Ministry of Industry building materials USSR
UNION NORMS
TECHNOLOGICAL DESIGN OF ENTERPRISES
FOR PRODUCTION OF PRODUCTS FROM CELLULAR
AND DENSE AUTOCLAVE CONCRETE
ONTP-09-85
Ministry of Construction Materials of the USSR
Approved
by order of the Ministry of Industry
building materials
October 02, 1985 No. 572
Agreed
with Gosstroy of the USSR, State
Committee of the Council of Ministers of the USSR
on science and technology and the Ministry of Health of the USSR
letter No. 45-499 dated 03.09.85
Tallinn 1989
"All-Union norms for the technological design of enterprises for the production of products from cellular and dense autoclaved concrete" contain the basic standards necessary for the development of projects for plants, workshops, technological lines for the production of products from cellular and dense autoclaved concrete.
Recommended for use in the development of standard and individual projects, binding standard projects, as well as in the implementation of projects for technical re-equipment, expansion and reconstruction of existing enterprises.
They are normative and reference material for engineering and technical workers of specialized design organizations.
Developed by institutes:
NIPIsilicate concrete (V.R. Clauson - director of the institute, A.I. Smirnova - responsible executor, L.A. Ivandi - chief specialist, A.A. Grunstam - chief specialist);
VNIIstrom - technology for the production of products from dense concrete (S.M. Medin - Deputy Director for Science, E.N. Leontiev - Head of Department, O.A. Kokovin - Head of Department, Yu.I. Draichik - Acting head of department);
NIPIOTstrom - sections 5, 6 (M.P. Zubchenok - Chief Engineer, N.M. Yudin - GIP, N.S. Nikulchenko - early department, N.S. Filimonova - ch. technologist).
Developed by the State Research and Design Institute for Autoclaved Silicate Concrete NIPIsilicate concrete (Sections 1, 2, 3, 4, 7) and the Research and Design Institute for Gas Treatment Facilities, Safety and Health in the Building Materials Industry NIPIOTstrom (Sections 5, 6).
With the entry into force of these all-Union norms process design ONTP 9-81 "All-Union norms of technological design of enterprises for the production of products from cellular and dense autoclaved concrete" become invalid.
1. GENERAL PROVISIONS
1.1. Application area
These standards apply to the technological design of enterprises and workshops for the production of products from cellular and dense autoclaved concrete using lime or mixed compositions (lime-cement, cement-lime, lime-slag) or shale ash as a binder, and as a silica component - sand and fly ash from thermal power plants.
The use of only cement as a binder is allowed in exceptional cases - in the absence of other types of binder.
The norms are applied in the development of standard projects and their binding, in the development of individual projects, in the construction of new ones, as well as the reconstruction and expansion of existing enterprises, workshops and individual production units.
If there is a lime shop as part of the enterprises, the design of the latter is carried out in accordance with the "Norms for the Technological Design of Lime Production Enterprises".
The design of quarries should be carried out in accordance with the "Norms for the technological design of enterprises in the industry of non-metallic building materials."
The indicators given in the "Norms ..." are not intended to establish planned norms for existing industries.
When developing projects for enterprises, the parameters and indicators of "Norms ..." are specified depending on the range of products, raw materials used and other local conditions.
The regulations provide for compliance with all applicable normative documents(SNiP, sanitary norms and rules, safety and environmental standards).
Products made of cellular concrete must be manufactured in accordance with the requirements of SN 277-80 "Instructions for the manufacture of products from cellular concrete", products made of dense concrete - in accordance with the requirements of SN 529-80 "Instruction for the technology of manufacturing structures and products from dense silicate concrete" .
The technology of forming products from cellular concrete can be selected according to one of the schemes;
flow-aggregate in individual forms;
flow-aggregate with mechanized cutting of the array;
conveyor with mechanized cutting of the array.
In the production of reinforced products using cutting technology, an enlarged assembly of elements is required.
1.2. Product range
The product range may include:
a) products made of cellular concrete:
panels of external walls of residential buildings, buildings for cultural purposes, industrial buildings and agricultural production buildings;
large wall blocks unreinforced;
small wall blocks;
partition plates (blocks);
panels (plates) of coatings;
panels (slabs) of floors;
thermal insulation boards;
sound-absorbing plates "Silakpore";
b) products made of dense concrete;
interior wall panels;
floor panels (slabs);
basement wall blocks;
ventilation panels;
landings;
road slabs;
plinth panels;
silo and drainage trench panels.
1.3. Plant capacity
The capacity of the enterprise is determined by the scheme of development and location of the industry, depending on the need for building materials, as well as the availability of raw material reserves, and is specified by calculations.
small block shop 80000 - 100000
small block plant 160000 - 200000
plant of small blocks and reinforced cellular concrete products 140000 - 175000
shop for products made of dense silicate concrete 50000 - 60000
factory of dense silicate concrete products 100000 - 125000
The calculation of the design capacity of enterprises is based on the performance of the leading equipment (autoclave), the operating mode and the net operating time fund of the equipment.
1.4. Working mode
The mode of operation of enterprises should be adopted: 2-shift work with 305 working days a year or 3-shift work with 260 working days a year.
Heat treatment is carried out in 3 shifts. The duration of the shift is 8 hours.
Reception of raw materials and shipment finished products rail transport is carried out around the clock with 365 working days a year.
1.5. Equipment operating time funds
The nominal annual fund of working time in hours is determined by the formula:
T= N D · N cm · T cm
where N D - nominal number of working days per year;
N cm - the number of shifts per day;
T cm is the duration of the shift, h.
