NEW TECHNOLOGY OF THE STEEL FIBER MANUFACTURING FROM TECHNOGENIC WASTE

International Journal of Mechanical and Production Engineering Research and Development (IJMPERD) ISSN (P): 2249–6890; ISSN (E): 2249–8001 Vol. 10, Issue 3, Jun 2020, 611–622 © TJPRC Pvt. Ltd.

NEW TECHNOLOGY OF THE STEEL FIBER MANUFACTURING FROM TECHNOGENIC WASTE ANDREY VAVILOV, ALINA KIM, GEORGY GURYANOV & ALEXANDR LIKUNOV School of Engineering, East Kazakhstan State Technical University, Ust-Kamenogorsk, Kazakhstan ABSTRACT The results of theoretical and exploratory investigations of new innovation and equipment for technogenic waste processing (waste cables and ropes) are described in the article. The processing result is a steel fiber for Steel-Fiber Reinforced Concrete (SFRC). Several essentially new aggregates and methods are offered, which considerably reduce the power consumption of engineering techniques of fiber production from technogenic waste (waste ropes and cables).

It provides a sales opportunity for a new product in the building materials market. The description of experimental and pilot models, a general technique of an experiment is presented. Data on the determination of effective operating modes of the new equipment are provided. Conclusions are drawn on the operability of the original equipment and its characteristics different from analogs to the best. This publication has been written as part of the sub-project "Technology of fiber manufacturing from technogenic wastes", funded by the Government of the Republic of

KEYWORDS: Steel Fiber, Steel-Fiber Reinforced Concrete, Processing Equipment, Energy Efficiency & Waste Recycling

Received: Mar 13, 2020; Accepted: Apr 03, 2019; Published: May 21, 2020; Paper Id.: IJMPERDJUN202056

Original Article

Kazakhstan and the World Bank under the Project "Stimulation of Productive Innovations".

1. INTRODUCTION The processing problem of some technogenic waste types usually most is particularly acute in industrial regions of the different countries of the world. A large number of mines led to a problem of the emergence of a significant amount of specific type of technogenic waste. These are namely, the fulfilled (withdrawn from consumption) cables and ropes of the handling equipment. So, only one of the mining industry leaders is Kazzink LLP, annually remove from consumption about 2000 tons of cables and steel ropes from the mines. Methods of effective waste processing do not exist now. High logistic expenses exclude the possibility of waste transportation for processing in other countries. Now-a-days, mining and construction entities are compelled to use this waste freely: their entombment or warehousing is commonly made. Obviously, for this situation, it is difficult to talk about the successful transformation of this sort of modern squanders. Simultaneously, this material (cables and ropes) is generally made of top-notch steel with extra alloying components that recognize these crude materials from ordinary modern squanders. For the answer to this issue, various innovative works was done. Thus, the new innovation and hardware for preparing waste cables and ropes of dealing with gear in steel fiber, which is utilized further in the creation of Steel-Fiber Reinforced Concrete (SFRC) is offered [1-2].

It is known that modern construction is impossible without concrete products. According to the experts, the annual world release of concrete surpasses 2 billion cubic meters significantly more surpasses the creation of different sorts of modern items and building materials. Concrete mixtures are widely used in construction, road,

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mining and other industries. At the same time, the quality of the received products (for example, in terms of strength and durability) and questions of reducing the energy intensity and cost of technological processes come to the fore. From this point of view, it is sufficient to widely introduce into the practice of construction and production of reinforced concrete products from the steel-fiber concrete [1-4], - a composite material in the form of fine-grained concrete reinforced with dispersed (discrete) steel fibers.

SFRC is widely applied around the world in special structures and designs, in road surfaces of airfields, in elements of seismic buildings and constructions, in case of production of bulk floors and in many other situations. The technical and economic efficiency of the application of SFRC is caused by its high strength characteristics and rather simple manufacturing techniques [5, 6, 7]. SFRC in world practice occupies a considerable share in the total amount of the used concrete; the serial production of steel fiber from a standard steel wire is arranged. However, the more widespread introduction of this effective material restrains, mainly, the high manufacturing cost of steel fiber from a wire (further – a standard fiber) which, as a rule, at most of the producers is prohibitive and constitutes a considerable part of SFRC cost.

The actual direction of research in this regard is the use of various waste products as a fiber.

One of the most perspective types of waste for this purpose [8, 9, 10, 11] are the cables and ropes of handling equipment which fulfilled the production resource (and also other hummock waste, for example, cords of tire covers, etc.) which, in fact, are production wastes, but are made of high-quality steel and which accumulated a large number in the industrial sector. In the modern industry, there are many positive examples of processing technologies, use of technogenic raw materials and other waste for the purpose of concrete production [12, 13, 14, 15, 16].

