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WO2017143384A1 - A method for the manufacture of foamed plaster - Google Patents

A method for the manufacture of foamed plaster Download PDF

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Publication number
WO2017143384A1
WO2017143384A1 PCT/AU2017/000051 AU2017000051W WO2017143384A1 WO 2017143384 A1 WO2017143384 A1 WO 2017143384A1 AU 2017000051 W AU2017000051 W AU 2017000051W WO 2017143384 A1 WO2017143384 A1 WO 2017143384A1
Authority
WO
WIPO (PCT)
Prior art keywords
powder
venturi
phosphoric acid
plaster
supply
Prior art date
Application number
PCT/AU2017/000051
Other languages
French (fr)
Inventor
Edgar Donald Knott
Original Assignee
Edgar Donald Knott
Priority date (The priority date is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the date listed.)
Filing date
Publication date
Priority claimed from AU2016900629A external-priority patent/AU2016900629A0/en
Application filed by Edgar Donald Knott filed Critical Edgar Donald Knott
Publication of WO2017143384A1 publication Critical patent/WO2017143384A1/en

Links

Classifications

    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B28—WORKING CEMENT, CLAY, OR STONE
    • B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
    • B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
    • B28C5/02—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing
    • B28C5/06—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions without using driven mechanical means effecting the mixing the mixing being effected by the action of a fluid
    • B—PERFORMING OPERATIONS; TRANSPORTING
    • B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
    • B01F—MIXING, e.g. DISSOLVING, EMULSIFYING OR DISPERSING
    • B01F25/00—Flow mixers; Mixers for falling materials, e.g. solid particles
    • B01F25/40—Static mixers
    • B01F25/42—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions
    • B01F25/421—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions by moving the components in a convoluted or labyrinthine path
    • B01F25/423—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions by moving the components in a convoluted or labyrinthine path by means of elements placed in the receptacle for moving or guiding the components
    • B01F25/4231—Static mixers in which the mixing is affected by moving the components jointly in changing directions, e.g. in tubes provided with baffles or obstructions by moving the components in a convoluted or labyrinthine path by means of elements placed in the receptacle for moving or guiding the components using baffles
    • C—CHEMISTRY; METALLURGY
    • C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
    • C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
    • C04B11/00—Calcium sulfate cements
    • C04B11/02—Methods and apparatus for dehydrating gypsum

