UBND TNH QUNG NGI

S KHOA HC V CNG NGH

TNG CNG TY LP MY VIT NAM

CNG TY C PHN C IN MI
TRNG LILAMA

Bo co tm tt D n
D N SN XUT TH NGHIM GCH KHNG NUNG T
XC TC FCC QUA S DNG CA NH MY LC DU
DUNG QUT

Ch nhim d n: PGS.TS. Nguyn Phi Hng

Qung Ngi, thng 6/2013

MC LC
Trang
M U................................................................................................................................1
Chng 1. TNG QUAN.....................................................................................................2
I.1. Tng quan cc kin thc lin quan n D n............................................................2
I.2. Tng quan v D n.......................................................................................................2
1.2.1. Thng tin chung v D n..........................................................................................2
1.2.2. a im thc hin D n..........................................................................................2
1.2.3. Mc tiu ca D n....................................................................................................3
1.2.4. Ni dung ca D n....................................................................................................3
1.2.5. Phng n trin khai..................................................................................................5
1.2.6. D bo nhu cu th trng v phng n kinh doanh sn phm ca D n................6
1.2.7. Sn phm ca D n..................................................................................................6
Chng 2. THC NGHIM...............................................................................................6
II.1. i tng nghin cu...................................................................................................6
II.2. Phng php nghin cu.............................................................................................6
II.2.1. Cc phng php xc nh thnh phn c tnh cu trc vt liu.........................6
II.2.2. Phng php x l, kim sot cc yu t nguy hi trong xc tc FCC qua s
dng.......................................................................................................................................6
II.2.3. Phng php to gch khng nung..........................................................................6
II.2.4. Cc phng php xc nh tnh cht c l ca sn phm gch khng nung..................7
Chng 3. KT QU V THO LUN...........................................................................7
III.1. Xc nh c tnh ca nguyn liu s dng sn xut gch khng nung................7
III.1.1. Cht xc tc qua s dng t Nh my lc du Dung Qut..............................7
III.1.2. Cc nguyn liu phi trn khc....................................................................................9
III.2. Nghin cu s thay i nguyn liu u vo cho dy chuyn sn xut gch khng
nung.......................................................................................................................................9
III.2.1. Thay i t l phi trn xc tc sFCC (c nh hm lng xi mng)...................9
III.2.2. Thay i t l phi trn xi mng (c nh hm lng xc tc sFCC)..................10
III.3. Nghin cu x l v kim sot yu t nguy hi ca xc tc FCC qua s dng
trong sn xut gch khng nung.......................................................................................11
III.3.1. Kt qu phn tch kim loi nng............................................................................11
III.3.2. X l bng cng ngh nc hot ho...................................................................12
III.3.3. X l kt hp bng bentonit...................................................................................13
III.4. xut v trin khai dy chuyn sn xut gch khng nung t xc tc FCC
qua s dng.........................................................................................................................14
III.5. Cc kt qu hon thin cng ngh khc.................................................................15
III.5.1. Nghin cu thit k h thng cp nguyn liu t ng........................................15
III.5.2. H thng bo dng gch t ng........................................................................15
III.5.3. Nghin cu thit k h thng x l bi cho dy chuyn sn xut gch khng nung...16
III.5.4. Nghin cu thay i khun gch v phi mu cho sn phm gch khng nung16
KT LUN V KIN NGH..............................................................................................17
CC CNG TRNH CNG B LIN QUAN N D N.....................................18

DANH SCH NHNG THNH VIN THC HIN D N

T chc
STT

H v tn

Nguyn Phi Hng

Trn Quang Hu

Nguyn Hu Hnh

Trn Cao H

ng Vn S

Ng Quc Bu

Th Hoan

Lu vn Nam

L Quang T

cng tc

Ni dung cng
vic tham gia
Ch nhim D
n

Trng i hc Quy
Nhn
Cng ty c phn c in - mi trng
Th k D n
Lilama
Cng ty c phn c Phn cng ngh
in - mi trng
v k thut
Lilama
Cng ty c phn T
Phn cng ngh
vn xy dng in 4
v k thut vt
- Tp on in lc
liu xy dng
Vit Nam
Cng ty c phn c in - mi trng
T vn
Lilama
Vin Cng ngh mi Nghin cu vin
trng-VKH&CNVN
chnh
Cng ty c phn c Phn ti chnh
in - mi trng
v kinh t
Lilama
Cng ty c phn c - Phn cng ngh
in - mi trng
v vt liu xy
Lilama
dng
Cng ty thit b
Nghin cu vin
PCCC Thng Long

DANH MC CC CH VIT TT, K HIU, THUT NG

AAS

Atomic Absorption Spectroscopy (Quang ph hp th nguyn t)

ASTM:

Tiu chun Hip hi Th nghim v Vt liu M

AW

Activated Water (Nc hot ha)

BET

Brunauer-Emmett-Teller (tn ring)

BJH

Barrett-Yoyner-Halenda (tn ring)

DTA

Differential Thermal Analysis (Phn tch nhit vi sai)

EDX

Energy Dispersive X-ray spectroscopy (Ph tn sc nng lng tia X)

FCC:

Fluid Catalytic Cracking (Cracking xc tc lp gi si)

GKN

Gch khng nung

ICP-AES

Inductively Coupled Plasma Atomic Emission Spectroscopy (Quang

ph pht x nguyn t cm ng plasma)

IR

Infrared (Hng ngoi)

MRET

Molecular Resonance Effect Technology (Cng ngh hiu ng cng

hng t phn t)

PC

Portland cement (xi mng Portland)

PLC

Programmable Logic Controller (thit b iu khin c lp trnh)

ppm

parts per million (phn triu)

QCVN

Quy chun Vit Nam

RE:

Rare-earth (t him)

RFCC

Residue Fluid Catalytic Cracking (Cracking xc tc lp gi si phn

cn)

SEM

Scanning Electron Microscopy (Knh hin vi in t qut)

sFCC

spent Fluid Catalytic Cracking (FCC qua s dng)

TCVN

Tiu chun Vit Nam

TGA

Thermogravimetric Analysis (Phn tch nhit trng lng)