The authors of this article have developed and proposed a number of innovative solutions-new technologies and equipment that can significantly reduce the energy processes intensity, the cost of consumables, some other production costs, and as a consequence, the cost of the new fiber producing. These innovations address the question of the market attractiveness of fiber production from waste cables/ropes.

2. EXPERIMENTAL STUDIES The innovative line for the creation of new fiber plays out the accompanying primary procedures: steel cable cutting (ropes) into sections (50-75 mm), steel cables separation into singular wires, washing the subsequent roughing fiber and afterward drying. This grouping of activities is notable [1-2, 17-19]. For every procedure, in view of logical techniques (analyze, investigation, displaying, and so forth.), new arrangements have been created and ensured by licenses, which make it conceivable to diminish the expense of creation fundamentally [1-2].

In light of nearby monetary contemplations, it is proposed to utilize cables and ropes with wire diameter 0,2 - 1,0 mm that have built up the specialized asset for assembling another kind of fiber. Distance across of ropes and cables is more than 60 mm. Basically, all trials completed in this work (and considered underneath) utilized a rope with a distance across of 19.5 and 25 mm, a payload reason, uncoated wire, disentangling, not fixed, usual precision. Cutting of links is the first and rather power-concentrated creation procedure of a fiber. Plus, tackling an issue of coordinating the sanest technique for cutting, it is important to think about expenses for consumable materials (replaceable plates, blades, and so forth.). It ought to be noticed that now for cutting of links and ropes, grating round saws are commonly utilized. In any case, it concerns the way toward estimating links cutting (on enormous pieces – from 1 m or more), and for our situation, it is the fast stopping of links on pieces (50 -75 mm) [1-2].

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For the solution of cables cutting problems, the theoretical and experimental analysis of possible metals cutting methods are presented, which carried out: hydro abrasive, laser, gas, plasma and mechanical cutting. Mechanical cutting can be made by means of abrasive circular saws, thermo-frictional saws, a guillotine cut, circular gear saws and band-saw machine. The main applicability criteria - the minimum cost value of the cutting process (proceeding from local economic conditions) and technological suitability.

Several cutting techniques are not appropriate for new fiber creation for mechanical reasons. Hence, utilizing gas cutting, the metal is softened in the spot of the cut; regarding this, the strands are welded together, which makes it difficult to additionally process. A similar impact happens by utilizing plasma cutting. The cutting technique utilizing roundabout rigging saws is likewise not reasonable for this innovation – when cutting a link, singular wires are pulled out. Cutting the guillotine cut is additionally not reasonable for this innovation, as it has a constrained thickness of the metal being sliced by and by up to 6 - 8 mm. With a further increment in the thickness of the cut, the utilization of this technique turns out to be financially unbeneficial [1-2].

The use of the cutting method with an abrasive saw depends on the cutting mode. The speed of the saw feed determines the level of welding of the strands (Fig. 1, B), which affects the possibility of their subsequent processing (separation into individual wires). In the course of the experiments, it was found that higher feeding speed of an abrasive circular saw is a result of fewer individual wires of the cable is welded together. The underestimation of speed also leads to the effect of welding individual wire ropes. In addition, it is exceeding a certain critical feed rate results in the destruction of the saw blade edge. Thus, for abrasive cutting, there is an optimum saw feed rate (in our experiments, not more than 8 m/s), which depends, first of all, on the angular speed of the saw blade and rope diameter.

When utilizing some cutting strategies (thermo-rubbing and grating roundabout saw), there are a few innovatively constructive outcomes: 

The impact of "self-destructing" strands (when the link breaks itself into wires), which extraordinarily improves the further preparing of links/ropes (partition into singular wires);



The impact of "discharging ointment" when slicing through warming, the lube is softened (with resulting spillage) of natural grease from ropes/links, which, from one viewpoint, is a positive factor - the procedure of ensuing washing of fiber is encouraged; then again, the issue of gathering and expulsion of waste information from the cutting zone (which confounds the general structure of the link cutting machine). This impact additionally happens when utilizing laser cutting [1-2].

To take care of the issue of the most effective strategy for cutting links, various analyses and counts were

completed to distinguish the most efficient technique. The outcomes are appeared in Table 1 and on the chart (Figure 1).

Here, in ascertaining the expense of cutting one ton of links, vitality utilization and the expense of consumables were considered. In all cases, the cutting time was considered so as to guarantee certain efficiency of the whole creation line in any event, 2 tons of fiber for each move. This profitability is gotten from nearby monetary contemplations. The staying cutting parameters are not considered as having an inconsequential impact [1].

