New Innovative Process of Calcium Carbonate Generic Integration Preparation to Boost Enterprises to Walk up a Self-help Development Road
Calcium carbonate is a kind of filler with the largest amount of production and application. The product features of calcium carbonate have been developed from general filling materials to functional materials in recent ten years, with diversified, functional and refine. Various crystal types, different size and surface modification products have appeared with more extensive use. It can be widely used in manufacture of rubber, plastics, paper, paint, ink, cable, construction, food, medicine, textiles, feed, toothpaste, feed, cosmetics, and 3D printing materials, leather and other industries.
Calcium carbonate is an important inorganic powder product, which has been used for more than one hundred years. Natural calcium carbonate is a non-toxic, tasteless, odorless substances, widely distributed in nature in the forms of limestone, marble and coral etc., it is very rich in reserves with the characteristics of low price, wide source etc. The calcium carbonate products obtained by processing of natural calcium carbonate have the additional advantages of high whiteness and high added value.
China is one of the countries with rich limestone resources in the world. According to statistics of the former National Bureau of Building Materials Geological Center, the national limestone area is 438 thousand Km2 (not including Tibet and Taiwan Province), accounting for about 1/20 of the land area of China. If we make scientific and effective utilization of limestone resources, cultivate and train leading enterprises at home and import foreign key enterprises, import and develop advanced process to produce high-end products with high technology, as well as Nano, ultra-fine activated calcium and other deep-processing products. We can build an enterprises union for green downstream supply chain of calcium carbonate industry, to achieve cluster development, and quickly create a group of 10 billion yuan enterprises and industrial park cultivating leading domestic and foreign enterprises and the introduction of key enterprises, and it will become an important new growth pole of regional economic development.
In recent years, Hubei University Tianshu Industrial Research and Design Institute of New Energy Materials (Tianshu IRDI) has unremittingly create an innovation way for small and medium sized enterprises in building materials industry, help enterprises to change the mode of economic growth and walk up a fine, special and hi-tech road. Convert excess capacity to upgrade of consumption, realizing the transformation and upgrading of traditional manufacturing. The key technology and process for preparation of calcium carbonate integrated system with our independent intellectual property rights, boost the transformation and upgrading of many small and medium sized enterprises under the background of the supply side structural reforms in China, to solve the problems unfavorable resources investment, low operation ability etc., and realize the wish of economic take-off.
I. High-quality Gravel Aggregate
Adopting the most advanced and optimal processing integrated design of the mining and processing, making full use of limestone, stone and mine rubbish, through the crushing system, sieving and conveying system, centralized control system, multi-level dedusting system and the container empty room, to produce 10000 tons of fine aggregate and meet the requirements of energy saving, high yield and low emission.
The production line can be used to process all waste rock into fine sand and gravel aggregate in the mining area, and there would be many effects of the whole mining area:
1) Environmental benefits are obvious: Making full use of mineral resources, the entire ore and rock can be used as aggregate raw materials, mines can reach zero emissions, which saves land and reduce secondary pollution;
2) Slump in production cost: Integrated mining and processing production can shorten the transport distance of mineral products, reduce transport investment, diluted aggregate production costs;
3) Economic benefits are obvious: the profit fine aggregate is nearly 40 RMB/t, according to an annual yield of 2.5 million tons of fine aggregate, the annual profit would be 100 million yuan. Meanwhile, profit of machine-made sand is 60 RMB/t, according to an annual yield of 300 thousand tons, and the annual profit would be 18 million RMB.
4) The social benefits are obvious: the market demand of fine aggregate and sand aggregate is huge, and the products can be used in various types of engineering buildings as well as various grades of concrete.
II. Precipitated Calcium Carbonate /Light Calcium Carbonate
Limestone and other raw materials calcined lime (mainly calcium oxide) and carbon dioxide, added water we get lime milk (mainly calcium hydroxide), and then fill carbon carbon dioxide in the milk, calcium carbonate will precipitate, through dehydration, drying and crushing we can get light calcium carbonate.