VLXD

Vt liu xy dng

XRD

X-ray Diffraction (Nhiu x tia X)

*
*

M U
Cng ngh sn xut gch trong nc hin nay vn ch yu l gch t
nung, v ang gy ra nhng h ly xu cho mi trng sinh thi. l vic
s dng ngy cng nhiu ti nguyn t m ch yu li l t nng nghip, km
theo l vic s dng cc nguyn liu khc phc v cho vic t gch nh than
, ci gy ra nhng hu qu nghim trng v cn kin ngun ti nguyn
v nhim mi trng.
V vy, trong my nm gn y, cng vi xu th pht trin chung ca th
gii, cc nh qun l v khoa hc, cng ngh trong nc cng rt quan tm
nghin cu, ng dng gch khng nung trong xy dng cng trnh. Chnh ph
ph duyt Chng trnh pht trin Vt liu khng nung n nm 2020 (Quyt
nh s 567/Q-TTg ngy 28/4/2010 ca Th tng Chnh ph). B Xy dng
cng ban hnh Thng t s 09/2012/TT-BXD ngy 28/11/2012, quy nh s
dng vt liu xy khng nung trong cc cng trnh xy dng k t nm 2013.
Qua kho st thc t ti a phng v cc tnh min Trung th tnh hnh
sn xut v s dng vt liu xy khng nung vn cn rt nhiu hn ch. Theo
thng k ca S Xy dng tnh Qung Ngi cho thy, tng sn lng sn xut
trong nm 2012 i vi gch t st nung l 460 triu vin, trong : gch
tuynel t trn 220 triu vin, gch nung l ng lin tc t 50 triu vin, gch
t st nung bng l th cng khong 170 triu vin. i vi gch xy khng
nung, hin nay trn a bn tnh mi ch c 2 chng loi gch xy khng nung,
l: gch xi mng - ct liu v gch khc ( ch, ong,), vic sn xut
v s dng vt liu xy khng nung ca tnh hin nay ch t khong 10% trn
tng s vt liu xy cc cng trnh vn nh nc.
S ra i v hot ng ca Nh my lc du Dung Qut gp phn rt
quan trng n s pht trin kinh t - x hi khu vc Min Trung, m bo nhu
cu nhin liu v nguyn liu ha du cho t nc. Bn cnh , vn pht
sinh cht thi c kh nng nhim mi trng t cc khu cng nghip ang
ngy cng gia tng, i hi phi c quan tm thu gom, x l v ti ch trit
. Hng nm, Nh my thi ra khong 2000 tn cht xc tc qua s dng,
ch yu l xc tc RFCC (Residue Fluid Catalytic Cracking). Thnh phn c
bn ca mt cht xc tc FCC bao gm hai hp phn: zeolit (Y dng trao i
RE3+ v/hoc H+, H-ZSM-5...), pha nn (SiO2, Al2O3, SiO2-Al2O3, khong
st...). Cht xc tc FCC mt hot tnh c b mt b u c bi cc kim
loi nng (V, Ni, Sb...), cc hydrocacbon v b cc ha. Kch thc ht gim do
xc tc b v vn, v th bi ca chng c kh nng gy bnh bi phi silic, ung
th khi tip xc v ht phi lin tc trong thi gian di. Tuy nhin, thnh phn

chnh ca cht xc tc FCC qua s dng vn l SiO2, Al2O3 tng t nh cc

hp cht aluminosilicat trong vt liu xy dng. V th, vic ti ch kt hp vi
x l cc tc nhn gy hi nu trn to gch khng nung trong xy dng l
rt cn thit, c c s khoa hc, ngha thc tin v kh thi.
Nhn thc c cc yu cu cp thit nu trn, vi vai tr l mt cng ty
tip nhn ngun thi v c kinh nghim trong lnh vc x l, ti ch cht thi
du kh, Ban lnh o Cng ty C phn C - in - Mi trng Lilama cng
vi mt s nh khoa hc tin hnh nghin cu quy m phng th nghim ch
to gch khng nung qua ti cp C s: Nghin cu sn xut gch khng
nung t cht thi zeolit (nghim thu ngy 21/02/2011). Trn c s cc kt qu
nghin cu c bn , bng kinh ph t c ca n v cng vi s h tr kinh
ph t ngn sch s nghip khoa hc tnh Qung Ngi, chng ti xut,
thc hin D n sn xut th nghim gch khng nung t xc tc FCC
qua s dng ca nh my lc du Dung Qut, vi hy vng D n thnh
cng s m ra mt hng ngnh ngh mi cho a phng, gim cc gnh nng
v chn lp cht thi rn, gim thiu nhim mi trng, gp phn tit kim
nng lng, bo v ti nguyn thin nhin v pht trin kinh t bn vng.
Chng I. TNG QUAN
I.1. Tng quan cc kin thc lin quan n D n
Trong Bo co tng kt D n, mc ny trnh by tng quan cc vn sau:
- Cht xc tc cracking, xc tc FCC;
- Cht thi xc tc FCC, cc hng ti ch trn th gii v trong nc;
- Gch nung v gch khng nung;
- Bn cht v nguyn l ca cng ngh hot ha nc (AW).
I.2. Tng quan v D n
I.2.1. Thng tin chung v D n
- Tn d n: D n sn xut th nghim gch khng nung t xc tc FCC
qua s dng ca nh my lc du Dung Qut
- Thi gian thc hin: 20 thng (t 10/2011 n 06/2013)
- C quan ch tr D n: Cng ty c phn C - in - Mi trng Lilama
- Ch nhim D n: PGS.TS. Nguyn Phi Hng, Trng i hc Quy Nhn
- Tng vn thc hin D n: 3.793,340 triu ng (t ngn sch s nghip khoa
hc: 1.130,000 triu ng; vn t c ca c quan ch tr: 2.663,340 triu ng)
I.2.2. a im thc hin D n
- Ti mt bng Khu lin hip x l cht thi EME thuc Cng ty c phn C in - Mi trng Lilama, Bnh ng, Bnh Sn, Qung Ngi

