Hatschek Process of Fiber Cement Production - Report Example

Hatschek Process of Fiber Cement Production Name Affiliation Date Hatschek Process of Fiber Cement Production Introduction to Hatschek process According to Agopyan et al (2005, p.530), Hatscheck process is a cycle followed in the manufacture of fiber cement products. It involves formation of the thin and paper-like films placed over each other until desired thickness of the sheet. The Hatscheck process of manufacturing fiber cement was an innovation made by the famous Austrian Ludwig Hatscheck in the early years of 1890. The process was a resultant of seven tedious years of cellulose experimentation of reinforcing the fibers using cement in water. The combination of cement, cellulose fibers and water (slurry) ended up in the papermaking machine through cylindrical sieves that rotate in the slurry. The solids end up in the sieve that attracts various layers of solids and ultimately transferring the layers into a continuous belt. The layers in turn develop the desired thickness and later removed and when necessary compression takes place. This is the process commonly referred to as the eternity process. The process changed from eternity to cembrit in 1894 when Werke Ludwig Hatscheck started manufacturing cement products for sale. The licenses end up sold in Europe more especially the Danish parent company known as the Dansk eternity holding A/S in 1927. This was among the independent companies that had the right to use the “Eternit” as the trademark of the company. In the course of time, many other factories emerged although they did not use “Eternit” as a trademark because most of them were counterfeit. However, THE Dansk Eternit has remained independent until 2008 where various amalgamations took place and the new name of the company became Cembrit (Alp et al, 2009, p.149). Alp, Deveci & Süngün (2008, p.392), affirms that Artificial PVA fibers have replaced the mineral fibers and various solids combined in the slurry to furnish various performances of features. Coloration involves occasional incorporation of the surfaces or in the slurry mixture and in the process extra curing takes place in attempt to improve the speed and strength of the process. However, the most essential part of the process is the Hatscheck machine and the magical conversion of the liquid to form the solid particles. The most important aspect of the fiber cement is the fourfold characteristic that are, lightweight, rot resistant, fire resistant and eventually malleability. Immediately after the formation of the cement, it is highly flexible and this means that it can take three-dimensional shapes as well as embossing. The embossing feature takes place because the fiber matrix can support cement as well as other solids that are thinner than concrete. Natural surface and random effects can materialize with consistency of the production line leading to formation of superb levels and efficiency in cost (Chen et al, 2002p.50). Simple formation of repeated waves in the wet materials forms larger panels that are self –supporting hence providing excellent methods cladding sections. Secondly, the fiber cement is a light building material and this makes it possible to mimic stone without getting to the low yields related to extraction. Moreover, it can produce the effect of clay-autoclave materials without necessarily using high temperatures. Third, the fiber cement is able to resist fire although there is a high percentage of wood fiber that is cellulose. Finally, fiber cement products are immune to rotting and humidity. These properties makes fiber cement an ideal material for construction especially in office and residential houses. Therefore, Hatschek process is a crucial process that involves formation of crucial fiber cement products (De Andrade Silva, Mobasher & Toledo Filho, 2009, p.725). Hatschek process in manufacturing of construction materials in current industry The current Hatschek production of construction materials is a modification of what happened in the past when Hatschek discovered the machine. The Hatschek process under normal circumstances magically transforms fluid slurry to solid particles that eventually construction materials. The most common construction materials is relevant in the market are the asbestos roofing materials that have reached the entire globe because of their effectiveness. Asbestos (a form of fiber cement) is highly applicable in the roofing products, walling products, the piping products, internal and external panels and planks and eventually the lining boards of the wet areas. The asbestos cement is highly applicable in various applications that require high resistance towards fire because they have great thermal stability (De Andrade Silva et al,2010,p. 779). The figure above indicates the formation of fiber cement the freezes that might take (http://www.google.com.ar/patents/US7815841.) The great thermal stability of asbestos makes it an ideal roofing product in areas that experience extremities of temperature. As posited above, the lightweight characteristics and immune to water due to low permeability and porosity has made fiber cement products ideal for construction. However, the disadvantage of the fiber-cement product is the high density that does not allow nailing to take place and the methods of fixing involves putting nuts in the drilled holes. Initially