Definitions

  • the present invention relates to a method for the manufacture of foamed plaster.
  • the present invention attempts to overcome at least in part, the disadvantages of previously known methods for the manufacture of foamed plaster
  • a method for the manufacture of foamed plaster which comprises feeding powdered casting plaster from a supply thereof to a Venturi apparatus, feeding the powder from the Venturi apparatus to a supply of phosphoric acid admixing the powder and phosphoric acid, and forwarding the resulting mixture to a dispensing and spray head so as to feed the mixture to a moulding means.
  • Figure 1 is a schematic diagram of an apparatus for putting the method of the present invention into practice.
  • Figure 2 is a view of a compressed air supply
  • Figure 3 is a schematic side view of air being fed to a Venturi apparatus.
  • Figure 4 is a view of a spray head which may form part of the present invention.
  • Figure 5 is a cross section of the spray head of Figure 4.
  • the present invention provides a method and apparatus comprising a feed means (10) for powdered material which powder to a platform (14) under the influence of gravity.
  • the feed means (10) is provided with a vibrating means (11) to ensure a steady flow of material to the vibrating platform (14) in use.
  • the vibrating platform (14) is arranged to feed the powder towards a Venturi apparatus (16).
  • the supply of powder feed may consist of about 93 per cent by weight of casting plaster with the balance of about 7 per cent of powdered limestone.
  • a compressed air supply (18) is arranged to provide a flow of air to draw in 25-50mm such as 40mm between the output of the compressed air supply (18) and the adjacent input end of the Venturi apparatus (16).
  • the powdered plaster falls from the platform (14) under the influence of gravity. This powdered plaster becomes entrained in the air flow from the compressor of the compressed air supply (18) and is fed into the Venturi apparatus (16) as shown
  • the platform (14) is part of a vibrating feeder of known type which is designed to provide a steady flow rate of powder to the Venturi (16).
  • the flow rate can be adjusted by means of a rheostat control. Variation of the vibration of the platform (14) urges the powder on the platform (14) to move forwardly to the right as seen in Figure 1.
  • a separate compressed air supply (20) is provided adjacent a narrow end on the Venturi (16). As shown in Figure 3, the air supply (20) is directed towards the wider end of the Venturi (16).
  • the wider end of the Venturi (16) is connected to an elongated chemical tube (22).
  • the tube (22) may be formed of a suitable plastics material.
  • the tube (22) is connected to an elbow (24) remote from the Venturi (16).
  • the elbow (24) may be formed of a high-density polyethylene having an internal diameter of 65mm
  • the 135% elbow (24) is provided with an inlet nozzle (26) arranged to receive dilute phosphoric acid. Further, the 135% elbow (24) is connected to a length of chemical tape (28). The phosphoric acid is sprayed into the elbow (24) to produce a mixture of the acid and the powder from the Venturi (16). The hose (28) delivers the phosphoric acid and plaster mixture to a mixing and spray head (40) via a further elbow 30 which has an inlet (31) for further compressed ait to ensure steady flow in the spray head (40).
  • a quantity of manila hemp fibres may be added to the material being processed.
  • the manila hemp fibres are preferably less than 4mm in length.
  • the use of manila hemp fibre is found to increase the strength of the resultant products whilst keeping the weight down.
  • the resultant products may have specific gravity of less than 0.4. It has been found that the Venturi system described above works well with the manila hemp but requires the addition of the air supply (18) to transfer the powder to the Venturi.
  • the Venturi apparatus (16) has a relatively narrow end adjacent to the air supply (18) and a relatively wide end remote from the air supply (18).
  • the narrow end could be 30mm in diameter whilst the wide end could be 65mm in diameter.
  • the air supply (18) may have an outlet plate with a plurality of apparatus (36) which ensure that a high velocity air flow is provided to transfer the powder into the Venturi (16).
  • FIG. 4 and 5 of the accompanying drawings there is shown a mixing and spray head (40) comprising a tubular member (42) having an inlet end (44) and an outlet end (46).
  • the tubular member (42) is connected to a hose (28).
  • the tubular member (42) has mounted thereto an outlet nozzle (48).
  • tubular member (42) contains spaced apart mixing baffle members (41) and (43).
  • the baffles (41) and (43) are arranged to induce turbulence in the tubular member (42) in use.
  • the baffle member (41) extends from one side of the tubular member (42) whilst the baffle member (43) extends from an opposite side of the tubular member (42).
  • the flow of air is initially interrupted by the baffle (41) and then returns to the full diameter section of the tubular member (42). Subsequently the flow of air encounters the baffle (43) and is again interrupted and then returns to the full diameter of the tubular member (42).
  • the result is that the flow of air is subject to variable back eddy currents.
  • the baffle member (41) blocks flow in part of the elongated member (42) which tends to throw air pressure sideways.
  • the baffle member (43) is of similar shape is therefore desirable to give an opposing throw to balance the elongate member (42) in use.
  • the baffles (41) and (43) have an effect on the elongated member for about 180 degrees. These could be replaced by three balanced baffles set at 120 degrees or four balanced baffles set at 90 degrees.
  • a mixture of casting plaster with calcium carbonate is entrained in the flow of air the hose (18) prior to entering the tubular member (42).
  • tubular member (42) it is desirable to induce shear in the mix. This could be achieved for example, by altering the shape of the baffles to give differential flow on one side thus tending to mix the for and after flow of the particulate matter. This enables a fraction of the flow to move forward and to be realigned with the Coriolis Effect to give a twist and provide stability to the outgoing jet of slurry. In that regard, results of tests in the Southern Hemisphere would require adj ustment to the mirror image in the Northern Hemisphere.
  • the airspeed through the mixing and spray head (40) should preferably be at least 200 km per hour to keep the fine particles in suspension. Further, frictional losses in pipes of less than 50 mm diameter tend to restrict the distance carried. Tests with pipe lengths of 3 to 5 meters have been carried out with pipes of 21 ⁇ 2 inch internal diameter which corresponds to about 56mm.
  • a nozzle (50) preferably provides a restricted outlet about 0.6 to 0.8 of the diameter of the tubular member (42) At the nozzle (50) particulate foamed plaster is ejected from the tubular member (42). Further, a preferred option is to provide a small water spray adjustment (49) at the spray head (40) to ensure that the resultant mixture has sufficient moisture content if required.

