The optimal raw materials for TITAN HYPERPRESS plants are sourced from stone quarry screenings. Given the variability in the types of stones extracted by different quarries, the suitability of their waste for our plants can vary. As such, we carefully consider the composition of each quarry’s waste to ensure optimal efficiency and effectiveness in our waste management processes.
Utilizing Screenings from “Soft” Stone Quarries as Raw Materials for High-Pressure Compaction Technology in Brick and Block Production through Hyperpressing.
Soft Rocks Quarry Recycling
Our technology is optimized for “soft” stones with a strength of up to 500 kg/cm², with the most favorable being those with a strength of up to 300 kg/cm².
The ideal raw materials for TITAN HYPERPRESS plants are the screenings from the following “soft” stone quarries:
- Shellrock
- Limestone
- Dolomite
- Tuff
- Marble
- Marl
- Some types of gneiss
The screenings from these stones make perfect raw materials for TITAN HYPERPRESS brick making plants, with the following composition:
- “Soft” stone screenings – a primary stone processing product (85%)
- Cement – a secondary stone processing product (7%)
- Water – a universal agent for chemical reactions (8%)
Quarries for these types of stones can be found almost anywhere, and their screenings are readily accessible and inexpensive raw materials.
The preferable building materials based on the «soft» stone screenings are high quality facing (facade) bricks in the supporting walls.
Utilizing Screenings from ‘Hard’ Stone Quarries as Raw Materials for High-Pressure Compaction Technology in Brick and Block Production through Hyperpress Technology.
Mountainous regions of the earth contain large accumulations of hard volcanic rocks such as:
- Granite
- Basalt
- Diorite
- Gabbrodiorite
- Siltstone
- Hard limestones
- Marbles
- Dolomitic limestones, and others.
Our brick making technology requires “hard” stones with a strength of over 500 kg/cm².
Screenings from the aforementioned “hard” stones make good raw materials for TITAN HYPERPRESS brick making plants, when mixed with “soft” stone screenings in the following composition:
- “Hard” stone screenings – a primary stone processing product (51%)
- “Soft” stone screenings – a primary stone processing product (32%)
- Cement – a secondary stone processing product (9%)
- Water – a universal agent for chemical reactions (8%)
The necessity to use “hard” stone screenings arises from their large accumulations, which are difficult to utilize by other technologies apart from TITAN HYPERPRESS brick making plants.
Building materials based on “hard” stone screenings possess colossal strength (up to 750 kg/cm² and higher) and are best transformed into anti-seismic bricks (both inside and outside) as well as sidewalk and road pavers with high strength and erosion resistance.
The ideal building materials based on ‘hard’ stone screenings are anti-seismic bricks and blocks, as well as paving and curbstones.
Because of the exceptional durability of ‘hard’ volcanic rocks, it is crucial to use a special mold lining to prevent wear and tear on the mold during the compaction process.
Hard Rocks Quarry Recycling
Ceramic brick crushing and claydite screenings as raw materials for high pressure compaction technology for brick and block production (Hyperpress)
Ceramic Brick Crushing and Claydite Screenings Recycling
Often, during ceramic brick and claydite production, large quantities of low-quality products accumulate in the form of ceramic brick crushing and claydite screenings.
Small ceramic items resulting from splitting are a suitable raw material for TITAN HYPERPRESS brick plants, and can be combined with ‘soft’ stone screenings, cement, and water in the following composition:
- Small ceramic items – a product of primary + secondary processing (63%)
- ‘Soft’ stone screenings – a product of primary processing of stone (20%)
- Cement – a product of secondary processing of stone (9%)
- Water – a universal agent of chemical reactions (8%)
Claydite waste from production is also a viable raw material.
Facing bricks and bricks for inner brickwork are the preferred building materials based on the ceramic breakage and screenings, while anti-seismic bricks and blocks, paving stones, and curbstones are ideal for ‘soft’ stone screenings.
Reinforced concrete demolition waste can be used as raw materials for high-pressure compaction technology for brick and block production (Hyperpress)
During the reconstruction of urban areas or after strong destruction, there is a pressing problem of how to use the ruins of buildings and constructions. The most complicated issue is separating iron reinforcements and millwork from the rubble of large concrete slabs. If we can solve this problem and crush the concrete rubble into fractions of screenings, we can obtain perfect raw material for TITAN HYPERPRESS brick making plants with the following composition:
- Crushed concrete – a product of primary and secondary processing of stone (85%)
- Cement – a product of secondary processing of stone (7%)
- Water – a universal agent of chemical reactions (8%)
This solution is unique because the production of new building materials from ground concrete or bricks can be made in immediate proximity to the site of new construction. By transforming local demolition waste into “green” high-quality bricks, we can promote sustainability and reduce the environmental impact of construction.