the original Hatschek process involved use of modified sieve that dominated the production of asbestos as the major fiber cement product. There are other methods used in making the product especially the thick sheets that are greater than 10mm and require approximately 30 films. These normally use the same mixture of cement and asbestos fibers in the Hatschek process. However, they use the same mixture although they are several mixtures added in the process (Dias, Savastano & John, 2010, p.144). The figure above describes the rate of solid subermerge in the process of Hatschek (http://patentimages.storage.googleapis.com/US7815841B2/US07815841-20101019-D00007.png.) Some development took place in the middle of previous century that affected significantly to the modern replacement of the asbestos to form the cement composites. Manufactures realized that during the cycle of curing it was possible to reduce it and that would reduce the cost by autoclaving the products. The venture allowed substantial replacements of cement with grounded silica that normally react at the autoclave temperatures through addition of excessive lime in the cement and eventually producing calcium silicates that are similar and normal to the cement Matrixes. Addition of silica, which is cheap even to the ground, makes the process cheaper than cement because autoclave and curing process ends up taking lesser time hence making the entire process cheap. Therefore, the inventions and modifications have made it clear that this is the universal method of producing fiber cement by the manufacturers. The typical formulation includes 5-10% of fibers of asbestos, 40-60% of silica and eventually 30-50% of cement. The second and most crucial development embarked on replacing the asbestos and later reinforcing them with cellulose fibers from wood. This approach was not highly welcomed though some siding products as well as those from the wet area lining sheets (DiLullo & Rae, 2004.p 67). The most advantageous aspect of the development involved the aspect of softness and hollow like characteristics of cellulose fibers and the resultant products could use nails. Initially, the prior products used drilled nails where nuts could hold the asbestos sheets. The subsequent lining and siding products are highly applicable on the vertical walls that are less demanding compared to roofing. However, it is paramount to note that cellulose induced cement products are susceptible to changes induced by water when compared to the asbestos cement composite materials. Under normal circumstances, typical formulation normally includes 3-4 percent and about 4-6 percent and ultimately 900% of cement from the air cured products. On the other hand, it could involve, approximately30—50% of cement and 40-60% of silica in the autoclaved products (Jarabo, et al, 2012, p.92). According to (Jarabo et al, 2012, p.17), the asbestos fibers have various advantages and that makes them popular in the market. The machines that use the sieve cylinders normally require the fiber machines that forms network to attract the solid cement or the sand/silica particles. These particles are far much too small to catch on the sieve itself. Asbestos is inorganic material can result to Asbes through refining. These Asbes are crucially stable at high temperatures. Moreover, the Asbes are immune to alkali and acidic attacks especially when they go through the autoclave conditions. The fiber cement products reinforced by the asbestos are naturally stiff and strong though brittle and are applicable in various hostile environments except the acidic environments where the cement they have rapid attack by the chemicals. The wet and dry cycling of the asbestos roofing product goes through eventually leads to significant problems related to dissolution of chemicals under wet conditions. Efflorescence cause aesthetic degradation of the roofing materials hence making them ineffective by the end of the day. The matrix of the asbestos normally reinforces the roofing products and under normal circumstances, it is dense increasing the amount of water entering especially under saturation. Lowering of the density, leads the product to become more and more workable while the rate of saturation and total absorption of water increases (Logan et al,2007,p.3340). There are alternative methods of fiber cement technologies developed in the early 1980s though there were various health complications that resulted from inhaling the asbestos. The alternative fiber Semen technologies who are the manufacturers of the asbestos cement products in USA, Western Europe and New Zealand sought a way substitute asbestos fibers in the reinforcement of the construction materials made by the Hatschek machines. Over quite a long time, researchers have provided a substitute that is a combination of PVA fibers at 2%, cellulose at 5percent and cement primarily 80%. In some cases, the inert fillers like silica and limestone. The product goes through air curing because the PVA fibers are not autoclave stable. The products follow the Hatschek process and later introduced to the hydraulic press. The hydraulic press compresses the cellulose fibers hence reducing the porosity of the matrixes. The PVA fibers cannot go through refining while cellulose is manageable (Merkley & Luo, 2004, p.15). The high success in the manufacture of fiber cement follows the quality