I.2.3. Mc tiu ca D n
- Gim thiu gnh nng pht sinh nhim th cp, gp phn m ra hng mi
v vic kt hp gia x l, ti ch, bo v mi trng v pht trin bn vng.
- Hon thin dy chuyn sn xut gch khng nung quy m 2 triu vin/nm t
xc tc FCC qua s dng ca nh my lc du Dung Qut, p ng tiu
chun mc gch t 70 tr ln theo TCVN 6477:2011 v quy chun QCVN
03:2008/BTNMT v gii hn kim loi nng cho php trong t dn sinh.
I.2.4. Ni dung ca D n
I.2.4.1. M t cng ngh, s hoc quy trnh cng ngh trin khai trong D n
Qua s tm hiu, th nghim cc phng php cng ngh ho rn, phi
trn v nn p, chng ti quyt nh la chn phng n Cng ngh p gch
(khng rung) t vt liu phi trn bng nc hot ha, tri qua nhiu ln th
nghim mang li nhng kt qu tt c v cht lng c l v mi trng.
S cng ngh c tm tt Hnh 1.
Khu vc cha xc tc

FCC qua s dng

Khu vc
cha ct

Thng nh
lng

Xi mng
H thng nc
hot ho, pha
ph gia

Bng
ti

Bng ti
Trc vt

My trn

My
phay

My p thu lc (2 chic my n, sn xut 2

loi gch khc nhau), tng cng sut l 2 triu
vin/nm

Xe ly gch

Hnh 1. S cng ngh sn xut gch khng nung t xc tc FCC qua s

dng
I.2.4.2. Nhng vn m D n cn gii quyt v cng ngh
Cc ni dung D n cn nghin cu b sung, hon thin c nu trong Bng 1.
Bng 1. Cc ni dung nghin cu ca D n
(Trch Ph lc 2 Hp ng s 14/2011/H-DASXTN)
TT

Cc ni dung, cng vic c th

Xy dng Thuyt minh cng chi

tit ca D n

Mua sm, lp t thit b

2.1

2.2

2.3

3
3.1

3.2

H thng cp nguyn liu t ng, ly

gch t ng v h bo dng gch

Sn phm phi t
cng hon thin sau thm nh kinh
ph D n. m bo yu cu khoa hc,
gii quyt mc tiu cn nhin cu.
H thng vn hnh n nh vi dy
chuyn sn xut hin c

H thng x l bi

H thng vn hnh n nh vi dy
chuyn sn xut hin c. m bo gim
bi trong khu vc sn xut.

H thng x l cht thi nguy hi

H thng vn hnh n nh vi dy
chuyn sn xut hin c. m bo ch
tiu thi nhim cc kim loi nng trong
sn phm nm trong gii hn cho php.

Hon thin cng ngh, o to vn

hnh, khai thc
Hon thin cng ngh:
Nghin cu, thit k H thng cp
nguyn liu t ng

Bo co chuyn , bn v thit k v
H thng cp nguyn liu t ng.

Nghin cu, thit k H thng nn p,

phi mu c th thay i khun gch
(hnh dng, mu sc,)

Bo co chuyn , bn v thit k v
H thng nn p, phi mu.

Nghin cu, thit k H thng x l bi

Bo co chuyn , bn v thit k v
H thng x l bi.

Nghin cu lp t H thng x l yu
t nguy hi thnh khng nguy hi

Bo co chuyn , bn v thit k v
H thng x l cht thi nguy hi.

Nghin cu thay i nguyn liu u

vo cho dy chuyn sn xut gch

Bo co chuyn v thay i nguyn

liu u vo, thay i t l phi trn xc
tc FCC qua s dng trong sn phm.

o to vn hnh, khai thc, tp hun

an ton lao ng:

o to cn b cng ngh, cng nhn

vn hnh, tp hun an ton lao ng, bo

v mi trng.
u t c s h tng

Nh xng, c s vt cht m bo cho

qu trnh vn hnh dy chuyn sn xut.

Tip th, qung co cho sn phm

Cc hnh nh, video gii thiu v cng

ngh, sn phm gch khng nung ca
D n.

Gim nh sn phm theo cc tiu

chun mi trng v tiu chun xy
dng

B s liu phn tch sn phm gch

khng nung ca D n theo cc ch tiu,
tiu chun xy dng v mi trng ca
c quan chuyn mn.

I.2.5. Phng n trin khai

I.2.5.1. Phng n t chc sn xut th nghim
a) Quy m u t:
- u t xy dng dy chuyn sn xut gch khng nung t xc tc FCC
qua s dng cng sut 2 triu vin/nm, tng ng vi lng xc tc FCC
qua s dng hng nm khong 2000 tn t Nh my lc du Dung Qut.
- D phng m rng cng sut.
b) a im xy dng v nhu cu s dng t:
- a im xy dng: Khu lin hip x l cht thi Cng ty Lilama EME, Bnh
Nguyn, Bnh Sn, Qung Ngi.
- Nhu cu s dng mt bng: Tng din tch s dng trn 2000 m2, bao gm:
+ Din tch lp t my (c mi che): 432 m2 (DxCxR = 36 m x 12 m x 7,5 m)
+ Din tch kho xc tc FCC qua s dng (c mi che): 144 m 2 (DxCxR =
12 m x 12 m x 7,5 m)
+ Din tch cha ct sng (sn c nn b tng): 150 m2
+ Din tch gch (c mi che): 360 m2 (cha cho 01 ngy sn xut)
+ Din tch sn phi gch (sn san phng, lu, ln): t 1000 m2 tr ln
c) Cc trang thit b my mc: nh trong Bo co tng kt D n.
d) Nguyn vt liu sn xut: ch yu l xc tc FCC qua s dng thu gom t
nh my lc du, ngoi ra lng xi mng, ct, ph gia th mua th trng.
e) Nhn lc cho trin khai D n: gm cc cng nhn k thut lm vic
khu x l cht thi, ngoi ra cn tuyn dng v o to cc cng nhn c tay
ngh bc cao ph hp vi tnh cht v quy m sn xut.
I.2.5.2. Phng n t chc ti chnh
- Tng vn thc hin D n: 3.793,340 triu ng. Trong :
+ T ngn sch s nghip khoa hc: 1.130,000 triu ng
+ Vn t c ca t chc ch tr: 2.663,340 triu ng

