One of the most pressing challenges of the new construction and maintenance of existing buildings and structures is a hydroprotection and restoration of the bearing capacity of building structures Water acts on structures in the outer or inner side atmospheric and groundwater ID: 441321
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Slide1
Urgency
One of the most pressing challenges of the new construction and maintenance of existing buildings and structures is a hydro-protection and restoration of the bearing capacity of building structures. Water acts on structures in the outer or inner side (atmospheric and groundwater).
In the spring thaw raises the groundwater level (GWL), which interact with mineral and organic particles, change their chemical composition and concentration. Groundwater level fluctuations activate the leaching of lime in concrete structures. Rainwater captures from the atmosphere of a large number of gaseous industrial emissions. Is converted to the acid rain solution destroying concrete, marble, silicate bricks, this increases the number of pores, capillaries, and cracks.
For protection of various constructions from surface wear and cracking, i.e. from the harmful effects of water and aggressive environment use various waterproofing materials (based on cement, bitumen, polymer).Slide2
Urgency
Relevant environmental, technical and economic problem in many countries is the utilization of sulfur formed as waste oil and gas, the amount of which is increasing every year, reaching several million tons.
Processing of low-cost sulfur is economically viable and could solve the environmental problem in any region.
The pollution of the environment sulfur dust, which in windy weather spreads over long distances. Are often sulfur dust explosions occur.Slide3
LLC «
Gubkin E & TC» has developed a unique product - a waterproof coating on the basis of polymeric sulfur, which would solve two problems at once: Slide4
The application of waterproofing coatings based on highly polymerized sulfur
The lining and protection of underground facilities
Waterproofing underwater, waterworks
Waterproofing dams, bridge piers, quays
Waterproofing pools, reservoirs, ponds
Waterproofing of building structures in the disposal of chemical wasteSlide5
Examples of constructions which can be used for waterproof coating on a highly polymerized sulfur:
Hydraulic facilities:
Reservoirs (open, diked etc.)Swimming pools (open and closed)
ManholesDocksBerthsThe design of treatment facilities (aeration tanks, septic tanks, sewers, pumping, etc.)concrete seawall
Dams, etc.Civil engineering structures:
FoundationsBasementsUnderground facilities (parking lots, garages, transitions, etc.)BalconiesLift shaftsSlide6
Examples of constructions which can be used for waterproof coating on a highly polymerized sulfur:
Industrial and agricultural facilities:
Industrial premisesPools of cooling towersVaultsChimneysMines
BinsConcrete structures exposed to aggressive action, etc.
Objects of energy sector:Spent nuclear fuel poolsPumping stationsStorage of spent nuclear fuelCanals
Overpass of fuelCable tunnelsSlide7
Examples of constructions which can be used for waterproof coating on a highly polymerized sulfur:
Objects of Defense and Emergencies :
SeekersFire tanks, etc.
Concrete structures exposed to radiation, etc. Transport infrastructure :
Tunnels (road, rail, walking, etc.)SubwaysThe elements of bridges and roads, etc.Slide8
The benefits of an innovative product
:Slide9
Market
Construction is one of the most important sectors of the national economy. Its condition largely determines the level of development of society and its productive forces.
Along with the development of the construction industry is growing demand for high-performance waterproofing coating. Existing on the market waterproofing materials have a number of drawbacks, such as high cost, low efficiency, fragility, low resistance to aggressive media, etc.
Thus, an innovative product - the waterproof coating on the basis of a highly polymerized sulfur will be worthy competition to existing waterproofing materials on the market and the demand is expected to be high.Slide10
Areas of use of an innovative product
Thus, the implementation of technology applied waterproofing coating can be carried out at the plants by entering additional workshops, as well as at the location of the object, using compact equipment necessary for the application of a waterproofing coating.