and correct specification of the Hatschek machines. The Hatscheck follows formation of thin and paper-like films placed over each other until formation of the required thickness. Formation of the sheet through that means ultimately distributes reinforcing fibers in various dimensions and later taking best advantage of the reinforcing fibers to increase the plane strength of that particular sheet. The strength of the sheets formed through the fashion forms approximately 50% greater sheets than formed in full thickness in the filter press process. The above methods and machines are applicable in various manufacturing companies such as Etex group, Euro Panels, Swiss Eternit or the Swiss pearl, Cembrit and James Hardi. These manufacturers have demonstrated significant similarity in production of fiber cement materials (Negro et al, 2006, p.200). Cycles of Hatschek process of cement sheets production As posited initially, Hatschek machine had universal purpose of producing asbestos using cement. Today, the basic form of the machine is still practical though the modern Hatschek are productive. However, if the inventor comes today, he would still figure out the similarities of the basic components. The most fundamental part of the machine is the VAT which is a cylindrical sieve that rotates when it comes in contact with dilute water mixed with slurry of fiber that are capable of forming filtering film as well as mineral materials such as the Portland cement. The sieve has an intricate mount along the axle and has a driving felt tied around the top of that particular sieve by using a couch roller. The felt has a thread around a drive or the anvil roller and tail roller. The anvil roller or drive later gets into contact with accumulation roller allow the formation to take place (Qi, 2006, p.510). The above diagram is an illustration of Hatschek process and the stages it undergoes (https://www.google.com.) The above diagram is an illustration of asbestos production machine (https://www.google.com.) The above diagram is an illustration of calcium -silicate production machine (www.google.com/search?q=images+of+complete+Hatschek+process.) Formation of sheets in the Hatscheck process takes place through the following procedure; Clean sieve gets under the slurry in the VAT and the water from the slurry gets through the sieve and deposits soft and porous film that contains cement and fibers on the surfaces of the sieve. The second step involves carrying the films exiting the VAT comes into contact with felts that have stretched tightly across the sieves and the action removes most of the water and later forcing it back through films. Later some of the solid film floats on the flat layers of water that gets to the felt according to the effects of removal of water. This is because it has greater affinity for the films compared to the sieve. The third step involves carrying the film on the felt that is an accumulator and later transferred by the action water at high pressure. Finally, the fourth step involves wrapping sufficient numbers of films on the accumulator in order to form a sheet that has desired thickness. The stack films later comes out of the roller and lay out to form a desirable sheet. Actions of dewatering successive films that are in contact adjacently under high pressure is a sufficient action make sure the films hold together in an attempt to form contagious solid sheets. The aim of the research paper is to examine the processes and identify the machine specifications that determine the rates at which it can produce fiber cement products through formation of the films (Roma,Martello & Savastano, 2008,p.670). The above diagram illustrates the production of fiber cement board (https://www.google.com.). From the structure of the Hatschek machine, it is not possible measure thickness of films as they go through the process of depositing on the sieve within vats of operating machines. On the other hand, it is not easy measure the thickness of soft films on sieve gaps between water and points where it comes into contact. Similarly, it is not an easy task to measure the thickness of films conveyed through felts on the accumulation rollers. Therefore, the average thickness of films must have inference thickness of the final sheet through dividing the films that made them. Experiences with secondary sheet formation assert that it is not possible to continue altering the pore structures formed on the particular sheets. Therefore, one would assert that formation pressure that occurs at the nip of drive and the calendar rolls normally influences thickness of the final sheets as well as the apparent thickness of films formed at the vat. Dewatering the films within the Hatschek machine during the transfer of films has a negligible effect on the final thickness of the film. Moreover, the thickness of sheet has considerable effect on the nip pressure that forms roll and that effect is minimal. Ignoring the nip pressure at times takes place and that translates to little or no loss of accuracy when considering the primary effects of film formation (Satyanarayana et al, 2010, p.1700) . Method of Hatschek process Hatschek production process has a basis of preparation of cement with asbestos and the water slurry. The subsequent formation of thin lamina of the dewatered slurry forms the foundation of the Hatschek process. Obtaining the final