Doc. no.

:
Concrete block plant for recycling of
coarse silica fume and quartz fines
First edition : 2019-04-10
Rev/date :
PROCESS DESIGN BASIS Page : 1

Table of contents
1 INTRODUCTION 2
1.1 A3 / BC and background 2
1.2 Process Description 2
1.3 Process Flow 2
1.4 Capacity Requirements / Demands 3
1.5 Consumption Figures and Calculations 3
1.6 External Factors 3

2 TECHNOLOGY AND PROCESS CONSIDERATIONS 5

2.1 Process Node 1 5
2.2 Process Node 2 5
2.3 Process Node 3 5
2.4 Process Node 4 5
2.5 Process Node 5 5
2.6 Common Systems 5

3 CONTROL SYSTEMS 5

4 UTILITIES 6
4.1 Electricity 6
4.2 Compressed air 6
4.3 Water 6
4.4 Utility 6

5 APPENDIX A: PARTICLE SIZE DISTRIBUTIONS 6

6 APPENDIX B: PRODUCT DATA SHEET FOR COARSE SILICA FUME 8

7 APPENDIX C: PICTURES OF PLANT AREA AS OF 10.4.2019 13

1 INTRODUCTION
This document serves as the required technological input into the engineering packages for the project
“Recycling of coarse silica fume and quartz fines” (hereby referred to as the Recycling project) that pertains to
the construction of a concrete block production plant. This document will supersede all other documentation
related to technical information that should be used during all phases of Engineering.

1.1 A3 / BC and background

The Recycling project is an initiative to construct a plant to produce 4600 tons of hexagonal concrete blocks
per annum. The primary objective of the Recycling project is to recycle 2000 tons of Elkem Thamshavn
coarse silica fume (D50 is 0,1 mm). Secondary objective is to recycle 2000 tons of quartz fines (D50 is 1,5
mm) and about 230 tons of silicon metal fines. To reach the objectives, these materials should be
agglomerated into concrete blocks bonded with cement or hydrated lime. Thereafter the blocks will be fed into
two of our Silicon metal furnaces of 44 MW and 25 MW. The product of these furnaces is metal containing
99% Silicon.

Chosen concept is a dry casting process. The materials should be thoroughly mixed since the silica fume is
hydrophobic. Expected density of the mix is 1,75 g/L. The visual appearance of the blocks is not important,
but the blocks should have hexagonal form and sized to 100 mm by 100 mm. Early strength is important,
since they will be handled in bulk after curing. The blocks should not produce fines during handling after 1
day of curing in a building heated to 15 °C.

1.2 Process Description

The concrete block production process uses the following raw materials:
Material Dry composition Size, D50 Bulk density Comments
Coarse silica fume 47 % 0,1 mm 400–800 kg/m3 Hydrophobic properties.
Also called radiclone dust
Quartz fines 43 % 1,5 mm 1600 kg/m3
Cement 6% 0,02 mm 1000–1300 kg/m3
Hydrated lime 6% 0,01 mm 400–500 kg/m3 Instead of cement
Silicon metal fines 4% 0,5–1,0 mm 2300 kg/m3

Quartz fines and silicon metal fines are fed into bins with a wheel loader. Coarse silica fume is pneumatically
transported into a silo. Either cement or hydrated lime is fed into a silo with big bags using a forklift. The dry
materials are transported from the bins and silos and weighed before they are fed into the mixer. The mixer
discharges the dry castable mix, which is fed into a hopper above the concrete block machine. Expected
density of the mix is 1,75 g/L. Material is processed by the machine which produces hexagonal blocks or
other shapes suitable of further bulk handling in transportation belts with 13° incline and storage in silos.

Boards with blocks are stacked and transported by truck, cart or other automatic means to nearby curing.
After 1 day of curing, the blocks are de-boarded and transported outside to a 22 m 3 open steel container. The
de-boarding should be automatic. The empty boards and pallets are transported back to the concrete block
machine.

1.3 Process Flow

Figure 1 shows a possible layout for the concrete block plant. The direction of flow is marked by arrows.
Some assumptions on dimensions on equipment have been made, but they are not required limits.
Figure 1: Proposed layout for the concrete block plant.

1.4 Capacity Requirements / Demands

1. Minimum 19 tons of product per 8 h working day.
2. Plant to be operated by one or two persons.
3. Accurate weighing of raw materials.

Equipment Capacity requirements Comments

Cement silo 1,5 m3 Fed with big bag
Coarse silica fume silo 1,5 m3 Pneumatic input 50kg batches. Silo filter needed.
Quartz fines bins 3 x 8 m3 One bin can be used for silicon fines.
Mixer Ca 400kg / 230L Batch size depends on time for weighing and
batches mixing.

1.5 Consumption Figures and Calculations

The following table shows the consumption and production of the different materials. 250 available work days
per year is used in the calculations.

Material Tons per year Tons per 8h day Comments

Concrete blocks 4538 18,2 Hexagonal 10 x 10 cm
Coarse silica fume 1941 7,77 2000 tons resource
Quartz fines 1941 7,77 7500 tons resource
Silicon fines from vacuum cleaner 50 0,20 Blended in silicon fines
Silicon fines from sweeper truck 180 0,72 Blended in silicon fines
Silica fume from vacuum cleaner 169 0,68 Blended in coarse silica
fume
Cement or hydrated lime 272 1,09

1.6 External Factors

Design temperature for the equipment placed outdoors is −20 °C to +35 °C. The temperature inside the
building will be kept at around 15 °C.

As seen in Figure 2, the plant is to be positioned near the sea, at 2,5 m above sea level with one long side
next to a slope and one short side next to existing factory. Since there are physical constraints, the project
must be categorized as brown field. Figure 3 and Figure 4 shows drawings of the planned building. This
building can be modified as no final decisions have been made. Nearby oxygen storage tank is positioned 20
m north of production plant, and should not interfere with the project. See Appendix C: Pictures of plant area
as of 10.4.2019 for more details. Current concrete structure and material will be removed and the site will be
leveled prior to the project construction phase.
Figure 2: Proposed layout for the surrounding area

Figure 3: 2D drawing of planned building

Figure 4: 3D drawing of planned building

2 TECHNOLOGY AND PROCESS CONSIDERATIONS

2.1 Process Node 1

2.2 Process Node 2

2.3 Process Node 3

2.4 Process Node 4

2.5 Process Node 5

2.6 Common Systems

3 CONTROL SYSTEMS
The level of automation must be enough to enable operation with one or two persons. Currently, Elkem
Thamshavn is using PLC hardware from Siemens, and these components will be preferred. Human Machine
Interface at site is expected. It should be possible to extract reports from the production plant.

4 UTILITIES

4.1 Electricity
100 kW 400 V-IT 50Hz is available near the site.

4.2 Compressed air

Supplier to present compressed air needs (quantity and pressure) for both equipment and instruments.

4.3 Water
Water is available

4.4 Utility
District heating is nearby and possible to connect. Need for drainage is mapped by supplier.

5 APPENDIX A: PARTICLE SIZE DISTRIBUTIONS

Figure 5: Particle size distribution of coarse silica fume.

Figure 6: Particle size distribution of quartz fines.
6 APPENDIX B: PRODUCT DATA SHEET FOR COARSE SILICA FUME
7 APPENDIX C: PICTURES OF PLANT AREA AS OF 10.4.2019