I.2.6. D bo nhu cu th trng v phng n kinh doanh sn phm ca D

n
a) D bo nhu cu th trng: nhu cu v s dng gch khng nung trong thi
gian ti l rt ln.
b) Phng n kinh doanh sn phm ca D n:
- Phn tch gi thnh, gi bn d kin ca sn phm trong thi gian sn xut th
nghim; gi bn khi n nh sn xut.
- u t tip th, qung b.
- Khng ngng ci thin cht lng, thay i mu m sn phm (kch thc,
gch c hoc c l,...) a dng ha s dng v p ng nhu cu th hiu.
I.2.7. Sn phm ca D n
Sn phm ca D n l dy chuyn sn xut gch khng nung t xc tc
FCC qua s dng. Sn phm gch khng nung phi m bo cc tiu chun
xy dng v mi trng.
Loi gch: gch c, kch thc 220x105x55 v 240x115x55 (mm); mc
gch t 70 tr ln;; bn nn trn 70 kg/cm2; bn un trn 14 kg/cm2;
ht nc di 13 14 %; mu sc: trng xm. Kch thc, mu m v mu sc
gch c th thay i tu theo nhng nhu cu s dng khc nhau.
Chng II. THC NGHIM
II.1. i tng nghin cu
- Cht xc tc FCC qua s dng t Nh my lc du Dung Qut v mt s
nguyn liu phi trn khc (ct sng, ximng, ph gia).
- Dy chuyn cng ngh xn xut gch khng nung t cht xc tc FCC qua
s dng v cc ngun nguyn liu khc.
II.2. Phng php nghin cu
II.2.1. Cc phng php xc nh thnh phn v c tnh cu trc vt liu
- Cc phng php c trng vt liu: nhiu x tia X (XRD), tn sc nng
lng tia X (EDX), chp nh hin vi in t qut (SEM), ph hng ngoi (IR),
phn tch nhit (DTA, TGA), hp ph - kh hp ph N2 77 K.
- Phng php nh lng kim loi nng: quang ph pht x nguyn t
cm ng plasma (ICP-AES) v ph hp th nguyn t (AAS).
II.2.2. Phng php x l, kim sot cc yu t nguy hi trong xc tc FCC
qua s dng.
Cng ngh nc hot ha (AW, activated water) kt hp vi s dng cht
hp ph v trao i ion (bentonit).
II.2.3. Phng php to gch khng nung

II.2.3.1. To gch khng nung quy m phng th nghim

Tin hnh phi trn xc tc sFCC, ct sng v xi mng cc t l khi
lng khc nhau, thm lng nc thch hp, sau tin hnh to mu (mu
c k hiu: FaXbCc vi a, b, c ln lt l phn trm khi lng ca xc tc
FCC qua s dng, xi mng v ct). Trong iu kin th nghim ny, mi mu
phi liu c khi lng l 2,5 kg, c trn kh, sau thm vo 500 ml nc
(cha 0,02% th tch cht ph gia b tng), tip tc trn u. Sau , mu c
nn bng my nn thy lc vi lc nn 110 kg/cm 2. Mu sau ch to c
dng m trong thi gian 3 ngy trong mt (ti mu 3 ln/ ngy), sau
phi kh t nhin thi gian 3 tun tnh t thi im ch to mu.
II.2.3.2. To gch khng nung quy m sn xut th nghim
Qua s tm hiu, th nghim cc phng php cng ngh ho rn, phi
trn v nn p, chng ti quyt nh la chn phng n cng ngh phi trn
c hc v nn p thy lc khng rung (lc nn p c th ln n 130 kg/cm2)
vi s c mt ca nc hot ha sn xut gch khng nung t cht xc tc
sFCC cng mt s nguyn liu khc. Thnh phn phi liu da trn c s kt
qu nghin cu to gch khng nung quy m phng th nghim. Gch sau khi
p c bo dng trong mt 3 ngy, sau phi nng ngoi tri trong 18
ngy.
S cng ngh sn xut gch khng nung t xc tc FCC qua s
dng c trnh by Hnh 1 (Mc I.2.4.1).
II.2.4. Cc phng php xc nh tnh cht c l ca sn phm gch khng nung
- Cng nn (Rn, kg/cm2) c xc nh theo TCVN 6355-1:1998.
- Cng un (Ru, daN/cm2) c xc nh theo TCVN 6355-2:1998.
- ht nc ca mu (Hp, %) c xc nh theo TCVN 6355-3:1998.
Chng III. KT QU V THO LUN

III.1. Xc nh c tnh ca nguyn liu s dng sn xut gch khng nung

III.1.1. Cht xc tc FCC qua s dng t Nh my lc du Dung Qut
nh SEM ca xc tc FCC qua s dng c trnh by Hnh 2a. Quan
st nhn thy xc tc FCC qua s dng rt mn, cc ht c kch thc khng
qu 20 m. Nh vy, xc tc FCC qua s dng sau khi s dng b v vn so
vi xc tc FCC qua s dng ban u (thng c kch thc trung bnh khong
60-70 m). C ht rt nh ca xc tc FCC qua s dng s to cho chng c
bm dnh rt cao, kh nh hnh. Tuy nhin y cng l u im ca xc tc
FCC qua s dng trong vai tr nh cht t chn cho b tng khi s dng chng
lm nguyn liu ch to cc vt liu nn p khng nung.

Thnh phn ha hc ca xc tc FCC qua s dng c xc nh theo

phng php EDX, kt qu c nu ra trong Hnh 2b. Kt qu cho thy, cc
oxit trong mu xc tc FCC qua s dng ch yu l Al2O3 v SiO2, vi phn
trm khi lng tng ng khong 50,74% v 43,18%, ph hp vi nguyn
liu to gch khng nung hoc cc vt liu xy dng h silicat khc.