product takes place through piling up the laminae while wet hence getting the desired thickness. Build up of the layered laminate takes place through a process of continuous winding the laminae into a mandrel. The cylindrical product exists inform of a pipe and the manufacturers can cut it into two to form flat sheet layers or other shapes through subsequent shaping. The shaping of the flat sheet or boards has the required strength and flexibility to obtain the required shape. Curing is the final stage and takes place at room temperature or through heat treatment. The most method applicable in the Hatschek process is Mazza process highly applicable in the making of pressure pipes. The curing process may take place at room temperature or through autoclaving process. The autoclave process normally involves use of 1800kpa and 180-200 degrees in temperature and it is the most appropriate method of curing (Shirakawa, 2003, p.148). The curing process might take approximately eight hours and after that, the fiber cement products are fit for construction. The air-cured products normally exhibit low contents of fiber cement adhesion making it in appropriate method of curing. The method (air curing) affects the mechanical composition and ability of the products making it ineffective method of curing. On the other hand, the mixtures used in the autoclave processes exhibit lower density and that leads to formation of products that have mechanical and resistant problems. Most of these products will exhibit waterproof problems making them default by the end of the day. The most applicable method for improving the fiber-matrix of fiber cement sheets involves increasing the density of the sheet by compressing fresh products after the forming process before proceeding to the curing and hardening process(Soares Del Menezzi,2007,p.110). Post-compression and it generally improves the matrixes of fiber in the contents fiber cement. The pressed fiber cement products have already undergone the process of compression while non-pressed articles have not undergone the process. There are two methods used in the process compressing the fiber cement sheets and they are stack press and single sheet press. Some specialized firms more especially in Switzerland and Germany have developed the single-sheet post compression strategy and it is highly applicable in corrugated fiber sheets. On the other hand, there is stack compression, it involves pressing stacks of products, and they can produce sheets produced in various production units. The longer the cycle of compression, it allows surplus water to move out gently from the fresh sheets and that turns out to be beneficial for the purpose of mechanical properties. During compression of the fiber sheets, every part of the fiber-cement gets into contact with platen. They must go through at least five homogenous compression forces that are perpendicular to the surfaces of the sheet (Soroushian 2004, p.800). Fiber Cellulous properties and Hatschek process The use of agricultural wastes in reinforcement of composite materials is one of the most important targets for fiber cement manufacturers. Industrial hemp is among the cellulous materials applicable in the manufacture fiber- cement materials especially those used in roofing. The cellulose from industrial hemp facilitates creation of fiber cement materials that have high strength, low density and high durability making it ideal for the purpose. The fibers from the industrial hemp facilitate creation of fiber cement products that are strong and durable. Using cellulose fibers in strengthening building materials have various advantages over the glass fibers and the most important one is the ability to manufacture products that have low density (Taha & Shrive, 2001, p.67). These products are biodegradable making it easy to dispose them when they get old. On the other hand, cellulose fibers have various disadvantages such as reduced elasticity, high rates of moisture absorption and high cases of decomposition when exposed to alkaline conditions. However, the problems are not permanent because extensive usage of tough fibers from pine that have 0.750 Gpa can eliminate the problem entirely. Moreover, the cellulous fiber cement products have great ability to withstand temperatures making it ideal in areas that have temperature extremities. For instance, they have ability to insulate heat and this property is ideal in insulating the house. For instance, using fiber cement materials to make roofing, it becomes easy to reduce cases of overheating during the days and at night, it is possible to retain considerable amount of heat in the house. These properties make the cellulous fiber products ideal due to the ability to withstand different extremities of temperature (Roma, Martello& Savastano, 2008, p.665). Prizes of the fiber cement sheets produced Australia only in AUD$ There are various fiber cement products in Australia such as exterior cement sheeting. For instance, the cement sheet measuring 2400 by 1200 by4.mm 2.88sqm costs $23.81 though the price varies depending on the quantity bought. When a client buys more products, there is a discount for that hence reducing the average cost for the item. On the other hand, BGC products measuring 2400 by 600 and 4.mm in width and fiber cement lining cost $11.07. Moreover, the Dura sheets 2400 by 1200 by 4.5mm of cladding with fiber