Waterproofing at during manufacture of building materials
Waterproofing on stage repair of finished constructionsSlide11
Technologies of drawing of waterproofing coating based on a highly polymerized sulfur on building materials:
Complete impregnation
In the first method the impregnation is carried out by dipping the product in the chamber with the melt impregnation of polymeric sulfur. This flow chart is best suited for permanent installation, for example, at an operating plant of concrete products as a complementary technology unit in which part of the products produced by the plant can be processed in the melt of polymeric sulfur. Possible to use this method for operating a mobile unit in which the impregnation products operate on site immediately before installation (for example, prior to impregnation pile elements clogging or zero cycle before their installation). The first method is used when processing prefabricated usually new, not yet assembled products. The depth of infiltration is provided and monitors the flow rate of the solution in the bath for impregnation cycle.
Surface impregnation
By the second method the melt polymeric sulfur applied to the surface of structures by brushing, rolling, spraying, or by another similar device. The method can be used for precast have not yet mounted structures and elements for existing buildings, including at their repair or reconstruction.Slide12
Embodiments of an innovative productSlide13
The calculation of the construction unit for production of polymeric sulfur capacity - 6000 tons / year. This will get the following amounts of development of technology:
The impregnation of concreteComplete impregnation requires the consumption of a building material for 1m3 approximately 6kg, which will handle about 1 000 000 m3 of building products.
A melt flow of polymeric sulfur per 1m2 for surface treatment is 0.8-1.0 kg. It will handle more than 6000000 m2 of surface.The impregnation of bricks
Complete impregnation of one brick requires the consumption of 0.11 kg of polymeric sulfur, which will handle nearly 54 mln bricks.In 1m2 masonry contains 51 brick, hence the polymer sulfur flow rate per 1m2 at full treatment is 51 * 0.11 = 5.61 kg.
A flow of polymeric sulfur per 1m2 for surface treatment is 0.8-1.0 kg. It will handle more than 6 000 000 m2 of surface.In 1m3 masonry contains 394 bricks, from here on 1m3 brick masonry with full treatment takes about 394 * 0.11 = 43.34 kg.Slide14
Technological scheme of the unit for the preparation of polymeric sulfur in 3DSlide15
Overview of the equipment needed to produce polymeric sulfur
Storage tanks and sulfur stabilizer, equipped with electric paddles and heating jacket, coolant - superheated steam.
Reactor-mixer for preparing a composition of liquid sulfur and stabilizer: equipped with a paddle stirrer with electric and heating jacket, Heat carrier - superheated steam.
Fridge-crystallizer scraper, refrigerant: cooling water or liquid propane from propane refrigeration cycle.Heater - heat exchanger scraper, Heat carrier - superheated steam;Pumps;
Dispensers.Slide16
Safety and environmental project
In the solid polymeric sulfur (polymerization degree 75-80%) -
fire resistant material, non-toxic, hazard class 4. Liquid sulfur is non-toxic. Melting point-120°C, the temperature of spontaneous combustion 575 °C. Solid polymeric sulfur is in the glassy state and does not generate sulfur dust.
Liquid polymeric sulfur in the overflow and storage (in direct contact with oxygen in air) generates sulfur dioxide (SO2) in a small amount (within the maximum allowable concentration). The maximum permissible concentration (MPC) for airborne concentrations are: for sulfur dioxide - 10 mg/m3. Monitoring the MPC is the local branch of environmental control. Polymeric sulfur is not more toxic compounds forms in the air and waste waters in the presence of other substances and it has no cumulative properties.
On this innovative product is designed MSDSSlide17
Safety and environmental projectSlide18
Calculation of income from the sale of polymeric sulfur
Item name
Amount
, in tons / year
Unit price of,
EUR / ton
Overall, EUR / year
Sulfur Polymer, including:
6 000
-
sulfur from the gas processing
5 940
37.5
222750
-
stabilizator
60
1875
112500
Total raw materials
6 000
335250
Sulfur Polymer
6 000
200
1200000
Total income
864750Slide19
Technical and economic characteristics of the installation for the production of polymeric sulfur capacity of 6000 tons / year
№
data
module
units of
1
Annual operating mode
час.