001

FeKb

TiKsum

FeKesc

FeKa

200

SLl

300

SKa

TiLl

400

SKb

500

TiKesc

FeLl FeLa

Counts

600

CaKa
CaKb

700

Fitting Coefficient : 0.2746

Element(keV) Mass% Error% Atom%
O K
0.525 50.26 0.36
63.93
Al K
1.486 26.86 0.19
20.26
Si K
1.739 20.15 0.26
14.60
S K*
2.307
0.40 0.21
0.25
Ca K* 3.690
0.42 0.30
0.21
Ti K* 4.508
0.59 0.37
0.25
Fe K
6.398
1.32 0.65
0.48
Total
100.00
100.00

TiKa

SiKa

800

AlKa

OKa

900

TiKb

1000

100
0
0.00

1.00

2.00

3.00

4.00

5.00

6.00

7.00

8.00

9.00

10.00

keV

(a)
(b)
Hnh 2. (a) nh SEM; (b) Ph EDX ca mu xc tc FCC qua s dng
Gin XRD ca mu FCC thi c trnh by Hnh 3a. Kt qu tnh t
XRD cho thy ngoi pha v nh hnh, mu cha khong 20% khi lng pha tinh
th zeolit, ch yu l zeolit Y (Si/Al = 4,48) vi kiu i xng cubic, kch thc
mng c s 24,3 . So snh t hai kt qu EDX v XRD, tnh c phn trm
khi lng ca Al2O3 v SiO2 trong pha v nh hnh ca xc tc FCC qua s
dng tng ng khong 47,79% v 25,55%. y l thnh phn quan trng to nn
kt dnh khi phi liu chng vi cc hp phn khc trong vt liu nn p khng
nung.
bn nhit v s thay i cu trc ca xc tc FCC qua s dng thi
c kho st bng phng php phn tch nhit. Hnh 3b l gin phn tch
nhit TGA-DTA ca mu xc tc FCC qua s dng. Kt qu phn tch nhit
cho thy xc tc FCC qua s dng khi hp phn vo gch khng nung s
m bo c tnh bn nhit cho cc cng trnh xy dng.

Faculty of Chemistry, HUS, VNU, D8 ADVANCE-Bruker - Mau Zeolite

300
290
280
270
260
250
240
d=14.109

230
220
210
200
190
180

160
150

100
90

d=3.710

d=3.349

d=8.608

110

d=7.340

120

d=4.666

d=5.581

130

d=4.302

140

d=5.416

Lin (Cps)

170

80
70
60
50
40
30
20
10
0
5

10

20

30

40

2-Theta - Scale
` - File: Hung QN mau Zeolite.raw - Type: Locked Coupled - Start: 5.000 - End: 45.000 - Step: 0.020 - Step time: 0.8 s - Temp.: 25 C (Room) - Time Started: 20 s - 2-Theta: 5.000 - Theta: 2.500 - Chi:
01-088-2287 (C) - Aluminum Silicate - (Al1.79Al.5Si10.25O24).96 - Y: 93.02 % - d x by: 1. - WL: 1.5406 - Cubic - a 24.30000 - b 24.30000 - c 24.30000 - alpha 90.000 - beta 90.000 - gamma 90.000 - Face-c

(a)
(b)
Hnh 3. (a) Gin XRD; (b) Gin phn tch nhit ca xc tc FCC qua
s dng
Nh vy, thnh phn chnh ca cht thi xc tc FCC vn l SiO2, Al2O3 tng
t nh cc hp cht aluminosilicat trong vt liu xy dng. V th, vic ti ch
to gch khng nung trong xy dng l rt cn thit, c c s khoa hc v kh thi.
III.1.2. Cc nguyn liu phi trn khc
- Xi mng Portland PC40.
- Ct: c ly t sng Tr Khc (Qung Ngi), kt qu phn tch XRD cho
thy, thnh phn chnh l pha quartz (SiO2), chim n 94,3%. Vi cc mu
ng rn khng nung, khong SiO2 ch yu lm ct liu v c th tng tc vi
cc thnh phn kim trong xi mng.
- Ph gia Vinkems CONREX HS: thnh phn gm cc polynaphthalene tng
hp hiu qu cao, ph hp vi tiu chun ASTM C494 loi F. Vinkems
CONREX HS c tc dng lm cho b tng c chc, t cng sm
ban u v tng cng cui cng.
III.2. Nghin cu s thay i nguyn liu u vo cho dy chuyn sn xut
gch khng nung
III.2.1. Thay i t l phi trn xc tc sFCC (c nh hm lng xi mng)
nh hng ca t l phi liu c kho st trn 2 nhm mu: nhm mu
khng dng ph gia c k hiu t F 25X10C65 n F45X10C45 v nhm mu dng
ph gia c k hiu t F25X10C65-(p) n F45X10C45-(p). Sau khi dng m mu,
tin hnh kho st nh hng ca t l hm lng phi liu v thi gian ng
rn n ht nc Hp (%) v bn nn Rn (kg/cm2) ca 2 nhm mu, kt qu
c th hin Bng 2 v Bng 3.
Bng 2. nh hng ca hm lng phi liu v thi gian ng rn
(mu khng dng ph gia, lc p 110 kg/cm2)
Thi gian

Thng s

F25X10C65

F30X10C60

F35X10C55

F40X10C50

F45X10C45

Tun 1

Hp%

20,2

22,18

24,94

25,48

26,14

Tun 3

Rn (kg/cm2)

41,67

40,15

42,14

39,84

38

Hp%

19.21

21,38

22.04

23.11%

24.64

Rn (kg/cm2)

51.26

46,84

48,51

41,89

40,92

Bng 3. nh hng ca hm lng phi liu v thi gian ng rn

(mu dng ph gia, lc p 110 kg/cm2)
Thi
gian
Tun 1

Tun 3

Thng s

F25X10C65(p)

F30X10C60(p)

F35X10C55(p)

F40X10C50(p)

F45X10C45(p)

Hp (%)

21,54

22,33

20,94

24,21

25,01

Rn
(kg/cm2)

56,55

40,09

53,57

21,34

26,6

Hp(%)

14,6

14,73

11,8

18,4

20,4

Rn
(kg/cm2)

75,5

68

85

39,4

28,35

Kt qu Bng 2 v 3 cho thy, cc mu dng ph gia c bn nn (R n)

cao hn v ht nc (Hp) tun th 3 thp hn ng k so vi cc mu
khng dng ph gia. Khi tng hm lng sFCC trong phi liu, xu hng
chung l ht nc tng dn v cng nn th gim dn. Tuy nhin, iu
th v rt ra t Bng 3 l mu F 35X10C55-(p) c cng nn t gi tr ln nht
v ht nc t gi tr b nht. iu ny c quan st r hn trong th
Hnh 4 trong trng hp mu c s dng ph gia sau 1 tun v 3 tun dng
m. bn nn c xu hng t cc i ti mu F 35X10C55-(p) ng vi hm
lng 35% khi lng sFCC trong nguyn liu u.