Normative annual fund of time equipment operation in hours:
T about \u003d T K ti K g K cm,
where K ti - coefficient of technical use of equipment;
K g - the readiness factor of the production line section;
K cm - shift time utilization factor.
The coefficient of technical use of equipment:
where T p - downtime due to repairs in one year, h.
Downtime is determined according to the "Regulations on scheduled preventive maintenance of equipment of enterprises for the production of products from cellular concrete." Approximately Kti = 0.95.
Availability factor of the technological line section between the buffer tanks:
K t = K r1 K r2 K r3 ... K r p,
where K r 1 , K r 2 - the availability factor of individual machines and equipment installed in series in the line.
Below are the availability factors of some machines.
Feeders and dispensers 0.99
Ball mills 0.97
Pneumatic pumps 0.99
Homogenizer 0.99
Vibrogas concrete mixer 0.97
Concrete mixer 0.97
Concrete paver 0.97
Vibration platform 0.98
Impact pad 0.98
Cutting machine 0.96
Autoclaves 0.98
Transmission bridge 0.97
Overhead cranes 0.98
Belt conveyors, etc. 0.99
Shift time utilization ratio:
where T cm is the duration of the shift, min;
T pz - time for preparatory and final operations, min;
T ln - time for personal needs, min;
T otd - time to rest, min.
Approximate values of coefficients K cm:
for grinding equipment 0.95
for forming and cutting equipment 0.85
for autoclaves 1.00
for finishing equipment 0.85
for reinforcing equipment 0.90
1.6. Guidelines for determining the number of production personnel
The attendance number of the main production workers is established based on the accepted mode of operation, the level of automation production processes, layout technological equipment, placement of performers in the workplace, taking into account the maximum use of working time and the combination of professions.
The number of workers employed in the repair of equipment is determined based on the program and the labor intensity of repair work in accordance with the "Regulations on preventive maintenance of equipment of enterprises for the production of products from cellular concrete".
The number of auxiliary workers is determined according to the "Norms for the number of auxiliary workers in the production of cellular concrete products."
The list number of workers is determined by the formulas.
Ministry of Machine Tool and Tool Industry
State Design and Research Institute of Industry for the production of products for general machine-building applications (GiproNIImash)
ALL-UNION STANDARDS for technological design of production facilities for the production of products from metal powders based on iron and copper
All-Union Research Institute of Information and Feasibility Studies in Mechanical Engineering and Robotics (VNIITEMR)
Moscow 1986
ALL-UNION STANDARDS FOR TECHNOLOGICAL DESIGN OF PRODUCTIONS FOR OBTAINING PRODUCTS FROM METAL POWDERS BASED ON IRON AND COPPER
DEVELOPED by the GiproNIImash of the Minstankoprom (E.I. Savransky - head; S.I. Chesnova; N.M. Rabinovich), IPM AS of the Ukrainian SSR (V.N. Klimenko, Ph.D. - head; V.S. Pugin, V. A. Kutnyak, E. Ya. Popichenko, Ph.D., O. D. Neikov, Ph.D., G. I. Vasilyeva, Ph.D. .), Giproautoprom of the Minavtoprom (V.F. Marunchak - head; V.Ya. Goldin; E.N. Grigoryeva), Kazakh sanitary project of the State Construction Committee of the USSR (Ya.I. Zilberberg, Ph.D. - head; F.B. Usmanov, G.D. Kuzmina, E.D. Nesterov, V.D. Popova) with the participation of other organizations.
INTRODUCED by GiproNIImash
PREPARED for approval by the Office for Coordinating the Production of General Machine-Building Products (V.G. Shumov).
With the introduction of these ONTP-10-85, the previously developed intradepartmental (industry) norms of technological design become invalid.
General provisions
These standards are intended for use in the design of the technological part of projects for the construction, expansion, reconstruction and technical re-equipment of shops (sites) for the manufacture of products based on iron and copper powders for the mechanical engineering, metalworking and instrument making industries.
Regulatory data for the technological design of workshops (sections) for the manufacture of powders and granules, which are the starting materials for the production of parts, are not included in these standards.
The development of all-Union norms is based on:
1. Instructions on the procedure for the development of new and revision of existing norms for technological design SN 470-75 *, approved by the Civil Code of the Council of Ministers of the USSR on Construction Affairs of March 14, 1975, No. 33.
2. The system of regulatory documents in construction, 1.01.02-83, 1.01.03-83.
3. Survey data of advanced operating enterprises for the production of powder products, as well as data of projects completed in recent years.
Technological design of departments for machining, repair of technological equipment, electrical and sanitary equipment, manufacturing of tools and technological equipment, automation and mechanization means, special and non-standardized equipment is carried out in accordance with the relevant current technological design standards.
The development of standards is based on technical directions that take into account the prospects for the development of powder metallurgy, optimal capacities for the production of products by powder metallurgy using advanced technology, progressive technological processes, the latest high-performance equipment, effective means of mechanization and automation of production processes, progressive forms of production organization, scientific organization labor.
The norms are linked with the requirements of all-Union regulatory documents and instructions for design and construction, sanitary and fire safety standards, safety regulations and security standards environment, state standards and the system of labor safety standards (SSBT).
1. Characteristics of the production of powder products. Classification of productions. Optimum Power
1.1. The production of products from metal powders should be designed taking into account their main characteristics and seriality.
1.1.1. The main characteristics of powder products are their purpose, the material of the main component, mass and shape.