Reinforced concrete demolition waste
Blast-furnace slags as raw materials for high pressure compaction technology for brick and block production (Hyperpress)
Blast-furnace slag recycling
The accumulation of blast-furnace slags on the territory of metallurgical industrial complexes quite often represents a real problem that requires an adequate and economically profitable solution.
Rather often, blast-furnace slags contain up to 13-15% of residual iron. A preliminary cleaning of blast-furnace slags from residual iron on special technological lines is required.
On the “tails” of the aforementioned technological lines, TITAN HYPERPRESS brick-making plants are installed.
When cleaned from residual iron, blast-furnace slag is an excellent raw material for our brick and block making plants, with the following composition:
- Ground blast-furnace slag – a product of primary and secondary processing (87%)
- Cement – a product of secondary processing of stone (5%)
- Water – a universal agent of chemical reactions (8%)
The preferable building materials based on purified blast-furnace slag are facing and inside bricks in the supporting walls, as well as sidewalk and road pavers.
We can help you produce the best facing (facade) bricks from waste and save on cement.
Burnt coal wastes of mining and processing complexes as raw materials for high pressure compaction technology for brick and block production (Hyperpress)
Burnt coal wastes of mining and processing
The accumulations of gob piles on the territory of mining and processing complexes frequently become a real problem that requires an adequate and economically profitable solution.
For the technology of TITAN HYPERPRESS plants, it is necessary to use old, completely burnt coal refuse (red dog). After crushing, small coal waste items are good raw materials for TITAN HYPERPRESS plants, with the following composition:
- Small coal waste items – a product of primary and secondary processing (60%)
- “Soft” stone screenings – a product of primary processing of stone (20%)
- Cement – a product of secondary processing of stone (10%)
- Water – a universal agent of chemical reactions (10%)
Fly ash and coal slag waste of the Thermal Power Plants as raw materials for high pressure compaction technology for brick and block production (Hyperpress)
Coal is the top heat carrier for Thermal Power stations, with a heating value that trumps natural gas by over two times. But with its combustion comes the burden of solid ash-slag waste, which, when left untreated, leads to an environmental catastrophe. The solution? Enter TITAN HYPERPRESS plants, which utilize solid ash-slag waste as a primary raw material for brick production. By doing so, the plants are able to cut production costs, improve ecological impact, and produce high-quality building materials for brickwork. So, what once was considered waste can now become a valuable resource, paving the way for a more sustainable future.
The technology of TITAN HYPERPRESS plants offers several economic advantages for the utilization of solid ash-slag wastes from coal combustion.
Firstly, it allows for the transformation of one ton of solid ash-slag wastes into bricks at a cost of only *20 euros, which is 40 euros cheaper than the cost of disposing of one ton of solid ash-slag wastes. Therefore, the installation of a TITAN HYPERPRESS plant on the output of solid ash-slag wastes can result in significant cost savings for a Thermal Power plant.
Secondly, the production of bricks from solid ash-slag wastes can generate additional profits of 10-30 million euros per year, as these bricks can be used for inside brickwork. This presents an opportunity for Thermal Power plants to diversify their revenue streams and increase profitability.
Finally, the installation of a TITAN HYPERPRESS plant on the output of solid ash-slag wastes eliminates the need for the construction of precipitation tanks or “slag tanks,” which can cost up to 36 million euros per year. Additionally, it can significantly reduce the ecological impact of Thermal Power plants on the environment.
The raw materials composition for TITAN HYPERPRESS plants consists of solid ash-slag wastes, which are a product of primary and secondary processing, comprising 70% of the raw material. Additionally, the raw material includes “soft” stone screenings, a product of primary processing of stone (20%), cement, a product of secondary processing of stone (5%), and water, a universal agent of chemical reactions (5%).
It is worth noting that the solid ash-slag wastes from coal combustion contain several substances, such as SiO2, Al2O3, CaO, MgO, K2O, Na2O, and sulfur compounds, among others. The TITAN HYPERPRESS technology utilizes the substances in the solid ash-slag wastes that are appropriate for brick making, namely, silicon dioxide (SiO2) and aluminum dioxide (Al2O3).