Tun 3

Tun 1

Hnh 4. Cng nn bin i theo hm lng xc tc FCC qua s dng (c

nh % xi mng)
III.2.2. Thay i t l phi trn xi mng (c nh hm lng xc tc sFCC)
C nh hm lng xc tc sFCC, nhng thay i hm lng xi mng t 8
12% khi lng v kho st nh hng ca chng n cht lng sn phm.
Quy trnh to mu v dng m nh trn. Kt qu xc nh bn nn Rn
(kg/cm2) c th hin Hnh 5. Kt qu Hnh 5 cho thy trong khong hm
lng xi mng kho st, cng nn t cc i ti mu F 35X10C55-(p), ng vi
hm lng xi mng 10%.

Hnh 5. Cng nn bin i theo hm lng xi mng (c nh % sFCC)

T cc kt qu thc nghim nu trn, chng ti cho rng t l khi lng
phi liu ph hp cho qu trnh ng rn l 35% xc tc FCC qua s dng,
10% xi mng, 55% ct, 0,02% cht ph gia (ng vi mu F 35X10C55). Kt qu
o c tnh c l i vi mu F35X10C55-(p): cng nn Rn = 85 (kg/cm2);
cng un Ru = 15,2 (daN/cm2) v ht nc 11,8%; t c mc gch
M75 theo TCVN 6477:2011 i vi gch b tng xy dng.
III.3. Nghin cu x l v kim sot yu t nguy hi ca xc tc FCC
qua s dng trong sn xut gch khng nung
Phi trn nguyn liu theo t l khi lng: 35% xc tc FCC qua s
dng, 10% xi mng, 55% ct, 0,02% cht ph gia ng cng nhanh. y l t l
ph hp theo cc nghin cu nu trn sn phm gch t cc tiu chun c
l v vt liu xy dng. Tin hnh kho st kt qu x l cc yu t nguy hi
ca xc tc FCC qua s dng trong gch bng cng ngh nc hot ha v
trao i ion bng bentonit.
III.3.1. Kt qu phn tch kim loi nng

Kt qu phn tch hm lng kim loi ca mu xc tc FCC qua s

dng t Nh my lc du Dung Qut c nu ra Bng 4. Bng s liu cho
thy, hm lng mt s kim loi nng c hi c hm lng rt cao nh Ni
4160,9 ppm, Pb 33,6 ppm, V 496,4 ppm, c th gy thi nhim kim loi
nng trong nc mt v nc ngm. V vy, cc yu t nguy hi ny cn phi
c x l khi s dng chng p gch khng khng nung.

Bng 4. Thnh phn cc kim loi v oxit kim loi trong xc tc FCC qua s
dng

III.3.2. X l bng cng ngh nc hot ha

Tin hnh kho st song song hai mu gch (mt mu dng nc thng
k hiu F35X10C55-(t), v mt mu dng nc hot ha k hiu F35X10C55-(n))
theo thnh phn ti u vi quy trnh bo dng gch nh cc nghin cu
trc, sau tin hnh xc nh thi nhim kim loi nng theo phng php

ngm chit (ngm mu trong axit acetic 4% trong 24 gi) ri em so snh vi

gii hn kim loi nng cho php trong t dn sinh ca B ti nguyn mi
trng (QCVN 03:2008/BTNMT). Kt qu c trnh by trong Bng 5 v 6.
Bng 5. thi nhim kim loi nng t mu F35X10C55-(t)
STT

Ch tiu

Phng php th
mu F35X10C55-(t)

n v

Kt qu

QCVN
03:2008/BTNMT

01

Pb

TCNB: 01-ICP/04

ppm

496,4

120

02

Cd

TCNB: 01-ICP/04

ppm

<2

03

As

TCNB: 01-ICP/04

ppm

< 20

12

04

Sb

TCNB: 01-ICP/04

ppm

23.2

100

05

Ni

TCNB: 01-ICP/04

ppm

4160,9

25-150

06

TCNB: 01-ICP/04

ppm

496

100

T kt qu Bng 5 ta thy, vi mu F35X10C55-(t) thi nhim mt s

kim loi nng (Pb, N, V) tng i cao so vi tiu chun cho php. Bng 6 cho
thy mu F35X10C55-(n) sau khi c x l bng nc hot ha thi nhim
kim loi nng gim ng k. Tuy nhin, hm lng niken vn cn cao hn
mt t so vi tiu chun cho php.
Bng 6. thi nhim kim loi nng t mu F35X10C55-(n)
STT

Ch tiu

Phng php th
mu F35X10C55-(n)

n v

Kt qu

QCVN
03:2008/BTNMT

01

Pb

TCNB: 01-ICP/04

ppm

20.7

120

02

Cd

TCNB: 01-ICP/04

ppm

<2

03

As

TCNB: 01-ICP/04

ppm

<2

12

04

Sb

TCNB: 01-ICP/04

ppm

< 10

100

05

Ni

TCNB: 01-ICP/04

ppm

167,5

25 - 150

06

TCNB: 01-ICP/04

ppm

22,54

100

III.3.3. X l kt hp bng bentonit

x l hm lng kim loi nng cn li trong mu F 35X10C55-(n), chng
ti s dng b sung 1% bentonit (theo khi lng phi liu), k hiu mu
F35X10C55-(n+b). Sau , tin hnh kho st thi nhim kim loi nng theo
phng php ngm chit. Kt qu c th hin Bng 7.
Bng 7. thi nhim kim loi nng t mu F35X10C55-(n+b)
STT

