THE USE OF SECONDARY PRODUCTS FORMED IN THE BRANCHES OF THE CHEMICAL INDUSTRY AS FILLERS IN THE PRODUCTION OF GYPSUM BUILDING MIXTURES

ABSTRACT

The article provides information on the technical conditions for the production of dry gypsum mixtures, regulatory documents and test methods applied to them. The waste generated at the “Ferganaazot” joint-stock company was studied, and it was determined that it can be used as a filler in the production and development of technology for gypsum dry construction mixtures for interior decoration of buildings and structures. The chemical composition and physicomechanical properties of these chemical industry wastes were determined, and the possibilities of their use as fillers in various sectors of the industry were considered. The technology of standardizing the composition of the mixture according to GOST(RU) and its granulometric composition were studied.

АННОТАЦИЯ

В статье приведены сведения о технических условиях на производство сухих гипсовых смесей, нормативных документах и методах испытаний, применяемых к ним. Изучены отходы, образующиеся на АО «Ферганаазот», и определено, что они могут быть использованы в качестве наполнителя при производстве и разработке технологии гипсовых сухих строительных смесей для внутренней отделки зданий и сооружений. Определены химический состав и физико-механические свойства этих отходов химической промышленности, рассмотрены возможности их использования в качестве наполнителей в различных отраслях промышленности. Изучена технология нормирования состава смеси по ГОСТ (RU)у и гранулометрический состав.

Keywords: Dry building mixes, waste sludge, gypsum decorative, carbonate compounds.

Ключевые слова: Сухие строительные смеси, гипс, декоративные, карбонатные составы.

Introduction

Various industrial wastes can be used as fillers in the production of dry construction mixtures. The use of secondary products as fillers helps to achieve environmental and economic efficiency. Regardless of the type of product being produced, the disposal of secondary products generated in the production processes of enterprises is a very urgent issue. For example, Ferganaazot JSC generates about 6,000 (six thousand) tons of solid carbonate waste per year [1,2]. Disposal of these wastes requires significant costs, and in many cases there are no economically viable technologies for their processing. As a result, the volume of waste continues to grow, which often leads to a reduction in the land available for agricultural crops. Due to the large amount of waste, the company disposes of it outside its territory. Currently, this solid waste is used in the production of lime, cement, asphalt [1]. However, its volume is so large that the development of new technologies for its effective use has become a very urgent issue for the company. The possibility of using these carbonate solid wastes as a filler for the production of composite polymer coatings for filling automobile bodies has been studied [3].

It is known from the literature that technological processes directly affect the quality of the product. The use of these wastes in the composition of dry building mixtures should also meet the requirements of established standards and not negatively affect the quality of the product. The main characteristics of the mixtures to be prepared should be such that they retain their properties for a long time even under the influence of external factors.

Method

Mixing gypsum with fillers helps to obtain a stable building material. Besides, the addition of plasticizers to the mixture improves the properties of the mixture, which makes it easier to use and has a positive effect on its strength[4].

When preparing gypsum mixtures, standard requirements are observed according to GOST 31356-2007, and test methods for the mixtures obtained are carried out according to GOST 31387-2008 and GOST 23789-2018. The physical and mechanical properties of gypsum mixtures are determined according to GOST 23789-2018. The process of preparing gypsum mixtures and testing them are standardized by GOST 31376-2008[5,6].

Spectrometric analysis was initially performed using an AL-27 mini-device X-ray diffractometer (Japan). This method allows for X-ray diffraction analysis of a powdered sample.

The IR spectrum of technogenic waste was recorded using a Shimadzu IRSpirit Fourier Transform infrared spectrophotometer QATR-S (reflection atr accessory) spectrometer[7].

These standards include all the necessary parameters to ensure the high quality of gypsum mixtures and verify their suitability for long-term use.

Results And Discussion

It is necessary to take into account that the granulometric and chemical composition of the fillers used in the preparation of gypsum mixtures does not adversely affect the properties of the mixture.

X-ray analysis of these wastes was carried out using a diffractometer. The analysis spectrum was obtained using an X-ray diffractometer (Fig. 1).

Figure 1. X-ray spectral analysis table of waste

The infrared spectrum analysis is presented in the following Fig. 2.

Figure 2. Infrared spectral analysis of technogenic

Spectra of technogenic waste (1) and CaCO₃ (2).

The granulometric composition of such solid waste was also studied. Figure 3 below shows the results of screening solid waste through sieves of different sizes.