Landscapes

  • Chemical & Material Sciences (AREA)
  • Engineering & Computer Science (AREA)
  • Structural Engineering (AREA)
  • Ceramic Engineering (AREA)
  • Dispersion Chemistry (AREA)
  • Chemical Kinetics & Catalysis (AREA)
  • Mechanical Engineering (AREA)
  • Materials Engineering (AREA)
  • Organic Chemistry (AREA)
  • Nozzles (AREA)

Abstract

A method for the manufacture of foamed plaster in which powder containing a major proportion of casting plaster is fed through a Venturi apparatus, and is then mixed with phosphoric acid subsequently fed to a dispensing spray head to be fed to a moulding means.

Description

TITLE
Ά METHOD FOR THE MANUFACTURE OF FOAMED PLASTER"
FIELD OF THE INVENTION
[0001) The present invention relates to a method for the manufacture of foamed plaster.
BACKGROUND
[0002 The present invention attempts to overcome at least in part, the disadvantages of previously known methods for the manufacture of foamed plaster
SUMMARY OF THE INVENTION
[0003] It is known to provide foamed plaster for the manufacture of moulded components for use in industry. The present invention provides a new and improved method for manufacture of foamed plaster.
[0004] In accordance with one aspect of the present invention there is provided a method for the manufacture of foamed plaster which comprises feeding powdered casting plaster from a supply thereof to a Venturi apparatus, feeding the powder from the Venturi apparatus to a supply of phosphoric acid admixing the powder and phosphoric acid, and forwarding the resulting mixture to a dispensing and spray head so as to feed the mixture to a moulding means.
BRIEF DESCRIPTION OF DRAWINGS
[0005] The present invention will now be described, by way of example, with reference to the accompanying drawings, in which: Figure 1 is a schematic diagram of an apparatus for putting the method of the present invention into practice.
Figure 2 is a view of a compressed air supply;
Figure 3 is a schematic side view of air being fed to a Venturi apparatus.
Figure 4 is a view of a spray head which may form part of the present invention; and
Figure 5 is a cross section of the spray head of Figure 4.
DESCRIPTION OF PREFERRED EMBODIMENTS
[0006] As shown in the accompanying drawings, the present invention provides a method and apparatus comprising a feed means (10) for powdered material which powder to a platform (14) under the influence of gravity.
[0007] The feed means (10) is provided with a vibrating means (11) to ensure a steady flow of material to the vibrating platform (14) in use. The vibrating platform (14) is arranged to feed the powder towards a Venturi apparatus (16).
[0008] The supply of powder feed may consist of about 93 per cent by weight of casting plaster with the balance of about 7 per cent of powdered limestone.
[0009] A compressed air supply (18) is arranged to provide a flow of air to draw in 25-50mm such as 40mm between the output of the compressed air supply (18) and the adjacent input end of the Venturi apparatus (16).
[0010] The powdered plaster falls from the platform (14) under the influence of gravity. This powdered plaster becomes entrained in the air flow from the compressor of the compressed air supply (18) and is fed into the Venturi apparatus (16) as shown
[0011] The platform (14) is part of a vibrating feeder of known type which is designed to provide a steady flow rate of powder to the Venturi (16). The flow rate can be adjusted by means of a rheostat control. Variation of the vibration of the platform (14) urges the powder on the platform (14) to move forwardly to the right as seen in Figure 1. To enhance the flow of air through the Venturi (16), a separate compressed air supply (20) is provided adjacent a narrow end on the Venturi (16). As shown in Figure 3, the air supply (20) is directed towards the wider end of the Venturi (16).
[0012] The wider end of the Venturi (16) is connected to an elongated chemical tube (22). The tube (22) may be formed of a suitable plastics material.
[0013] Further, the tube (22) is connected to an elbow (24) remote from the Venturi (16). The elbow (24) may be formed of a high-density polyethylene having an internal diameter of 65mm
[0014] The 135% elbow (24) is provided with an inlet nozzle (26) arranged to receive dilute phosphoric acid. Further, the 135% elbow (24) is connected to a length of chemical tape (28). The phosphoric acid is sprayed into the elbow (24) to produce a mixture of the acid and the powder from the Venturi (16). The hose (28) delivers the phosphoric acid and plaster mixture to a mixing and spray head (40) via a further elbow 30 which has an inlet (31) for further compressed ait to ensure steady flow in the spray head (40).