Ch
tiu

Phng php th

n v

Kt qu

QCVN
03:2008/BTNMT

Mu F35X10C55-(n+b) c ngm bng dung dch axit acetic 4% trong 24 gi

01

Pb

TCNB: 01-ICP/04

ppm

17.6

120

02

Cd

TCNB: 01-ICP/04

ppm

<2

03

As

TCNB: 01-ICP/04

ppm

<2

12

04

Sb

TCNB: 01-ICP/04

ppm

< 10

100

05

Ni

TCNB: 01-ICP/04

ppm

126,04

25 - 150

06

TCNB: 01-ICP/04

ppm

17,8

100

Kt qu Bng 7 cho thy, hm lng kim loi nng trong mu

F35X10C55-(n+b) p ng c tiu chun QCVN 03:2008/BTNMT. Bng
cng ngh nc hot ha kt hp vi cht hp ph trao i ion, nguy c thi
nhim cc kim loi nng t xc tc FCC qua s dng c gii quyt
trit . Sn phm gch t mu F35X10C55-(n+b) t cng nn Rn = 89,5
(kg/cm2); cng un Ru = 16,3 (daN/cm2) v ht nc 12,4%; m bo
c yu cu v tnh cht c l v mi trng theo quy nh.
III.4. xut v trin khai dy chuyn sn xut gch khng nung t xc
tc FCC qua s dng
T cc kt qu nghin cu nu trn, chng ti xut, xy dng v trin
khai dy chuyn sn xut th nghim gch khng nung t xc tc FCC qua
s dng, cng sut 2 triu vin/nm, theo phng n Cng ngh p gch
(khng rung) t vt liu phi trn bng nc hot ha. Dy chuyn cng ngh
c trnh by Hnh 1 (Mc 1.2.4.1).
Thnh phn phi liu (theo phn trm khi lng) bao gm:
- Xc tc FCC qua s dng: 3035%;
- Ct: 5560%;
- Ximng PC40: 1015%;
- Nc hot ho: chim 10% tng khi lng thnh phn kh ca vin gch
(nc hot ha c pha 0,02% th tch cht ph gia ng cng nhanh);
- Bentonit: 1%.
Khi lng trn 01 m: 550 kg
Thi gian trn trung bnh cho 01 m hot ng lin tc: khong 15 pht.
Tnh nng k thut ca dy chuyn:
- Nng sut khong 2 triu vin/nm, tc ln nht khong 16 vin/pht.
- Tng cng sut dy chuyn: 35 KW (hot ng khng lin tc); 3 pha; 380V
(cng sut uc hiu l bao gm cng sut my p gch, h bng ti chuyn
ng, cng sut my phay, my trn, h thng cn in t, bm nc).
- Tiu th in cho thit b (tnh cho sn xut th nghim 1 nm): 87.360 KW.
- Tiu th nc cho sn xut (tnh cho sn xut th nghim 1 nm): 440 m3.
- H thng lp t ng b phn nh lng, trn, phay v p thu lc hot
ng t ng, cn phn cp liu vo v ly gch sau p: bng tay.

- Lng nguyn vt liu tiu th cho 01 nm sn xut:

+ Cht xc tc FCC qua s dng: khong hn 1.500 tn;
+ Ct: 1.754 m3;
+ Cht kt dnh (xi mng): 440 tn;
+ Ph gia ng cng nhanh, ph gia tng cng cng : 2.400 lt;
+ Nc hot ho: 10% tng khi lng vt liu.
Sn phm gch khng nung t mc gch t 70 tr ln theo TCVN
6477:1999, vi cc c tnh: Gch c; kch thc 220x105x55 mm hoc
240x115x55 mm; cng nn trn 70 kg/cm 2; cng un trn 14 daN/cm2;
ht nc di 14 %; mu trng xm.
Sn phm gch ny ph hp vi vic xy tng ro, vch ngn, lt sn, va
h, mng thot nc nh hng bc u ng dng ti cc cng trnh xy
dng ca Cng ty. Tnh n nay, sn phm gch khng nung t xc tc FCC
qua s dng c s dng xy tng ro 81.262 m2 x 50 vin =
4.063.100 vin, mng thot nc, lt ng, va h: 21.670 m 2 x 50 vin =
1.083.500 vin ti Khu lin hip x l cht thi EME ca Cng ty CP C in - Mi trng Lilama, tnh Qung Ngi (Hnh 6) vi cht lng rt tt.

Hnh 6. Sn phm gch khng nung t xc tc FCC qua s dng v ng

dng
III.5. Cc kt qu hon thin cng ngh khc
III.5.1. Nghin cu thit k h thng cp nguyn liu t ng
- Qu trnh nh lng nguyn liu bng trc vt v bng ti di ng.
- Qu trnh nh lng ct bng cm gt liu.
- Ton b h thng cp liu c din ra lin tc di s iu khin bi b
PLC p ng vic vn hnh, lu tr, phn tch d liu v c th ci t m rng
khi cn thit.
III.5.2. H thng bo dng gch t ng

H thng dn phun dng gch c thit k xy dng gm 3 b phn: h

thng iu khin t ng iu khin bi b PLC c np sn chu trnh theo
thi gian, h thng cp nc, h thng dn v phun nc to mng phun ti.
H thng bo dng gch t ng m bo qu trnh bo dng c
din ra u n v gi m thy ha xi mng, to lin kt trong vt liu,
ng thi tit kim lng nc s dng v nhn cng. Thng th qu trnh bo
dng trong nh 2 ngy sau xp vo palet ln v bo dng tip n 7 ngy
th xut xng, khi gch s m bo cng .
III.5.3. Nghin cu thit k h thng x l bi cho dy chuyn sn xut gch
khng nung
Cng ngh x l bi bng thit b lc ti vi c la chn cho phn xng
sn xut gch khng nung. Bi c thu gom ngay ti v tr pht sinh thng qua
cc chp ht. Cc chp ht c ni vi h thng ng dn vo thit b lc ti
vi. Khng kh ln bi i qua tm vi lc, ban u cc ht bi ln hn khe gia
cc si vi s gi li trn b mt vi theo nguyn l ry, cc ht nh hn bm
dnh trn b mt si vi lc do va chm, lc hp dn v lc ht tnh in, dn
dn lp bi thu c dy ln to thnh lp mng tr lc, lp mng ny gi
c tt c cc ht bi c kch thc rt nh. Hiu qu lc t ti 99,8% v lc
c tt c cc ht rt nh nh c lp tr lc. Sau mt khong thi gian lp bi
s rt dy lm sc cn ca mng qu ln, ta phi ngng cho kh thi i qua v
tin hnh loi b lp bi bm trn mt vi. Thao tc ny c gi l hon
nguyn kh nng lc. Kh sau khi qua thit b lc ti vi c dn ra ng thi
v thot ra ngoi.
III.5.4. Nghin cu thay i khun gch v phi mu cho sn phm gch
khng nung
Do hn ch v thi gian thc hin D n nn Cng ty bc u nghin
cu thay i mu m khun gch v phi mu cho sn phm gch khng nung.
Mt s hnh nh v kt qu nghin cu v ng dng ny c trnh by Hnh 7.

