.

23. The arrangement according to claim 22, further comprising a separating device for separating the foamed or blown particles from non-foamed or non-blown basic particles based on a different specific weight of the particles, the separating device comprising a cyclone separator or a fan for generating a rising air stream.

24. The arrangement according to claim 23, wherein the multi-zone furnace is arranged vertically, and the fan for generating an ascending air flow is structurally combined with the multi-zone furnace such that the separation step is carried out in conjunction with the thermal treatment step in the multi-zone furnace or a cooling step.

Description

BRIEF DESCRIPTION OF THE DRAWINGS

[0029] The advantages and usefulness of the invention are further described in the following embodiment example by reference to the FIGURE.

[0030] The sole FIGURE is a diagrammatic representation of a production line for the production of foamed sand.

DETAILED DESCRIPTION

[0031] The FIGURE shows a synoptic representation of a production line 1 for the production of foamed sand as a thermally treated bulk material 3 made of normal sand 3 containing water glass as starting material.

[0032] A screw conveyor 5 conveys the sand 3 into an NIR treatment station 7, in which an NIR emitter module 7a is arranged above an oscillating conveyor 7b and NIR irradiation of the starting material continuously conveyed through the irradiation station 7 is carried out with predetermined power density and dwell time. The setting of the power density and the dwell time (via the conveying speed of the oscillating conveyor 7b) is controlled by a process control unit 9 After leaving the NIR treatment station 7, the pre-treated material enters a vertical furnace 11 with inductive heating, which comprises three heating zones 11a, 11b, 11c with independently adjustable temperature and in which the thermal treatment of the sand is completed. Also the treatment in vertical furnace 11 and especially the temperatures in the heating zones 11a-11c are controlled by the process control unit 9.

[0033] The thermally blown or foamed sand is cooled in a cooling system 13, which includes (not shown) cooling air fans and a cooling pipe 13a. It is then fed to a cyclone separator 15, where the non-blown product fraction 3 is separated from the final product 3 with the desired properties. While the thermally unmodified starting product 3 enters a storage container 17 from where it can be brought back to the starting point of the process, the cleaned end product is blown into a fabric bag 19.

[0034] The execution of the invention is not limited to this example, but is also possible in a variety of modifications, which are within the scope of professional action.