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Table 1: The Summed Up Cost of Cutting in Various Manners Diameter of a Cable/Rope, mm Conventional Cutting Method Designation 5 10 20 Hydroabrasive 4,607 10,135 22,837 Laser А 0,856 1,695 2,386 Abrasive В 0,165 0,329 0,658 Thermal friction С 0,082 0,181 0,395 Band Saw Machine D 0,099 0,230 0,461

40 52,978 0,856 0,494 0,592

Clearly, it is not suitable to apply methods for hydro grating and laser cutting for our situation. Moreover, laser cutting cannot be applied and for the innovative reasons (unacceptable with a measurement of link more than 20 mm) [12]. Three remained cutting methods in price expression are approximately in one range. That is in case of medium-sized production (in our case – about 2 … 3 tons of fiber per shift), any of these methods are applicable. Nevertheless, in our case, it is possible to consider the most applicable –method of thermo frictional cutting. The main lack of this method is increased electricity consumption (in our experiments – around 2,41 … 2,57 kW/h) in comparison with abrasive cutting (capacity is lower by 18 … 20%) and cutting on the band saw machine (has the minimum power consumption). The main benefit of this method is the use of the non-damaging tool. It is due to the minimum cost of rope/cable of the cutting process is ensured.

Figure 1: The Specific Cost of Cables Cutting in Different Ways.

According to the obtained solutions, the first exploratory establishments (Fig. 2) of thermofriction and grating cutting were structured and produced. Over the span of examinations, another unique plan of the plate for thermofriction cutting was invented, secured by the patent of the Republic of Kazakhstan [1-2, 20]. Likewise, the issue of mechanizing the work process of these machines is comprehended. Practically, full robotization is permitted to accomplish the necessary execution - around 2 tons of fiber for each move [1-2].

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Figure 2: Equipment for Abrasive (Left) and Thermofriction (Right) Cable Cutting.

The second crucial mechanical procedure in the creation of fiber is the division of cut bits of cables into independent strands and afterward into singular wires. This procedure has the most elevated vitality power in the entire innovative chain [1]. In previous studies and analyses on this subject, it was proposed to use twin-roll crushers with smooth rolls to separate the cable. Separation of the cable is due to crushing, during which the effect of dividing into individual wires occurs. For this situation, it is important to utilize two twin crushers (only four rolls). It significantly increases the energy intensity of the entire technological process, and as a result, substantially increases the cost of production.

The authors proposed two new answers for this issue, which can lessen the vitality utilization of the detachment activity by a few times. The primary arrangement is the utilization of a solitary level smasher. For this situation, just one roll is utilized, and the weight is made by the devastating plate, which is exposed to the extra vibrating activity. A patent of the Republic of Kazakhstan [21] was gotten for this choice [1].

To execute and test the proposed technique for link partition, exploratory and afterward, modern establishments were created and produced (Fig. 3). The formula can determine the oscillation amplitude of the movable plate (except for measurements) of separation unit [1]: а≈

𝑚𝑜 𝑟𝑜 𝑚

,m

(1)

where mo is the total mass of the centrifugal pathogen unbalance, kg; m is the total mass of the oscillating parts, kg; ro is the eccentricity of the location of the mass of unbalance, m [1]. However, to determine the amplitude, the perturbing force, elastic modulus, geometric characteristics of the cross section of the elastic elements, their sizes and their layout should be taken into account. Then the magnitude of the amplitude can be defined as the magnitude of the deflection of the cantilever-fixed plate, loaded with a disturbing force Fpr. The elastic line equation will be presented as follows: 𝑦𝑐𝑎𝑙𝑐 =

𝐹𝑝𝑟 2𝐸∙𝐽𝑥

(

𝑧3 3

− ℓ ∙ 𝑧2)

(2)

where ycalc - deflection, mm; z - the coordinate of the reference point; E - the modulus of elasticity (0.55 ∙ 105 MPa); Jx - axial moment of inertia (for the calculated case of 2287 mm4); ℓ - console length (450 mm).

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Figure 3: The Cables Separation Unit.

On the test set-up (after PC reenactment) of the unit for link partition, various examinations were completed, which completely affirmed its viability. Over the span of the tests, the fundamental undertaking was to build up such a working method of the establishment (sufficiency and recurrence of motions of the moving plate, and speed of the primary drum), which guarantees total partition of the cut bits of wire for singular wires for a base time. The productivity of partition E% was evaluated as a level of the quantity of the complete wire to the quantity of free (after division) wires [12].