[0015] In a variation of the method of the present invention, a quantity of manila hemp fibres may be added to the material being processed. The manila hemp fibres are preferably less than 4mm in length. Further, the use of manila hemp fibre is found to increase the strength of the resultant products whilst keeping the weight down. For example, the resultant products may have specific gravity of less than 0.4. It has been found that the Venturi system described above works well with the manila hemp but requires the addition of the air supply (18) to transfer the powder to the Venturi.
[0016] Further, it has been found that a rotary screw compressor with air dryer, overcame problems in the compressed air supply with minimal variation in pressure and moisture. Typically, the operating pressure is 8 bar and provides free air capacity of 50 cubic feet per minute.
[0017] As shown in the drawing, the Venturi apparatus (16) has a relatively narrow end adjacent to the air supply (18) and a relatively wide end remote from the air supply (18). By way of example, the narrow end could be 30mm in diameter whilst the wide end could be 65mm in diameter.
[0018] As show in Figure 2, the air supply (18) may have an outlet plate with a plurality of apparatus (36) which ensure that a high velocity air flow is provided to transfer the powder into the Venturi (16).
[0019] In Figures 4 and 5 of the accompanying drawings there is shown a mixing and spray head (40) comprising a tubular member (42) having an inlet end (44) and an outlet end (46).
[0020] At the inlet end (44) the tubular member (42) is connected to a hose (28). At the outlet end (46) the tubular member (42) has mounted thereto an outlet nozzle (48).
[0021 ] Further, the tubular member (42) contains spaced apart mixing baffle members (41) and (43).
[0022] The baffles (41) and (43) are arranged to induce turbulence in the tubular member (42) in use. As seen in Figure 4, the baffle member (41) extends from one side of the tubular member (42) whilst the baffle member (43) extends from an opposite side of the tubular member (42). The result is that the flow of air is initially interrupted by the baffle (41) and then returns to the full diameter section of the tubular member (42). Subsequently the flow of air encounters the baffle (43) and is again interrupted and then returns to the full diameter of the tubular member (42). The result is that the flow of air is subject to variable back eddy currents.
[0023] In the arrangement described the baffle member (41) blocks flow in part of the elongated member (42) which tends to throw air pressure sideways. The baffle member (43) is of similar shape is therefore desirable to give an opposing throw to balance the elongate member (42) in use. The baffles (41) and (43) have an effect on the elongated member for about 180 degrees. These could be replaced by three balanced baffles set at 120 degrees or four balanced baffles set at 90 degrees. In an operation, a mixture of casting plaster with calcium carbonate is entrained in the flow of air the hose (18) prior to entering the tubular member (42).
[0024] In addition, in the tubular member (42) it is desirable to induce shear in the mix. This could be achieved for example, by altering the shape of the baffles to give differential flow on one side thus tending to mix the for and after flow of the particulate matter. This enables a fraction of the flow to move forward and to be realigned with the Coriolis Effect to give a twist and provide stability to the outgoing jet of slurry. In that regard, results of tests in the Southern Hemisphere would require adj ustment to the mirror image in the Northern Hemisphere.
[0025] It has been found that in practice, the airspeed through the mixing and spray head (40) should preferably be at least 200 km per hour to keep the fine particles in suspension. Further, frictional losses in pipes of less than 50 mm diameter tend to restrict the distance carried. Tests with pipe lengths of 3 to 5 meters have been carried out with pipes of 2½ inch internal diameter which corresponds to about 56mm. A nozzle (50) preferably provides a restricted outlet about 0.6 to 0.8 of the diameter of the tubular member (42) At the nozzle (50) particulate foamed plaster is ejected from the tubular member (42). Further, a preferred option is to provide a small water spray adjustment (49) at the spray head (40) to ensure that the resultant mixture has sufficient moisture content if required.
[0026] The present invention will now be described with reference to the following example. [0027] It has now been found that the method using the apparatus of the present invention can reduce the specific gravity of the foamed plaster from, for example, 0.6 to 0.4.
[0028] Thus, it is possible to convert 18kg of casting plaster together with 7% by weight of calcium carbonate and deliver it as dry powder together with 4% phosphoric acid at 6 litres per minute to produce 48 litres of dry foam plaster at a specific gravity of 0.4 per minute.
[0029] Modifications and variations in fact would be apparent to a skilled addressee are deemed to be within in the scope of the present invention.