Calcium carbonate is widely used as a filler for 3D printing materials, pharmaceutical, leather, rubber, plastic, paper and paint, ink and other industries, as well as powder, toothpaste, cosmetics etc., daily chemical products. Moreover, it is also used as a binder, sealant in production of organic synthesis, metallurgy, glass and asbestos.
With the development of technology and the needs of human, the application field and demand of calcium carbonate are expanding, and it has a long-term development prospect and broad application space. Calcium carbonate industry can make full use of calcite, limestone with the advantages of rich in resources and easy to exploit, forming a special industry of mining and powder processing. It can create a serial of complete industrial chain and value chain, with a new growth engine. It is also a strategic industry, plays an important role in promoting transformation and upgrading of related industries and growth of the regional economic.
Due to cheap resources of limestone and calcite, processed by high-tech equipment and technology, we can get special crystal form of has no special natural calcium carbonate which is not exist in natural environment. It would have high application performance and technical added value. So that calcium carbonate industry will still be a sunrise industry with sustainable development and great achievements in twenty-first Century.
Our institute has independently designed an annual yield of 1 million tons of high activity calcium oxide production line, the profit of calcium oxide is 300 RMB/t, so that the annual profit is 300 million RMB.
III. Nano Calcium Carbonate
In recent years, with the emergence of Nano and ultra-fine technology, calcium carbonate has entered the Nano era, and has led to the rapid development of the fields of paper making, plastics, rubber, medicine and food industry. Nano calcium carbonate is a new type of high-grade inorganic functional filler, it is currently the only one with price per ton less than 10 thousand RMB in Nano materials, and its products have been widely used in rubber, plastic, paint, building materials, paper, textile, leather, printing, sealants, inks, cosmetics, food, feed, medicine, to be as filler, additive and reinforcing agent and modifying agent and brightener, characterized by saving masterbatch, compatibilization increment, reduce costs and improve product quality, enhance product function and improve product added value.
At present, the demand of Nano and ultra-fine grade calcium carbonate and active calcium is increasing in western developed countries, and just in plastic the demand is 9 million tons/year. The production and market of Nano and ultra-fine calcium carbonate are matured abroad, and large-scale industrial production has been formed.
China's Nano and ultra-fine calcium carbonate production started late, there are only a few Nano and ultra-fine calcium carbonate production enterprises, and the production yield is only several hundreds of thousands of tons. With a new round of technological revolution and the industrial revolution, and requirements of improve the quality of calcium carbonate products on the downstream of the green supply chain industry, market demand of high-end product will keep increasing with the rapid development of China, the average annual increase quantity is 200 thousand tons.
Nano and ultra-fine calcium carbonate produced by carbonization, with the characteristics of ultra-fine and pure, it can effectively control the crystal type and particle size in the production process. It has good compatibility of Nano calcium carbonate and rubber through the surface modification, thus showing a spatial structure in the rubber, fundamentally change the performance of rubber products.
In the rubber industry of developed countries, Nano calcium carbonate has been widely used in oil seals, auto parts, even in tire, belt and other industries. It is not only can be used as a reinforcing filler in conjunction with other packing production needs such as carbon black, light calcium or calcium carbonate, kaolin and titanium dioxide. To fill strong, filling, color, improve process and product performance, reduce binder content or replace some of the imported white filler titanium dioxide, white carbon black and other white expensive fillings.
At present, requirements of particle size, surface modification and product application of calcium carbonate are higher, we should produce various specifications of products to meet the market demands. ultrafine grain, surface modification and industrial application become the development direction of calcium carbonate. Nano calcium carbonate as a technology with high content and high added value, it is a sunrise industry, having great social and economic benefits.
Our institute has independently designed an annual yield of 100 thousand tons of Nano calcium carbonate production line, the profit of calcium is 3200 RMB/t, so the annual profit would be 320 million RMB.
From May 2015 to June 2017, the Nano calcium carbonate production line designed by our institute in Shandong, Guangxi, Hunan and other enterprises have put into operation or construction, which help enterprises to realize the transformation in the structure, increase motive power, exploit advantages and make up the short boards. They have walked up a self-help development road under the new normal background of national economic growth.