cement costs $21.95(Negro, et al, 2006, p.197). The figure above illustrates a fiber cement product derived from (http://www.bunnings.com.au/bgc-2440-x-1200-x-7-5mm-2-93sqm-duratex-blueboard_p0710117L.) The above diagram illustrates James Fiber cement product that has an average cost of $23.81. The product has high temperature limit (ability to withstand high temperatures) and stress limit making it ideal material for external cladding. The smooth clad sheets come in various widths and they have specific design for external wall cladding. They also have eaves or the soft lining in the medium density and residential homes. Moreover, most of them have intricate paints hence creating flat panel outlook. As indicated above, one can use the product for cladding the walls and creating soft linings in the residential homes where flat panels are a requirement. Moreover, it is ideal for full wraps or the composite construction designs on either timber or the light steel gauge framed homes. The Hardie Flex sheets have fast installation attribute making it ideal for the entire process of cladding. The figure above illustrates a fiber cement product derived from (http://www.bunnings.com.au/bgc-2440-x-1200-x-7-5mm-2-93sqm-duratex-blueboard_p0710117.) The above product is a BGC product measuring 2440 by 1200 by 7.5mm. A Duratex blue board product goes for $32.85 Australian dollars. The BGC Duratex product has unique design that ensures that the solid substrate for the applied decorative finishes renders especially when combined with proprietary and the systems of coating. The product is durable and tough making ideal for construction work. Moreover, the product has high temperature limit (fire resistant) increasing its credibility for construction work. It is applicable in residential and commercial houses making it ideal for variety uses in the construction work. Textural coating accepts wide variety thus increasing the value of the product by the end of the day (Qi, 2006, p.78). Effects of Hatschek process on production of construction materials production in Australia Hatschek process produces fibre cement materials that exhibit high quality in terms of appearance, temperature limit and strain limit. Moreover, the Hatschek process highly makes use of sustainability approach making it ideal for contemporary production of construction materials. Sustainability is part of the millennium development goals, every project that has to run on industrial level must have the sustainability aspect, and fibre cement production has high levels of sustainability making it ideal in the 21st century (Roma et al, 2008, p.665). According to (Shirakawa, & Inoue, 2003, p.23) every individual in the world today has sole responsibility of conserving the environment for the purpose of future generations. When individual embarks on building a house, one will want to ensure that the designs and the products must highly restrict emission of the green house gases among other pollutants that contributes to global warming. This does not only apply to the process of construction, but it has to apply even to the entire life cycle of the building. Most of fibre cement products have a manual design that have the intention to assist designers to conceive sustainable and the energy-efficient offices and homes using the James Hardie products of building. The products have intricate and well-outlined performance of products related to James Hardie based on various results obtained from the life-cycle analysis (LCA) studies undertaken by the James Hardie Company. The company seeks to conduct business in sustainable and environmental friendly way as well as using management and operating procedures in identification, controlling and monitoring in an attempt to reduce the impacts of various operations as well as products on the environment (Shirakawa, & Inoue, 2003, p.22). The company seeks to improve continually the process of manufacturing and product formulation in attempt to minimise the carbon footprints. Ecologically sustainable development (ESD) is the main goal of the company and therefore making it an ideal company that seeks to sustain the environment. The aspects and environmental orientation has made it possible for the company to produce sustainable products hence increasing the number of customers who buy fibre cement products continually. Most Australian residents will prefer using construction materials that follow the (ESD) approach taking into account that most of them are elites and they would prefer making informed decisions. Moreover, the fibre cement products exhibit subtle characteristics that make them ideal in the entire process of construction. For instance, the process of fibre cement production applies resource and water conservation in the course of manufacture and construction (Merkley & Luo, 2004, p.744). Management and consumption of energy is minimal, intensive use recyclable raw materials, minimising wastes through recycling are among the most important features that increases marketability of fibre cement products in Australia. According to () 35% people who embark on residential and office construction will prefer using fibre cement materials compared to other materials because of the above attributes. This does not only increase the demand of the product, but also the rate of manufacturing. Generally, fibre cement products have intensively