8 000
2
Commercial products in
natural units
:
2.1
Polymeric sulfur
tons / year
6 000
3
Commodity output
EUR
1 200 000
4
Growth of commodity products
EUR
864750
5
Additional operational expenses
EUR
350000
6
Profits tax
EUR
103000
7
Net income for the year
EUR
411875
8
Capital expenses
EUR
432497,5
9
Payback period
year
1,05Slide20
The dynamics of growth of tariffs for raw materials, wages, operating costs and the cost of commodity product
data
normative,%
module
today
after 1 year
after 2 year
after 3 year
after 4 year
after 5 year
wages
8
EUR / year
25467
1
275045
29704
9
320812
346477
3749
60
the cost of electric power
2,5
EUR / year
78
000
7995
0
8194
9
8399
8
8609
8
882
50
operating costs (transport, replacement materials, service)
2
EUR / year
14178
1446
2
1475
1
1504
6
1534
7
1565
4
raw material costs
1,5
EUR / year
33525
0
34027
9
345383
35056
4
355822
3611
60
commodity price of the product
2,3
EUR / year
200
204
,
5
209
,
2
5
214
219
224Slide21
The dynamics of growth of wages, insurance premiums and tax payments
тыс. руб.Slide22
Technology of production of building materials with a waterproofing coating
This technology is to fully melt impregnation of building materials, and polymeric sulfur can be carried out directly on plants producing building materials.
Below are the results of calculations of this technology for the impregnation of concrete and brick. The calculation for each construction material is kept separately.Slide23
The calculation of the capital cost of the introduction of the installation for applying a waterproofing coating for building materials
№
Name of equipment and costs
Number of units
.
Required Ratio% of the cost
Unit price of,
.
EUR
Sum
,
EUR
.
1
basic equipment
:
1.1
Heated tank for liquid polymeric sulfur
1
16250
1
6
2
50
1.2
The conveyor-belt
1
50
000
50
000
1.3
Other
25
00
Total capital equipment
6875
0
2
Iinstrumentation
20
13750
3
Shut-off and control and relief valves
30
20625
Total equipment
34375
4
Transportation, harvesting and storage costs
10
1031
3
5
Dismantling, assembly
15
1546
9
6
Project work
50
5156
3
Total capital expenditures
18046
9Slide24
Calculation of income from the sale of building materials with a waterproofing coating of polymeric sulfur.
Waterproofing concrete
Waterproofing brick
Item name
Number of m3 / year (concrete cubes)(S, ton/year)
Unit price of,
EUR./ м3
Sum
,
mln
EUR
.
/
year
Raw materials, including:
-
concrete
1 000 000
100
100
-
polymeric sulfur
6 000
200
1,2
Total raw materials:
101,2
concrete with waterproofing coating
1 000 000
110
110
Total income
8,8
Item name
Number,
ths
units / year
(S, ton/year)
Unit price
,
EUR
/
ths
units
Sum
,
mln
EUR
.