Products are divided:
by appointment - for structural, anti-friction, magnetic, filter and electrical;
by weight - especially small (up to 0.010 kg);
small (from 0.01 to 0.1 kg);
medium (from 0.1 to 0.5 kg);
large (over 0.5 kg);
in form - in accordance with the classification of “Price List No. 25-02. Wholesale prices" .
1.1.2. The classification of production facilities for the manufacture of powder products is made in accordance with the requirements of GOST 14.004-83, taking into account work experience industrial enterprises depending on the breadth of the nomenclature and volumes of production of products and is presented in table 1.
Table 1
Note. The minimum values for the number of parts assigned to a unit of forming equipment refer to presses with a capacity of up to 5 pcs/min, the maximum value - for presses with a productivity of more than 16 pcs/min.
1.2. The optimal production capacity of powder products, in which independent (universal) production units are created, are shown in Table 2.
table 2
|
Production name |
Average weight of products, kg |
Maximum weight of products, kg |
serial production |
Optimal production capacity, thousand tons |
||
|
maximum allowable |
most effective |
|||||
|
Serial and small-scale |
||||||
|
Large scale and mass production |
||||||
|
Serial and small-scale |
||||||
|
Large scale and mass production |
||||||
|
Centralized factories |
All types of production |
|||||
|
The first stage of the plant |
Table 2 lists the most characteristic and common types of powder products production.
Powers less than the values specified in Table 2 can be accepted with appropriate justification, based on the calculation of the optimal power factor (Kom), which must be equal to or greater than 1.6.
Kom \u003d Ksp × Kmso ≥ 1.6, (1)
where Kom is the optimal power factor that characterizes multi-machine maintenance throughout the entire cycle of the technological process, taking into account the use of equipment;
Kisp - the average coefficient of equipment utilization throughout the entire technological cycle;
Kmso - the average coefficient of multi-machine maintenance of equipment throughout the entire technological cycle.
where K1, K2, ..., Km - the utilization rate of each group of technological equipment (without lifting and transport and industrial robots) throughout the entire cycle of the technological process;
n1, n2, ..., nm - the number of pieces of equipment included in one group.
where P is the estimated annual load of equipment per program for groups of all technological equipment (without lifting and transport and industrial robots) throughout the entire cycle of the technological process, h;
T - the labor intensity of the annual program will be determined through P and the density of teams - the reciprocal of the multi-machine service, man-hour;
Some technical and economic indicators optimal production are given in Appendix 7 of Table. 48.
2. Calculation of the amount of equipment. The level of use of the main technological equipment. Annual fund of time of the main technological equipment
2.1. The estimated amount of equipment is determined by the formula
where Нр is the estimated amount of equipment, units;
M - annual program, kg or piece;
n is the estimated productivity of the equipment, taking into account the applied technological process and the specific range of products, kg/h or pcs./h;
Fe - effective annual fund of equipment operation time, h;
K - coefficient taking into account the time for setting up equipment, readjusting and replacing a press tool, depending on the type of production, organizational and technical maintenance.
The value of the coefficient K is given in tables 5, 6.
The choice of technological equipment is determined in accordance with the "Standard technological processes for the manufacture of parts by powder metallurgy", developed by the Institute of Materials Science Problems of the Academy of Sciences of the Ukrainian SSR in 1981; the design capacity of the technological equipment is determined by the passport of the selected equipment, taking into account the accepted technological process and product range.
Annual fund of operating time of the main technological equipment
2.2. The annual fund of the grinding and mixing, classifying, drying, furnace and other equipment is presented in Table 3.
Table 3
|
Type of equipment |
Nominal annual fund of equipment operation time, h |
Losses on PPR, % |
Effective annual fund of equipment operation time, h |
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|
Grinding and mixing and classifying equipment |
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|
Vibrating equipment |
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|
Drying equipment |
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|
Vacuum oil impregnation plants |
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|
Gas preparation plants |
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|
Furnace, thermal equipment |
|||||||||
|
Line for stamping parts (furnaces for heating for stamping, presses) |
USE DISCLAIMER
The text is provided for reference and may not be relevant.
Print edition fully updated to the current date
Ministry of Machine Toolth and instrumental
industry
State design and research
institute of industry for the production of products
general machine-building application
(G iproNIIMash)
UNION NORMS
process design
productions to receive
metal products
iron-based powders and copper
ONTP 10-85
All-Union Research Institute
information and feasibility studies
in mechanical engineering and robotics (VNIITEMR)
Moscow 1986
ALL-UNION STANDARDS FOR TECHNOLOGICAL DESIGN OF PRODUCTIONS FOR OBTAINING PRODUCTS FROM METAL POWDERS BASED ON IRON AND COPPER
DESIGNED BY GiproNIIMash of the Ministry of Stankoprom (E.I. Savransky - head; S.I. Chesnova; N.M. Rabinovich), IPM AS of the Ukrainian SSR (V.N. Klimenko, Ph.D. - head; V.S. Pugin, Ph.D. V. A. Kutnyak, E. Ya. Popichenko, Ph.D., O. D. Neikov, Ph.D., G. I. Vasilyeva, Ph.D. ), Giproavtoprom of the Minavtoprom (V.F. Marunchak - head; V.Ya. Goldin; E.N. Grigoryeva), Kazakh sanitary project of the State Construction Committee of the USSR (Ya.I. Zilberberg, Ph.D. - head; F.B. Usmanov; G.D. Kuzmina; E.D. Nesterov; V.D. Popova) with the participation of other organizations.
VN ESENY GiproNIImash
APM REFERRED for approval by the Office for Coordinating the Production of Products for General Machine-Building Applications (V.G. Shumov).