Claims

1. A method for the manufacture of foamed plaster which is characterised by comprising feeding powdered casting plaster from a supply thereof to a Venturi apparatus, feeding the powder from the Venturi apparatus to a supply of phosphoric acid, admixing the powder and phosphoric acid and forwarding the resulting mixture to a mixing and spray head so as to feed the mixing and moulding means.
2. A method according to claim 1, characterised in that a vibrating feeder feeds the powdered casting plaster at a predictable flow rate from the supply thereof.
3. A method according to claim 2, characterised in that, the powdered casting plaster is fed from the supply onto a vibrating feeder which is arranged to provide a steady flow rate and from which the powders falls under the influence of gravity.
4. A method according to claim 3, characterised in that a compressed air supply is provided to blow the powder falling? from the vibrating table into a Venturi apparatus.
5. A method according to claim 4, characterised in that there is gap between the compressed air supply and the Venturi and the powder from the vibrating table is blown into the Venturi as it falls from the table.
6. A method according to any one of the preceding claims, characterised in that the Venturi is provided with an additional compressed air flow to ensure that there is sufficient suction in the Venturi for the powder to be drawn into the Venturi.
7. A method according to any one of the preceding claims, characterised in that powder from the Venturi is fed to an input device arranged to receive phosphoric acid and to admix the phosphoric acid with the powder.
8. A method according to any one of the preceding claims characterised in that the mixture of acid and powder is fed through a tube means to a mixing and spray head. A method according to any one of the preceding claims, characterised in that the additional compressed air is arranged to be fed into the apparatus to ensure a steady flow of the phosphoric acid and powder mixture to the mixing and spray head.
A method according to any one of the preceding claims in which a quantity of manila hemp fibres are added to the powder prior to addition of phosphoric acid.
PCT/AU2017/000051 2016-02-23 2017-02-22 A method for the manufacture of foamed plaster WO2017143384A1 (en)

Applications Claiming Priority (2)

Application Number Priority Date Filing Date Title
AU2016900629 2016-02-23
AU2016900629A AU2016900629A0 (en) 2016-02-23 Mixing & Spray Head

Publications (1)

Publication Number Publication Date
WO2017143384A1 true WO2017143384A1 (en) 2017-08-31

Family

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Family Applications (1)

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PCT/AU2017/000051 WO2017143384A1 (en) 2016-02-23 2017-02-22 A method for the manufacture of foamed plaster

Country Status (1)

Country Link
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Cited By (1)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020010381A1 (en) * 2018-07-11 2020-01-16 Edgar Donald Knott A method and apparatus for the manufacture of foamed plaster

Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1585065A (en) * 1976-07-26 1981-02-25 Bpb Industries Ltd Treatment of gypsum plaster
US5393341A (en) * 1991-06-06 1995-02-28 Rume Maschinenbau Gmbh Method and apparatus for the production of structural foam, particularly cement foam
US20040201120A1 (en) * 2003-01-31 2004-10-14 Lafarge North America, Inc. Gypsum wallboard process
US7678189B2 (en) * 2005-01-07 2010-03-16 Edgar Donald Knott Foaming plaster

Patent Citations (4)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
GB1585065A (en) * 1976-07-26 1981-02-25 Bpb Industries Ltd Treatment of gypsum plaster
US5393341A (en) * 1991-06-06 1995-02-28 Rume Maschinenbau Gmbh Method and apparatus for the production of structural foam, particularly cement foam
US20040201120A1 (en) * 2003-01-31 2004-10-14 Lafarge North America, Inc. Gypsum wallboard process
US7678189B2 (en) * 2005-01-07 2010-03-16 Edgar Donald Knott Foaming plaster

Cited By (2)

* Cited by examiner, † Cited by third party
Publication number Priority date Publication date Assignee Title
WO2020010381A1 (en) * 2018-07-11 2020-01-16 Edgar Donald Knott A method and apparatus for the manufacture of foamed plaster
AU2018431621B2 (en) * 2018-07-11 2020-07-23 Edgar Donald Knott A method and apparatus for the manufacture of foamed plaster

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