/
year
Raw materials, including:
-
brick
53
93258
300
16
,
179
8
-
polymeric sulfur
6 000
200
1,2
Total raw materials:
17
,
379
8
brick with waterproofing coating
53 93258
337,5
18
,
202
3
Total income
0,
822
5Slide25
Technical and economic parameters of the unit for applying a waterproofing coating for building materials
Waterproofing concrete
№
Data
module
U
1
Annual operating mode
hour
2
Commercial products:
2.1
Concrete with waterproofing coating
м3
1 000 000
3
Cost of commodity production
ths
. EUR
110
000
4
Growth of commodity products
ths
. EUR
8800
5
Additional operational expenses
ths
. EUR
8388,
2
6
Profits tax
ths
. EUR
82,36
7
Net income for the year
ths
. EUR
329,44
8
Capital expenses
ths
. EUR
180,4
7
9
Payback period
year
0,55
Waterproofing brick
№
Data
module
U
1
Annual operating mode
hour
2
Commercial products:
:
2.1
Brick with waterproofing coating
ths
units
53 93258
3
Cost of commodity production
ths
. EUR
18202
,3
4
Growth of commodity products
ths
. EUR
822,
5
5
Additional operational expenses
ths
. EUR
701,
4
6
Profits tax
ths
. EUR
24,21
7
Net income for the year
ths
. EUR
96,8
6
8
Capital expenses
ths
. EUR
180,4
7
9
Payback period
year
1,86Slide26
The dynamics of growth of tariffs
Waterproofing concrete
data
normative,%
module
today
after 1 year
after 2 year
after 3 year
after 4 year
after 5 year
wages
8
Ths
EUR / year
254,67
275,05
297
,
0
5
320,81
346,4
8
374,
20
the cost of electric power
2,5
Ths
EUR / year
8125
8328,1
3
8536,3
3
8749,7
4
8968,48
9192,69
operating costs (transport, replacement materials, service)
2
Ths
EUR / year
7,01
7,15
7,
30
7,44
7,59
7,74
raw material costs
1,5
Ths
EUR / year
101200
102718
10425
9
10582
3
1074
10
109021
commodity price of the product
1,7
Ths
EUR / year
0,11
0,11
18
0,113
8
0,115
8
0,117
8
0,119
8Slide27
The dynamics of growth of tariffs
Waterproofing brick
data
normative,%
module
today
after 1 year
after 2 year
after 3 year
after 4 year
after 5 year
wages
8
Ths
EUR / year
254,67
275,05
297
,
0
5
320,81
346,4
8
374,
20
the cost of electric power
2,5
Ths
EUR / year
438,2
449,1
6
460,3
9
471,
9
483,69
495,7
9
operating costs (transport, replacement materials, service)
2
Ths
EUR / year
7,01
7,15
7,
30
7,44
7,59
7,74
raw material costs
1,5
Ths
EUR / year
173
8
17640,
5
17905,
1
18173,7
18446,
3
18722,9
commodity price of the product
1,7
Ths
EUR / year
0,3375
0,34325
0,349
0,355
0,361
0,36725Slide28
The dynamics of growth of wages, insurance premiums and tax payments
тыс
. руб
.
Waterproofing concrete
Waterproofing
brickSlide29
conclusion
:ООО «Губкинский инженерно-технический центр»http://gubkin-etc.ru/
Necessary information from the customer to design the plant for the production of polymeric sulfur:
Productivity of the plant;
Information about the initial temperature of the raw sulfur coming to the plant;
Type of refrigerant (propane, ammonia, water) and parameters (t, P);
Selection of shipment (packaging) of the finished product (type, size of package).Slide30
Comparative characteristics of waterproof materials and placement of seats in accordance with the evaluation criteria
The
evaluation criteria
Type of waterproofing material
Waterproofing on the basis of polymeric sulfur
Waterproofing cement-based
Waterproofing bitumen-based
P
olymer waterproofing
Cost-effectiveness (cost / expense)
0,2 € /m
2
1,75 € /m
2
3,2 € /m
2
15 € /m
2
Efficiency (ratio of water absorption)
durability
Comparable with the lifetime of the building material
Comparable with the lifetime of the building material
15
years
20-30
years
The need for pre-treatment
Pretreatment is not needed
required surface preparation
required surface preparation
requires careful preparation of the surface
Safety and environmental
-
operation
at
elevated
temperatures
operation at elevated temperatures;
- hazardous emissions into the atmosphere
Resistance to aggressive environments
Total:
2
4
1
3
1
4
3
2
1
2
1
2
4
3
1
3
4
3
1
4
2
1
3
2
2
4
3
1
2
4
3