With the introduction of these ONTP-10-85, the previously developed intradepartmental(industry) norms of technological design.
Note. The minimum values for the number of parts assigned to a unit of forming equipment refer to presses with a capacity of up to 5 pcs/min, the maximum value - for presses with a productivity of more than 16 pcs/min.
where K ohm is the coefficient of optimal powersti , which characterizes multi-machine maintenance throughout the entire cycle of the technological process, taking into account the use of equipment; K isp - average coefficientthe use of equipment throughout the entire technological cycle; To mso - medium th coefficient of multi-machine maintenance of equipment throughout the entire technological cycle. where K 1 , K 2 , ..., K m- coefficient of use of each group of technological equipment(without lifting and transport and industrial robots) throughout the entire cycle of the technological process; n 1 , n 2 , ..., nm- the number of pieces of equipment included in one group. where P is the estimated annual load of equipment per program for groups of all technological equipment (without lifting and transport and industrial robots) throughout the entire cycle of the technological process, h; T - the complexity of the annual program will be determined through P and the density of teams - the reciprocal of multi-machine maintenance, th l.-h; Some technical and economic indicators of optimal productionin are given in the appendix table. . 2 . Calculation of the amount of equipment. The level of use of the main technological equipment. Annual fund of time of the main technological equipmentwhere H p - the estimated amount of equipment, units; M - annual program, kg or pcs.; n- the estimated performance of the equipment, taking into accountapplied technological process and specific range of products, kg/h or pcs/h; Ф e - effective annual fund of equipment operation time, h; K - coefficient taking into account the time for setting up equipment, readjusting and replacing a press tool, depending on the type of production, organizational and technical maintenance. The value of the coefficient K is given in tables , . The choice of technological equipment is determined in accordance with the "Typestechnological processes for the manufacture of parts powder metallurgical method and”, developed by the Institute of Problems of Materials Science of the Academy of Sciences of the Ukrainian SSR in 1981; the design capacity of the technological equipment is determined by the passport of the selected equipment, taking into account the accepted technological process and product range. Annual fund of operating time of the main technological equipment | Losses on PPR, % | Effective annual fund of equipment operation time, h |
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| shifts | shifts | shifts |
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| Razmoln o-mixing and classifying equipment | 1830 | 3660 | 5490 | 1793 | 3550 | 5270 |
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| 2070 | 4140 | 6210 | 2010 | 3975 | 5835 |
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| Drying equipment | 2070 | 4140 | 6210 | 2010 | 3975 | 5835 |
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| 1830 | 3660 | 5490 | 1775 | 3514 | 5216 |
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| 6490 | 5970 |
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| Furnace, thermal equipment | 4140 | 6490 | 3975 | 5970 |
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| Line for stamping parts (furnaces for heating for stamping, presses) | 4140 | 6210 | 3910 | 5835 |
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Time funds of equipment not presented in the tablece, take according to ONTP 06-80.
| Rated force, kN | Nominal annual fund of equipment operation time, h | Losses on PPR, % | Effective annual fund of equipment operation time, h |
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| shifts | shifts | shifts |
||||||||
| Automatic machines mechanical | Before 1600 | 4140 | 6210 | 3809 | 5651 |
|||||
| St. 1600 | 4140 | 6210 | 3685 | 5465 |
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| Hydraulic machines | Before 1600 | 4140 | 6210 | 3685 | 5465 |
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| St. 1600 | 4140 | 6210 | 3519 | 5154 |
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| Rated force, kN | Coefficient taking into account the time for setting up equipment and changeover of a press tool, K |
|||
| type of production |
||||
| small-scale | medium series | large-scale and mass |
||
| Automatic machines * | 0,06 - 0,15 | 0,06 - 0,1 | 0,05 |
|
| Hydraulic machines | Before 1600 | 0,09 - 0,19 | 0,06 - 0,08 | 0,05 |
| St. 1600 | 0,11 - 0,2 | 0,07 - 0,1 | 0,06 |
|
* With the use of mechanization when setting up stamps.
| Equipment utilization factor, not less than |
|
| Grinding-classifying and mixing equipment | 0,80 |
| Vibrating equipment | 0,80 |
| Drying equipment | 0,85 |
| Vacuum oil impregnation plants | 0,85 |
| Gas preparation plants | 0,85 |
| Termice kiln equipment | 0,85 |
| Mechanical presses | 0,85 |
| Press s-automatic hydraulic | 0,81 |
Shift ratio of the main technological equipment
where e P 1 , P 2 , P 3 - the number of pieces of equipment operating respectively in the first, second and third shifts;
P - the number of pieces of equipment installed.