Figure 3. Amount and size of carbonate solid waste fractions

The results show that the main part of solid household waste is calcium and magnesium carbonate, 1.71% silicon (IV) oxide, 0.358% aluminum oxide, 0.263% iron (III) oxide, etc.

In addition, the amount of carbon dioxide in the solid waste was determined by titration. The analysis results showed that the waste contained 38.23% (wt.) carbon dioxide.

The above chemical analyses and tests show that the main composition of the waste is calcium and magnesium carbonates.

This indicates that these wastes expand the possible areas of application of carbonate fillers. In particular, they are used in the production of lime, cement, asphalt and automotive putties[1]. However, their volume is so large that the development of new technologies that can effectively use them remains an extremely urgent issue for the enterprise. Of course, based on the data provided, it can be said that solid household waste generated at the “Ferganaazot” joint-stock company can be used in various sectors of the national economy. The development and implementation of effective technologies for their use can lead to a positive solution not only to the environmental problems of the enterprise, but also to other social and economic problems.

The dispersion level of the waste can be further improved by special processing, which means that the degree of fineness can be achieved to any desired size.

The analyses show that various additives in the studied carbonate waste do not significantly affect the quality indicators of gypsum mixtures in the preparation of their composition. The possibility of using the above-mentioned carbonate wastes as fillers in various proportions in the production of gypsum (GOST 125-2018) building mixtures was studied [8,9]. Tests were conducted to determine the strength (elasticity and compressibility), mobility and adhesion to the base of the obtained samples. The proportions that can be used to develop dry mixtures were determined. Figure 4 below shows examples of elastic and compressive test work.

Figure 4. Processes for determining bending (a) and compression (b) strength

Thus, the waste generated at the “Ferganaazot” joint-stock company can be fully used as a filler in the composition of gypsum-based mixtures. Carbonate minerals, in addition, do not significantly affect the physical and mechanical properties of gypsum and help improve the quality of the mixtures within the framework of accepted standards.

Conclusion

From the literature studied and the analysis conducted on the basis of GOST, it became clear that the main part of these wastes consists of carbonate compounds.

This indicates that carbonate wastes can be used for the preparation of gypsum dry building mixtures. It is possible to use them in various proportions in the composition of the gypsum mixture and produce mixtures based on the necessary requirements.

In addition, the absence of substances harmful to humans and the environment in the wastes further expands the scope of use.

References:

1. Domulajanov I.Kh., Teshabayev A.M., Domulajanova Sh.I. Technologies for producing quicklime ground lime from waste of JSC Ferganaazot. Lambert Academic Publishing. 2020, 81 p.
2. Domulajanova Sh.I., Abdullaev O.G., Khoshimov F.F. Obtaining unsaturated polyester-based composite materials from secondary products produced at Ferghanaazot JSC. Proceedings of the International Scientific and Practical Conference on “Problems in Chemical Technology, Chemical and Food Industries and Ways to Eliminate Them”, Namangan, NamMTI, November 18-19, 2022, pp. 241-243.
3. Abdullaev O.G., Umarov A.V. Development of a technology for the production of auto body fillers based on unsaturated polyester resin and generated solid household waste at “Fergonaazot” JSC. Composite materials. Scientific and technical practical journal. 1/23, p. 135-140.
4. Xolbek Zokirov, Olim Abdullaev; Preparation of dry building mixtures based on local raw materials for plaster works in accordance with standards. AIP Conf. Proc. 27 November 2024; 3244 (1): 050022. https://doi.org/10.1063/5.0242052
5. GOST 31376-2008 "Methods for Testing the Strength of Plaster Mixtures. Testing Procedures"
6. GOST 31387-2008 Dry Construction Plastering Mixtures Based on Gypsum Binder. Technical Conditions.
7. M.V. Korovkin, L.G. Ananyeva “Infrared spectroscopy of carbonate rocks and minerals” Recommended as a textbook by the Editorial and Publishing Council of Tomsk Polytechnic University-2016.
8. GOST 125-79 Binding Gypsum. Technical Conditions.
9. O.G. Abdullaev, A.V. Umarov, "Establishing the Technology for Producing Auto-Body Filler Based on Unsaturated Polyester Resin and Solid Waste Generated by “Ferganaazot” JSC," Uzbekistan COMPOSITE MATERIALS Scientific-Technical and Practical Journal, No. 1/2023, pp. 135-140.