Hnh 7. Hnh nh mt s kt qu nghin cu thay i khun gch v phi mu

cho sn phm gch khng nung
Trong thi gian n, bn cnh vic khng ngng nng cao cht lng,
Cng ty s y mnh nghin cu thay i mu m, mu sc cc sn phm gch
khng nung p ng nhu cu th hiu v m rng kh nng ng dng.
KT LUN V KIN NGH
KT LUN
D n sn xut th nghim gch khng nung t xc tc FCC qua s
dng l nguyn vng, tm huyt ca tp th cn b Cng ty C - in - Mi
trng Lilama v mt s nh khoa hc hp tc, nhm mc tiu ti ch, ti s
dng cht thi, bo v mi trng v pht trin bn vng. Nhn chung, kt qu
ca D n hon ton p ng cc yu cu t ra trong cng Thuyt
minh ban u. Qua qu trnh thc hin v hon thnh D n, chng ti rt ra
mt s kt lun nh sau:
1. tin hnh kho st cc yu t nh hng n cht lng ca sn phm
gch khng nung nh: thnh phn v hm lng nguyn liu, thi gian ng
rn, lc nn p, s x l bng nc hot ha v cht hp ph trao i cation.
Kt qu thc nghim cho thy, iu kin ng rn ph hp l: t l khi lng
phi liu 35% cht FCC qua s dng; 10% xi mng; 55% ct; 1% bentonit;
nc hot ho (c pha 0,02% th tch cht ph gia ng cng nhanh) chim
10% tng khi lng thnh phn kh ca vin gch; lc nn p 110 kg/cm2 ;
thi gian bo dng 3 tun trong c 2-3 ngy u dng m trong mi che.
2. thc hin v hon tt cc hng mc v lp t b sung thit b, hon thin
cng ngh, tng cng mc t ng ha, m bo sc khe cho cng nhn
vn hnh, nh cc h thng cp nguyn liu t ng, bo dng gch t ng,
x l bi, thit b nc hot ha... Cc h thng vn hnh n nh vi dy
chuyn sn xut hin c. Nh xng, c s vt cht m bo cho qu trnh vn
hnh dy chuyn sn xut cng c u t xy dng thm. Thc hin tt

cc cng tc o to cn b k thut cng ngh, cng nhn vn hnh, tp hun

an ton lao ng, bo v mi trng.
3. nghin cu, xy dng v trin khai dy chuyn sn xut gch khng nung
cng sut 2 triu vin / nm t xc tc FCC qua s dng ca Nh my lc
du Dung Qut. Dy chuyn sn xut vn hnh lin tc v n nh. Sn phm
p ng tiu chun mc gch M75 theo TCVN 6477:2011 i vi gch b tng
xy dng v quy chun QCVN 03:2008/BTNMT v gii hn kim loi nng cho
php trong t dn sinh ca B Ti nguyn v Mi trng. Sn phm gch
khng nung ca D n c ng dng xy dng tng ro, lt ng, lt
va h, xy k, xy mng thot nc ti Khu lin hip x l cht thi EME
thuc Cng ty C - in - Mi trng Lilama tnh Qung Ngi, m bo c v
cht lng v m quan cng trnh.
KIN NGH
D n ti ch xc tc FCC qua s dng - mt cht thi cng nghip,
to ra sn phm gch khng nung c gi tr s dng thit thc, v th mang
ngha thc tin cao. kt qu D n ng gp nhiu hn na vo s pht trin
kinh t - x hi bn vng, mt s nh hng m rng D n nh sau:
1. Khng ngng ci tin dy chuyn cng ngh, nng cao cht lng v h gi
thnh sn phm; tip tc nghin cu thay i mu m, mu sc cc sn phm
gch khng nung a dng ha kh nng s dng v p ng nhu cu th
hiu; nghin cu s p ng ca dy chuyn hin c vi cc ngun nguyn liu
hoc cht thi khc nh t i, dm , x than, x tro bay, Kim tra, nh
gi s thay i, bin i tnh cht ca sn phm di tc ng ca iu kin kh
hu, thi tit sau mt thi gian a vo s dng c gii php x l kp thi.
2. Pht trin th trng cho sn phm ca D n qua vic y mnh nghin cu
nhu cu v phn phi sn phm; tip th, qung b sn phm. Thc hin ng
k bo h quyn s hu cng nghip i vi sn phm D n.
3. Tng cng cng tc tham vn cng ng, gp phn nng cao thc ca
ngi dn trong vic ti ch cht thi, tit kim ngun ti nguyn v bo v mi
trng.

CC CNG TRNH CNG B LIN QUAN N D N

1.

Nguyn Phi Hng, ng Vn S, Trn Quang Hu, Nguyn Hu Hnh, H Mnh

Hng, Nghin cu ch to gch khng nung t xc tc FCC qua s dng ca Nh
my lc du Dung Qut, Tp ch Xc tc v Hp ph, ISSN 0866-7411, Hi Xc tc v
Hp ph Vit Nam, 2013, 2(1), tr. 107-112.

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H Mnh Hng, Nghin cu tn dng cht thi FCC t Nh my lc du Dung Qut

sn xut gch khng nung, Lun vn Thc s khoa hc Ha hc, i hc Hu, 2012
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