Enlarged norms of areas per unit of equipment
| equipment identification | Technical specifications or model 1 | Area, m2 |
|
| 1. Mixing equipment | |||
| 1.1. | Mixers with working capacity | Up to 100 kg | |
| From 100 to 250 kg | |||
| St. 250 kg | |||
| 1.2. | Crushers, mill | ||
| 1.3. | Mechanized complexes for unloading bags, sieving and preparing mixtures for the annual production of products 1 | up to 600 t | 400 - 500 |
| From 600 to 5000 tons | 600 - 800 |
||
| From 5000 to 10000 tons | 1400 - 1600 |
||
| St. 10000 t | 1600 - 2000 |
||
| 2. I form equipment | |||
| 2.1. | Mechanical machines for pressing powder products with a nominal force of 2 | up to 1000 kN | 30 - 50 |
| From 1000 to 4000 kN | 60 - 80 |
||
| Over 4000 kN | 80 - 110 |
||
| 2.2. | Automatic hydraulic presses for pressing powder products with a nominal force of 2 | up to 4000 kN | 70 - 90 |
| Over 4000 kN | 100 - 120 |
||
| 2.3. | Mechanical automatic machines for calibration of powder products with nominal force | up to 630 kN | |
| From 630 to 1600 kN | |||
| From 1600 to 4000 kN | |||
| 3. Electrothermal wallpaper ore mining | |||
| 3.1. | Pusher electric furnaces for sintering | STN-2.45.1.6/11.5 | |
| STN-2.45.1,6/13 | |||
| 3.2. | Electric Walking Hearth Sintering Furnaces | SYUN-3.5.66.1/12.5 | |
| About KB-1582 | |||
| 3.3. | Conveyor electric furnaces for sintering | SKZ-6.95.1.2/11.5 | |
| SKZ-4.40.1/11.5 | |||
| 3.4. | Shaft electric furnace for steam-thermal oxidation | SShO-6.12/7 | |
| 3.5. | Electro ovens for normalization, type | STZZ-5.40.5/10B2 | |
| 3.6. | Rotary electric furnaces for heating workpieces for hot stamping | SAZ2 1.11.3/12-M01 | |
| 3.7. | Gas preparation plants with hourly output | 16 m 3 | |
| 30 - 60 m 3 | |||
| 125 m 3 | |||
| 4. Other equipment | |||
| 4.1. | At vacuum oil impregnation machine | ||
| 4.2. | Ma packing tires |
Notes . one . Large areas should be taken when crushing and grinding operations are included in the complex.
| equipment identification | Rated force, kN | Span, m | Distance between columns in the middle row, m | Heights before tightening trusses, m | Handling equipment |
|
| Automatic machines (mechanical, hydraulic) for pressing powder products, mixers, vibrating screens, mills | Before 1600 | 18 - 24 | Overhead crane with a lifting capacity of 3.2 t |
|||
| Integrated mixing system | 12,6 | |||||
| Hydraulic press machines, machines for calibration, stamping, automatic hammer for high-speed pressing of powder products | Up to 10000 | 18 - 24 | 12,6 | |||
| Automatic rotary machines for pressing products from metal and non-metal powders | 100; 250 | 18 - 24 | Overhead crane with a lifting capacity of 2 t |
|||
| Electrothermal and gas preparation equipment | 18 - 24 | Overhead crane with a lifting capacity of 5 t |
Note . The table is based on GOST 23837-79.
Dl When designing multi-storey industrial buildings, it is recommended to use GOST 24337-80.
Height Calculation Method production building is based according to the summation of the maximum height of the equipment, the overall dimensions of products and vehicles.
Norm s widths of aisles and driveways
| Mechanical and hydraulic automatic presses, nominal force, kN | |||||||
| 3600 | 2500 | 9500 | 7000 | 2500 | 6000 |
||
| 3600 | 2500 | 9500 | 7000 | 2500 | 6000 |
||
| 3700 | 2900 | 9500 | 7000 | 3000 | 6000 |
||
| 1000 | 3900 | 2900 | 9500 | 8000 | 3000 | 6000 |
|
| 1600 | 4100 | 4200 | 9500 | 8000 | 3500 | 6000 |
|
| 2500 | 4300 | 4500 | 10000 | 8000 | 3500 | 6000 |
|
| 4000 | 4500 | 6000 | 10000 | 8000 | 4000 | 6000 |
|
| 6300 | 4500 | 8500 | 10000 | 9500 | 4500 | 6000 |
|
| 10000 | 5000 | 8500 | 10000 | 13000 | 6000 | 6000 |
|
Notes: 1. When installing equipment on individual foundations, the dimensions indicated in the table are specified according to the drawings of the shaping equipment adopted in the project, taking into account the dimensions of the foundations and building structures.
Automatic mechanical devices for calibrating products from metal powders, nominal force, kN
Dimensions of distances, mm, not less than
3000
1200
8000
3000
2000
5500
3000
1300
8000
3000
2000
5500
3500
1400
8000
3500
3000
5000
1000
3500
1500
7500
3500
3000
5000
1600
4000
1500
7500
4500
3500
5000
2500
4000
1500
7500
5000
4000
4500
4000
4000
1500
7500
5500
4000
4500
Notes: 1. When installing the equipment onindividual foundations, the dimensions indicated in the tables are specified according to the drawings of the calibration equipment adopted in the project, taking into account the dimensions of the foundations and building structures.
Norms of distances, mm
Impregnation tanks
3000
4000
2500
Mechan insulated parts impregnation plants
4000
4500
3000
4 . Consumption rates and requirements for the parameters and quality of raw materials, basic and auxiliary materials, semi-finished products, water, electricity, gas, steam, etc.