crippled other construction materials that do not observe (ESD) hence making them inadequate for the entire process of construction. (Merkley & Luo, 2004, p.745) asserts that for the next ten years fibre cement products will dominate the construction market suffocating the other materials that do not observe ecological sustainability development. Details of the retailers that sell Hatschek machines in Australia and Machines specifications Various retailers sell readymade Hatschek machines in Australia to small-scale companies and individuals willing to make fibre cement products for construction and business. The most common retailers are Alibaba holdings that carry out business on Canberra streets as well as established online platforms. The client requires making an order through the website and delivery takes place within speculated time. The retail shops are all over Australia making it easy for clients who require the services to access them conveniently. For instance, Calcium silicate board sheeting machine is a machine readily available in the streets of Canberra. The brand name of the product is Sinoma-Wuhan having an automatic grade. Moreover, after buying the machine, the customer normally gests the after sale services hence increasing credibility of the retailer. The 2015 Hatschek machine is a fiber -cement production board derived from the Sinopwer group of manufacturers (Jarabo et al, 2012, p.19). The retailers collaborate with manufacturers because the machine is extensive making it difficult for one time purchase. The supplier works hand in hand with retailer providing trade assurance of approximately $20,000. The machine does not contain asbestos at one hundred percent. The class of materials normally use limited scope of GB6566-2001 of building materials that have radionuclide limited among other crucial features. The main space application involves the exterior and interior space (Jarabo et al, 2012, p.19). Details of manufacturers of fibre cement products Various manufacturers that apply Hatschek process in production of fibre cement products and among them is James Hardie. The James Hardie industries are an industrial company that specialises on construction of fibre cement based construction materials. It has the main headquarter in Ireland and other branches all over the world including Australia. The products from James Hardi have international acceptance because of quality and sustainability aspects. Continuous application of James Hardi products in Australia has brought satisfaction and environmental consciousness among the users. Etex is another fibre cement company headquartered in Brussels. It is an affiliate of original Austrian inventor Ludwig Hatschek and it has produced fibre cement products for a long time. Though headquartered in Brussels, it has constituent branches in other countries like Australia where it has continually provided the products. Finally, Cembrit is among the best fibre cement companies based in Australia and United Kingdom. It produces roofing and cladding materials that have exquisite quality and appearance. It has a reputation of timely delivery and supply of natural slates. It has various depots in Australia among other countries making the delivery process easy and convenient (Logan et al, 2007, p.3343). Conclusion Hatschek process is ideal in construction of fibre cement products. An invention of ludwing Hatschek Austrian citizen has made great contribution in the construction milieu today. The transition from using asbestos to cellulose fibre has been a great milestone towards facilitating better production of fibre cement materials. Asbestos made products have high density and that makes them fragile contrary to cellulose made products. The strain and temperature is a crucial factor that determines the quality of fibre cement products. Most of them exhibit intricate ability to withstand high strain and temperature making them ideal for construction. For James Hardi fibre cement products exhibit high strain and temperature limit increasing the quality of such products. The Hatscheck machines are readily available in the streets of Australia as well as website platforms where people can make inquiries and deliveries made. Consequently, fibre cement industries and business affiliations have made significant changes in profit due to increases in demand of the products. References Agopyan, V., Savastano, H., John, V. M., & Cincotto, M. A. 2005. Developments on vegetable fibre–cement based materials in São Paulo, Brazil: an overview. Cement and Concrete Composites, 27(5), 527-536. Alp, I., Deveci, H., Yazıcı, E. Y., Türk, T., & Süngün, Y. H. 2009. Potential use of pyrite cinders as raw material in cement production: Results of industrial scale trial operations. Journal of hazardous materials, 166(1), 144-149. Alp, I., Deveci, H., & Süngün, H. 2008. Utilization of flotation wastes of copper slag as raw material in cement production. Journal of hazardous materials,159(2), 390-395. Chen, G., Lee, H., Young, K. L., Yue, P. L., Wong, A., Tao, T., & Choi, K. 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Cement-bonded straw board subjected to accelerated processing. Cement and Concrete Composites, 26(7), 797-802. Taha, M. M. R., & Shrive, N. G. 2001. Enhancing fracture toughness of high-performance carbon fiber cement composites. ACI materials journal, 98(2). Read More