Jornadas tecnicas da ceramica e 27 de novembro de 2015 Presentation of LB Microgranulation Technology

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Lindsey Poole
6 years ago
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1 Jornadas tecnicas da ceramica e 27 de novembro de 2015 Presentation of LB Microgranulation Technology

Main Business Units Porcelain Tile Technology Dry

Technology LB develops systems for handling powder that

colouring, granulation and compression of the bodies,

necessities relating to weighing and dosing processes,

the bodies LB designs and manufatures complete systems

construction industry LB also designs and builds bulk

2 Main Business Units Porcelain Tile Technology Dry Grinding Technology Dry Mixing Technology Powder treat. Technology LB develops systems for handling powder that includes innovative weighing and dosing processes, dry colouring, granulation and compression of the bodies, press feeding and decoration LB technology fulfils all necessities relating to weighing and dosing processes, dry grinding, micronization, granulation and drying of the bodies LB designs and manufatures complete systems for the production of dry mortar products for the construction industry LB also designs and builds bulk handling terminals, and complete plants for fertilizers, feed stuffs, and other similar sectors

3 LB group 120 employees (180 operators) Average turnover Over 35 millions of euro Quality system certified ISO 9001 Holder of several patents related to machinery and processes

4 The dry preparation of ceramic bodies The concept of micro-granulation is signed by

5 From the dry grinding to the microgranulation LB has been working since 40 years in the dry grinding systems for ceramic bodies. In the latest 10 years the technological research has given a great impulse to dry grinding system of the bodies, traditionally made with pendular mills, designing more efficient systems with vertical roller mill MRV until arriving to the innovative technology

More flexible and eco-friendly technology 2010 the first plant for the production of ceramic body with technology MIGRATECH is installed 2011 the first press feeding

6 More flexible and eco-friendly technology 2010 the first plant for the production of ceramic body with technology MIGRATECH is installed 2011 the first press feeding optimized with technology DRY FEEDER is installed 2015 the technologies with high production efficiency and low environmental impact developed by LB have changed the rules of the game

7 The traditional process of wet milling GRINDING MILLING WETTING STORAGE PRESS FEEDING

8 Dry milling + Microgranulation GRINDING MILLING MICROGRANULATION DRYING STORAGE PRESS FEEDING

9 From the dry grinding to the microgranulation

10 Higher efficiency and lower environmental impact VERTICAL MILLING SYSTEM MICROGRANULATION SYSTEM FLUID BED DRYING SYSTEM

11 Grinding with vertical roller mill MRV High production capacity up to 45 Ton/h Optimal homogenization of raw materials Very fine milling Reduction of times and costs for maintenance

12 Microgranulation in continuous with GRC Perfect humidification and homogenization of powders Output product with characteristics similar to those of the atomized Better fluidity of the powders to optimize the pressing process

13 Drying in continuous with fluid bed EVF A perfect and homogeneous drying of the microgranulated powders guarantees excellent fluidity of the body and make easier the loading phase of the mould press

14 The advantages of dry grinding with MRV Icompared to traditional dry milling (hammer and pendular mills) Drastic reduction of defects due to organic and inorganic impurities contained in the raw materials Increase of the mechanical properties of the ceramic product (mechanical strength, abrasion and frost resistance) Reduction of the temperatures during the firing cycle and consequent increase of the output capacity Increase of the aesthetic properties of the final product

15 Grain size curves in comparison

16 Better compaction and easiness of pressing The technical parameters that most influence the quality of the product exit from the press are: Humidity Grain size distribution Shape of the grain

17 Grain size curves in comparison Weght (%) Spray-dried powder Dry-ground and wetted powder Microgranulate A Microgranulate B Microgranulate C

18 Grain size curves in comparison Peso (%) Granulometria µm Microgranulate A Microgranulate B Microgranulate C Dry-ground and wetted powder Füller-Bolomey 500 µm Maximum density curve - Füller-Bolomey

19 La forma dei micro-granuli MIGRATECH Size ranging from 500 to 1,000 µm

20 La forma dei micro-granuli MIGRATECH Size ranging from 250 to 500 µm

21 La forma dei micro-granuli MIGRATECH Size ranging from 125 to 250 µm

22 La forma dei micro-granuli MIGRATECH Size ranging from 63 to 125 µm

23 Innovative features of MIGRATECH Good flowability of the body in filling the mould Easy degassing in pressing Higher homogeneity of the pressed green Reduced thickness of the powders loaded in the mould Lower energy consumption Elimination of costs of deflocculants and additives Lower costs for plant maintenance Reduced environmental impact: less CO2 in atmosphere and lower water consumption Worldwide average return on investment: 12/18 months

24 Average Energy Saving

25 Average Energy Saving

ROI return on investment Economical advantages associated to the following factors: - Impressive reduction in energy consumptions - Elimination of costs of

26 ROI return on investment Economical advantages associated to the following factors: - Impressive reduction in energy consumptions - Elimination of costs of deflocculants and additives - Lower cost of plant maintenance - Lower man power needed in body preparation area ROI - Return of Investment from 12 to 18 months

27 MIGRATECH plant

28 MIGRATECH

29 High Quality - Big Sizes

30 REFERENCE LIST Dry Grinding and Microgranulation - MIGRATECH More than 200 international customers among them AL ANWAR - Oman CARTHAGO - Tunisia CERAMICA ALFAGRES - Colombia CERAMICA AL OMAARA - Egypt CERAMICA CLEOPATRA - Egypt CERAMICA COOPERATIVA DI IMOLA - Italy CERAMICA MEDITERRANEA- Italy CERAMICA LIMA - Perù CERAMICA GLADYMAR - Bolivia CERAMICA OMEGA - Egypt CERAMICA PYRAMIDS - Egypt CERAMICA SAN LORENZO - Argentina/Perù/Mexico COLCERAMICA - Colombia COLOROBBIA Turkey/China IDEAL CERAMIQUE - Algeria HISPACENSA CERAMICA - Guatemala SAUDI CERAMICS CO. Saudi Arabia SOGUTSEN - Turkey CERAMICA OPERA - Italy VITRA - Turkey

31 Proud of our past, firmly in the present, tracing a new future for ceramic tiles Thank You for your attention

PORCELAIN TILES BY THE DRY ROUTE

PORCELAIN TILES BY THE DRY ROUTE (1,) F. G. Melchiades, (1) M. T. Daros, (1,) A. O. Boschi (1) Laboratório de Revestimentos Cerâmicos - LaRC Departamento de Engenharia de Materiais - DEMa Universidade