The utilization rate of basic materials for iron-based products is 0.8
based on iron
copper based
Petrol
kg
Industrial pure oil GOST 20799-75
kg
40 - 50
Plasticizers, zinc stearate
kg
3 - 5
Mesh according to GOST 6613-73
№ 1
m 2
0,06
№ 0,8
Average mass of parts, kg
up to 0.1
from 0.1 to 0.5
0.5 to 1.0
over 1.0
Electricity (380/220 V)
Consumption of electricity consumed per 1 ton of products:
production equipment, kW ∙ h
1900,0
1500,0
1300,0
1100,0
heating equipment (furnaces, heating devices, dryers), kW ∙ h
3000,0
2800,0
2600,0
2400,0
handling equipment, kW ∙ h
150,0
100,0
80,0
50,0
Szh compressed air (6.3 atm)
550,0
500,0
450,0
400,0
Compressed air consumption per 1 ton of products
gases
Consumption of natural gas (for the preparation of a protective atmosphere, flame curtain) per 1 ton of products, nm 3
180,0
170,0
150,0
100,0
Consumption of dissociated ammonia per 1 ton of products, m 3
280,0
260,0
250,0
240,0
Nitrogen consumption (for purging thermal furnaces) per 1 ton of products, nm 3
Steam
Steam consumption for technological needs (pressure 3 - 6 atm) per 1 ton of products, kg
320,0
280,0
250,0
200,0
Industrial and circulating water
Water consumption for cooling equipment and tools (18 - 20 ° C, pressure 0.15 - 0.20 MPa) per 1 ton of products, m 3
additional pressing
calibration
hot stamping
Product iron based ion
Interchangeable parts of the press tool
SHH12; SHH15; 40X; X12M; X12F1; CVG; 3Х2В8
30 - 50 *
VC
300 - 600 *
Block
1000
1000
1000
1000
Copper based productsRated force, kN
Press block weight, kg
Automatic machines mechanical
КА8120
КА8122
KA8124
KA8126
KA8128
KA8130
1000
KA8132
1600
KA8134
2500
Stock standards for storage of materials, semi-finished products, products, etc. depend on the serial productionproperties, type of supplier and their value is determined by the requirement of reliable uninterrupted supply of the entire cycle of the technological process.
Norms of stocks of storage and warehousing, standards storage facilities, given in the table, are the initial data for calculating the areas of warehouses according to ONTP 01-80 , GOST 16553-82.
ALL-UNION NORMS OF TECHNOLOGICAL DESIGN
ENTERPRISES OF NON-METAL BUILDING MATERIALS
Introduction date 1986-01-01
DEVELOPED by the institutes of Soyuzgipronerud, VNIPIIstromsyrye and NIPIOTstrom based on many years of experience in the design and operation of non-metallic industries, modern solutions used in standard design, as well as domestic and foreign achievements of science and technology in the field of mining and production technology of non-metallic building materials. The norms are coordinated with the USSR Ministry of Health and the USSR Gosgortekhnadzor.
Compiled by: Soyuzgipronerud (M.G. Mikhalchenko - director of the institute, A.K. Karasev - chief engineer of the institute, V.G. Gurevich - responsible performer, V.Sh. Abramson, I.K. Andronikov, G.F. Antipov , V. G. Balkov, S. I. Varlamov, Yu. M. Voronenkov, N. V. Golubeva, O. E. Golberg, V. M. Gushchina, M. A. Zhukov, A. V. Zezyukin, M E. Kulte, I. E. Lebedev, E. P. Litvinov, R. L. Mikhilev, L. P. Obrezumova, I. A. Sen, V. L. Serova, G. I. Sidorenko, A. V. Strelsky, E.I. Fishkin), VNIPIIstromsyre (N.N. Rogatin - director of the institute, R.A. Rodin - chief engineer of the institute, K.L. Yesherkin - responsible performer, K.S. Bassolo, V.V. Golubkova, V.I. Dolzhenko, A.R. Safarov, D.L. Yarosh), NIPIOTstrom (M.P. Zubchenok - chief engineer of the institute, N.M. Yudin - responsible performer, N.S. Nikulchenko, N.S. Filimonova).
INTRODUCED by the All-Union State Institute for the Design of Non-Metal Industry Enterprises Soyuzgipronerud. AGREED BY Gosstroy of the USSR and the State Committee on Science and Technology (letter No. 45-914 dated 11/20/85).
APPROVED by the order of the Ministry of Industry of Building Materials of the USSR of December 20, 1985 No. 808.
INSTEAD OF Technological design standards approved by the Ministry of Building Materials Industry of the USSR
1. GENERAL PROVISIONS FOR USE
1.1. These Standards establish requirements for the design of technological processes for the extraction of raw materials at a quarry and the production of finished products at a plant that are part of non-metallic building materials enterprises with both excavator and hydromechanized mining methods.
1.2. ONTP are intended for the development of standard projects and their binding, individual construction projects, expansion projects, reconstruction and technical re-equipment of enterprises in the non-metallic building materials industry.
1.3. ONTP are developed taking into account the main directions of technical development of the industry of non-metallic building materials for the XII five-year plan and until 2000, taking into account the use of cyclic, cyclic flow and flow technological schemes conducting mining operations using high-performance mining and transport equipment, waste-free and low-waste technology for processing raw materials based on high-performance, automated equipment and installations and other progressive technical solutions aimed at improving the technical and economic indicators of the designed industries.
2. QUARRY
2.1. GENERAL PROVISIONS FOR DESIGN
2.1.1. The design of the field development should be carried out on the basis of geological exploration and the protocol of the State Reserves Committee of the USSR
(or TKZ) on the approval of reserves, as well as materials covering the resource base: reports on technological research raw materials, geological and surveying documentation and the state of mining operations by the time the design began.
2.1.2. When determining the preparedness of explored mineral deposits for industrial development, the possibility of using data on reserves and determining the principles for calculating and accounting for reserves in the design, one should be guided by the "Classification of reserves of deposits and predicted resources of solid minerals", approved by Decree of the Council of Ministers of the USSR dated November 30, 1981 No. 1128.
2.1.3. The mineral resource of the developed deposit must meet the requirements of "Mountain rocky rocks for the production of crushed stone for construction works. Technical requirements and test methods" GOST 23845-86, GOST 24100-80 “Raw materials for the production of sand, gravel and crushed stone from gravel for construction work. Specifications and test methods.