A portion of the got outcomes over the span of tests appear in Figure 4. From the introduced diagram, it very well may be seen that the most reasonable working method of the unit relates to the base vibration frequencies of the plate (rpm - the vibration speed of the vibration drives) and principle drum - around 997 and 36 rpm (individually). Simultaneously, the analysis demonstrated that further decrease prompts a reduction in profitability, that is, not judiciously (not appeared in the diagram). The most satisfactory is the normal estimations of swaying abundancy of the vibroplate (about 0.6 - 1 mm).

Simultaneously, similar conduct of diagrams affirms the ampleness of the acquired information [1-2]. Also, to identify the optimum operating conditions for the separation plant, in the course of experiments, the rational power of the entire unit was determined, which amounted to 2.3 kW. The second solution for the efficient separation of cables into wires is the use of a roll crusher (type DVG 200x125) - Fig. 3. In this case, the non-standard operating mode of the crusher established experimentally is used. The frequency of rotation of the rolls differs from each other by 10... 15%. In this case, the speed of rotation of the rolls should not be lower than 2800... 3000 rpm. In addition, a specially shaped notch was used on the rolls to capture cable segments better.

Figure 4: Computer Model of the Cables Separation Equipment.

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During the analysis of various sources, it was revealed that for today there are no aggregates of roughing fiber that are optimally suitable for effective use.

The third essential mechanical procedure in the fiber creation is a washing of the subsequent wire - harsh fiber.

Washing the links is a compulsory procedure, on the grounds that in any case, the natural oil of links and different polluting influences don't permit to acquire the necessary quality parameters of steel-fiber fortified cement. This procedure can likewise have huge vitality power (particularly when utilizing warmed water). Moreover, the utilization of standard cleanser arrangements altogether builds the expense of the activity [1].

During the examination of different sources, it was uncovered that for now, there are no totals of roughing fiber that are ideally appropriate for viable use. A series of experiments was carried out to find the best way to wash rough fibers. Thus, the ultrasonic washing method showed good efficiency, which, however, decreases with an increase in the volume of washable rough fiber (when washing 1 kg of fiber, washing is achieved in 5-7 minutes, only in hot water without the use of reagents; with an increase in volume up to 10 kg, the washing efficiency is sharp decreases). This method is not suitable for the industrial processing of cables. Using an ultrasonic bath, the average amount of pollution in the rough fiber was established, which amounted to about 0.5... 0.6 kg of pollution per 100 kg of fiber (Fig. 5, a) [1].

Furthermore, authors proposed their own new plan of the vibrating washing and the relating better approach for washing, which are ensured by the creative licenses of the RK [1-2, 22, 23]. This method showed a rather high efficiency, but also, like the previous version, had a limit on the volume of a once-processed draft fiber - not more than 20 kg per one tank of a vibration wash (Figure 5, b) [1].

The most effective (in terms of speed, cost, and cleanliness of the sink) was a method for manually treating rough fibers with water under pressure on a long flat sieve – figure 5, s (water temperature - 400С; sieve area not less than 2 m2).

Fiber is pre-treated with a new cleaning solution developed by the authors [24-27]. All segments of the arrangement have minimal effort and low natural risk. The cleanser arrangement is likewise secured by the patent of the Republic of Kazakhstan [1, 24]. Its fundamental bit of leeway is the capacity to clean harsh filaments without warming the water [1].

For the subsequent drying of the fibers, the authors developed a drying complex according to their original scheme. The complex consists of a feeder-agitator, a loading conveyor and a vibration dryer (a vibratory conveyor with forcing warm air and the subsequent removal of moist air to the side). This scheme provides fiber drying in a semiautomatic mode with a speed of up to 200 kg per hour [1].

All arrangements adequacy for roughing fiber washing has been demonstrated tentatively. Simultaneously, the expense of the washing activity contrasted with conceivable assessments is diminished by 2 - 2.5 occasions [1].

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a

b Figure 5: Experiments on Washing Rough Fibers.

с

Accordingly, considering the above mentioned, it very well may be reasoned that it has been proposed as a rule another mechanical line for the creation of fiber from human-made waste. The limit of the new line is as much as 2 tons of fiber for each move. The phases of fiber preparation are introduced in Figure 6. The principle highlight of all arrangements is a noteworthy decrease in underway expenses, for the most part, because of vitality productivity [1].

а b Figure 6: Stages of Fiber Processing (a) and the Finished Product (c).

To check the utilizing adequacy of the got items utilizing new innovation, trial investigations of new fiber and SFRC on its premise were directed, so as to demonstrate their appropriateness in present-day development creation, to ensure certain physical and mechanical attributes of the SFRC adequate for the plan of building structures. Trial investigations of the new fiber and SFRC on its premise were directed as per the prerequisites of worldwide standards and guidelines. A few examples acquired during the examinations have appeared in Figures 7, 8 and 9. The discoveries are gotten in the accompanying area [1].