2.1.4. Scope of field development methods:
excavator - for the development of rocky rocks that require the use of drilling and blasting or mechanical loosening, and loose rocks with the irrationality of using the hydromechanized method of their development;
hydro-mechanized - for the development of partially or fully flooded gravel-sand, sand-gravel and sand deposits using floating dredgers, as well as for the removal of overburden and the development of dry sand deposits with hydromonitor-soil pump installations, with the technical possibility of organizing water supply and placing hydraulic dumps.
2.1.5. Open pit mines are subdivided according to the volume of rock mass extraction into: small - up to 700 thousand tons per year; medium - over 700 to 2000 thousand tons per year; large - » 2000 thousand tons per year.
2.2. FUNDS OF TIME AND MODES OF OPERATION OF MACHINES, EQUIPMENT, PRODUCTIONS
Excavator method of field development
2.2.1. The operating mode of a quarry for the extraction of raw materials is taken year-round, three-shift and synchronous with the work of the plant.
2.2.2. The calendar annual fund of the operating time of a quarry for the extraction of raw materials is taken according to Table. 2.1 .
Table 2.1
2.2.3. The effective fund of the open pit operation time for the supply of raw materials, subject to synchronous operation with the plant, is determined by the calculation according to
clause 3.2.5.
2.2.4. The regime of overburden work in a quarry can be seasonal and year-round. Number of working days per week and shifts per day
is substantiated by the project depending on the scope of work, type and capacity of the main mining and transport equipment.
When using continuous (in-line) equipment, as well as scrapers and bulldozers, overburden operations are performed seasonally.
2.2.5. The effective annual fund of the operating time of the main mining equipment is taken according to the "Norms of technological
design of mining enterprises of ferrous metallurgy with open way developments" 
. Hydromechanized method of field development
2.2.6. The operating mode of a quarry for the extraction of raw materials is taken seasonal, three-shift with 21 shifts per week and its duration is 8 hours.
2.2.7. The calendar annual fund of time (number of working days) of the operation of a quarry for the extraction of raw materials is taken taking into account the climatic data of the area where the enterprise is located (Table 1). 2.2) minus the time required for scheduled preventive maintenance (excluding medium and major repairs that should be carried out during the off-season), taken according to Table. 2.3.
Table 2.2 |
||||||||
Temperature zone ENiV in open pit mining 1979 |
||||||||
Estimated number of days according to SNiP II-1-82 |
||||||||
Table 2.3 |
||||||||
Sand pit with content |
Sand and gravel (gravel and sand quarries) with the content |
|||||||
Name |
||||||||
gravel up to 10% |
||||||||
Overhaul period, shifts |
||||||||
Duration of repair in the overhaul period, shifts |
||||||||
In necessary cases, stipulated by the project, when determining the annual working time fund, the number of working days additionally excludes the time of floods (at high water levels, when the operation of floating dredgers is impossible) and the downtime of dredgers due to fish protection measures.
2.2.8. The effective fund of operating time of mining equipment per year (“net” operating time) is determined based on the calendar annual fund of the operating time of a quarry for the extraction of raw materials, taking into account the utilization factor of equipment operation by time Kv,
taken according to the table. 2.4.
Table 2.4 |
|||||
Characteristics of working conditions |
Number of pumping stations |
||||
When supplying a sand-gravel mixture with a gravel content of 5 to 60% with a gap |
|||||
technological line between the quarry and the plant |
|||||
justified |
project for |
based on data |
|||
similar operating companies.
2.2.9. The regime of overburden operations performed by the hydromechanized method is, as a rule, seasonal.
2.2.10. K coefficient values in the production of overburden works with hydraulic monitors are given in table. 2.5.
Table 2.5
Place of laying the soil
Reservoir or dump without dike device
Wide profile parts of structures or stacks Narrow profile parts of structures or stacks
2.3. NORMS OF PLACEMENT AND NORMS OF THE WORKING AREA PER MACHINE, EQUIPMENT, INSTALLATION
2.3.1. The placement of machines and equipment in a quarry is determined by the following main parameters of the development system while providing safe conditions labor and trouble-free operation:
the height of the developed ledges; the length of the front of mining operations per 1 excavator;
width of working platforms and transport berms.
2.3.2. The height of the working ledges and the angles of their slopes are taken in accordance with the "Uniform Safety Rules for the Development of Mineral Deposits by the Open Method.
2.3.3. The minimum length of the work front per one downhole excavator at road transport taken according to the table. 2.6 .
Table 2.6
Note. Under the active front of work, one should understand the front of work minus temporary exits, under transshipment nodes, i.e. a work front that has reserves ready for extraction.
2.3.4. Width of working platforms, transport and safety berms 2.3.4.1. Width of work sites in the production of mining operations using excavators with a bucket with a capacity of 5 m3 and
dump trucks with a carrying capacity of 27 - 40 tons with a ledge height of 10 - 15 m are taken according to table. 2.7, and for other conditions - calculation according to standard design solutions "Elements of mining operations in quarries of the industry of non-metallic building materials" (p. 409-023-43).
Table 2.7
2.3.4.2. The width of the transport berms is determined depending on the type of dump trucks and the characteristics of the developed rocks and is taken from Table. 2.8, and on rocks - not less than twice the height of the ledge.
2.3.4.3. The width of the safety berms on separate ledges at the end of the quarry is taken equal to at least 8 m, from the conditions for ensuring their mechanized cleaning.
2.3.5. Parameters of the hydromechanized field development system 2.3.5.1. The minimum dimensions of pioneer pits for installation and input of hydromechanization equipment are given in Table. 2.9 and 2.10.
Table 2.9 |
||||||||
Productivity of the dredge on water, m3/h |
Dimensions of pits, m |
|||||||
water depth |
bottom width |
bottom length |
||||||
Table 2.10 |
||||||||
Productivity of the installation in terms of water, m3 / h (hydraulic monitors) |
Dimensions of pits (on the bottom), m |
|||||||
Note. The exit to the pit is taken 4-6 m wide with a slope of 1:8. |
||||||||
2.3.5.2. The total minimum face height, |
minimum allowable depth |
development, optimal |
working slot width |
|||||
floating suction dredgers are taken according to Table. 2.11.
Table 2.11
Productivity of suction dredgers according to |
The total minimum face height, |
Minimum allowable depth |
|
ensuring normal operation |
|||
water, m3 / h |
development below the water level, m |
||
dredger, m |
|||
Notes: 1. With a total bottomhole height less than indicated in Table. 2.11 the performance of the dredger is reduced by 10%. 2. The maximum allowable height of the above-water part of the face is set by the project.
2.3.5.3. The parameters of the development system in case of jet washout should be taken from Table. 2.12.
Options
Bench height (h mouth), m:
Optimum slot width along the water line in the reservoir, m
Table 2.12
Values
2.4. CONSUMPTION RATES AND REQUIREMENTS FOR THE PARAMETERS AND QUALITY OF RAW MATERIALS, BASIC AND AUXILIARY MATERIALS, SPARE PARTS, WATER, ELECTRICITY, FUEL
2.4.1. Raw material consumption rates The consumption of rock mass per unit of finished product for all methods of field development is determined in accordance with clause 3.4.2 and c
taking into account operational losses. 2.4.2. Raw material loss rates
2.4.2.1. The size of operational losses of rock mass in the production of explosive and transport work with the excavator method of development, it is taken according to Table. 2.13, and the number of losses in the whole career is calculated according to the "Industry Instruction for Determining and Accounting for Losses of Nonmetallic Building Materials during Mining" (VNIInerud, 1974); the procedure for writing off reserves is determined by the "Regulations on the write-off of reserves", approved by the USSR Gosgortekhnadzor Resolution No. 28 dated 05.06.84.
Table 2.13 |
|||
Name of losses |
Place of Birth |
||
sand and gravel and |
|||
sandy |
|||
Note. Losses during blasting on the slope are determined by the project.
2.4.2.2. The size of operational losses in the hydromechanized method of field development during the transportation of sand
and sand and gravel mass from the quarry to the plant is taken in the amount of 0.5 - 1.0% of the volume of the transported mass.
2.4.3. Output rates for oversized pieces in the production of drilling and blasting 2.4.3.1. Yield of oversized pieces as a percentage, depending on the size of the piece and the category of rocks by fracturing at
short-delayed blasting of continuous borehole vertical charges is taken according to Table. 2.14.
Table 2.14 |
|||||||
Linear dimension |
|||||||
Well diameter, mm |
oversized piece, mm, |
||||||
Notes: 1. The degree of rock fracturing was adopted according to the classification of the interdepartmental commission for explosives.
2. For other designs of charges, these tables are multiplied by correction factors: for dispersed charges - 0.7, for inclined charges (wells) - 0.8.
3. With several factors taken into account, the correction factors are multiplied.
2.4.4. Requirements for the granulometric composition of the blasted rock mass
explosions of the developed deposit, and in the absence of their average granulometric composition of the exploded rock mass is taken from Table. 2.15.
All-Union norms for technological design of enterprises of non-metallic building materials |
Page 8 out of 59 |
||||||||||||||||||
Table 2.15 |
|||||||||||||||||||
Class size |
Size of classes, mm |
||||||||||||||||||
depending on the |
|||||||||||||||||||
head |
|||||||||||||||||||
crushers, mm |
|||||||||||||||||||
igneous |
rocks (σ com.av |
100 - 150 MPa) |
|||||||||||||||||
carbonate |
|||||||||||||||||||
and metamorphic rocks (σ com.av = 60 - 100 MPa) |
|||||||||||||||||||
Different-strength and weak carbonate rocks (σ szh.av = 40 - 80 MPa) |
|||||||||||||||||||
Table 2.16 |
|||||||||||||||||||
Group of breeds according to SNiP 1982 (According to Protodyakonov) |
|||||||||||||||||||
degree of fracturing |
XI (16 and over) |
||||||||||||||||||
Notes: 1. The table shows the average consumption of explosives for ammonite No. 6ZhV (or grammonite 79 (21), the transition to other explosives is carried out by multiplying by the coefficients of Table 2.17.
2. The average consumption of explosives is calculated for a ledge height of 10 - 12 m and a well diameter of 200 - 250 mm.
Table 2.17
Name of explosive |
Coefficient |
Aquatol M-15 |
|
Grammonal A-45 |
|
Alumotol |
|
Granulite AS-8 |
|
Aquatol MG |
|
Aquatol AVM |
|
Granulite AS-4 |
|
Grammonite 50/50-B |
|
Ifzanit T-80 |
|
Grammonal A-60 |
|
Aquatol 65/35 |
|
Ifzanit T-60 |
|
Granulite M |
|
Aquatol AV |
|
Granulotol |
|
Ifzanit T-20 |
|
Grammonite 30/70-B |
2.4.5.2. Fuel consumption rates for excavators, scrapers, bulldozers, rippers are taken according to Table. 2.18
Consumption, t per 1000 h
diesel fuel
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