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Figure 7: Field Tests of a New Fiber.

(а) Concrete Cube (b) Reinforcing (1%), (c) Reinforcing (2%) Figure 8: Pieces of SFRC Cubes after the Compression Test.

(а) Concrete Cube

(b) Reinforcing (1%), (c) Reinforcing (2%) Figure 9: Pieces of SFRC Prisms after the Tensile Test.

3. RESULTS 

New methods and devices for steel fiber production from technogenic waste - withdrawn from consumption wires and cables of technological equipment are proposed [1].



The establishment of the pilot and industrial sample of the innovative line for the fiber production from technogenic waste (for the further production of SFRC) has been approved [1].



Pilot studies are conducted, and effective operating modes of the new equipment are determined. At the same time, energy consumption in comparison with analogs is lowered on 40 ….50%.



Using technogenic waste fiber, cost (respectively and steel-fiber reinforced concrete) can be reduced in 2... 2,5 times that proves cost efficiency of application of the proposed solutions.



Studies of SFRC, obtained with the use of new fiber, showed that it is not inferior in its performance to fiberreinforced concrete based on industrial fiber from wire. In this case, for some parameters (for example, flexural strength) even exceeds it:



As the analysis showed, SFRC samples with new fiber work for compression in the same way, or very similar, as well as concrete samples. With an increase in the reinforcement percentage in the specimens destruction, the elastoplastic and plastic characters predominate. The compressive strength of SFRC samples is slightly lower than the strength of concrete samples (up to 6... 8%).



Testing samples of SFRC prisms with new fiber for tension, the nature of the destruction was predominantly

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plastic. With an increase in the reinforcement percentage, the load in the breakage remained constant for some time, which characterizes the SFRC from the positive side. The tensile strength of the SFRC samples is higher than the strength of concrete samples in 1.6... 2.8 times. 

Comparing SFRC specimens with fiber from waste ropes and factory-manufactured fibers Hendix 1/50, it was found that: the strength of a compression-bonded fiber with fiber from waste ropes is slightly lower than the strength of SFRC by factory Hendix 1/50 (in some cases, up to 12%), the strength of the SFRC with the new fiber for stretching proved to be higher than the strength of the SFRC with the factory manufactured Hendix 1/50 fiber in 1,3... 1,9 times.

4. CONCLUSIONS The complex of hypothetical and trial investigations of new innovation and gear for the waste handling permitted proposing new arrangements in this field. The information permit is talking about the further business prospectivity of the presentation of the offered choices. During the time spent further undertaking usage, it is normal that the proposed innovation and gear will be settled in modern pilot conditions. The introduced outcomes filled in as the reason for the making of an imaginative creation venture for fiber creation from technogenic squander. The creation of the enterprise is currently carried out through a joint grant from the government of Kazakhstan and the World Bank. The amount of the grant (the cost of the project) is about 400,000 US dollars. The term of the grant is 3 years. The estimated volume of new products is up to 500... 600 tons of fiber (from industrial waste) per year [1].

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747–758 27. Baigereyev S., Guryanov G. New method for increase in product fineness in stirred mills. Archives of Civil and Mechanical Engineering. 2019, №3, pp. 768-778. DOI: 10.1016/j.acme.2019.03.003 28. B. Abdeev, S. Baigereyev, G. Guryanov, Generalized dynamic theory of a solid particle grinding by pulse-force compression with two non-deformable balls, PNRPU Mechanics Bulletin, 4 (2018), pp. 278-289. DOI: 10.15593/perm.mech/2018.4.25 29. Mikhail Doudkin, Alina Kim, Andrey Savelyev, Mikhail Zhileikin, Vladimir Gribb, Valeria Mikhailovskaya. Modernization of the Metal Structure of the Grader Working Equipment. International Review of Mechanical Engineering. Vol 14, No 1 (2020) 30. Аizhan Zhaparova, Dimitry Titov Alexander Baklanov, Study of the Effectiveness of Switching-on LED Illumination Devices and the Use of Low Voltage System in Lighting печатный Acta Polytechnica Hungarica., Vol. 12, No. 5, 2015, pp.7180doi.org/10.12700/APH.13.5.2016.5.6 31. A.T. Zhaparova, A.E. Baklanov, D.N. Titov. Improving the Efficiency of Led Lighting by Switching to Low-voltage Technology Published: 2015 in Procedia Engineering https://doi.org/10.1016/j.proeng.2015.12.028

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