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NEWS 2019
 

CALCIUM CARBONATE GROWS IN MOROCCO WITH M&S TECHNOLOGY.


Urussanga Mineiros

Manfredini and Schianchi, in addition to coal grinding, is developing important experience in sectors where the market requires a technology that can produce materials with fine grain sizes with a range of 50-40 microns such as calcium carbonate.

In recent years Morocco has had strong growth and development in this particular sector having an excellent quality of raw material. Manfredini e Schianchi recently supplied two plants for the complete treatment of calcium carbonate.

The first system was installed at Micromix Sarl- Gruppo Orobrique, a new production company located in the city of Berrechid. The unit is mainly composed of a MOLOMAX 6/190-AIR PIG hammer pre-grinder mill, these mills are equipped with centrifugal fin separators to optimize the percentage of fine material after grinding, driven by a process of great potential, and unload the material directly ready to be bagged and transported to its destination.

Near Casablanca, M&S has installed another very similar unit, we are talking about the factory of a long-standing M&S customer, SARL BROYCHIM. In this case there are two production lines in operation: the first, composed of a MOLOMAX MS4/150, treats calcium carbonate for a production capacity of 15 tons/h and the other, recently installed, was designed to grind, treat , bagging and loading onto trucks, barite with a high percentage of silica for a production potential of 16 tons/h.

The plant line is mainly composed of a SLAMMER Hammer Mill (designed to treat raw materials with a very high percentage of wear) and MOLOMAX MS6/190-AIR. Thanks to the automatic control of the internal depression, the MOLOMAX separates the silica particles inside the raw materials which are discarded and automatically collected at the base of the mill itself.

Urussanga mineiros


UM-URUSSANGA MINEIROS EXPANDS ITS PRODUCTION AND RELYS ON M&S


Urussanga Mineiros

The important Brazilian company UM-Urussanga Mineiros, located in the state of Santa Catarina, already a historic customer of M&S, has recently commissioned a new coal grinding plant from the Brazilian branch which will be added to the one already functioning and always supplied by M&S in 2008 with MOLOMAX MS6/190.

This new supply is essentially equipped with an MS-3/120-AIR Pendulum Mill with process filter and with a drying system via an innovative heat recovery system leaving the coquery ovens.

The plant operates on "Cardiff" type charcoal, with an initial humidity of 10% and has a production of 5,5 tons/h with a 90% separation cut below 40 microns.

With the costs of classic energy sources continuing to grow, the whole world is re-evaluating energy sources that were considered obsolete but which, if properly prepared, can be both economical and low-polluting, such as coal, which we remember, is still used today in all the world in many industrial realities, such as foundries and steel mills.

Urussanga mineiros


MANFREDINI E SCHIANCHI ESTABLISHES ITSELF IN KAZAKHSTAN AS A LEADING COMPANY IN THE GRINDING OF CALCIUM CARBONATE


Alina calcium carbonate

Over the last three years, Manfredini and Schianchi has installed several plants for the production of Calcium Carbonate in Kazakhstan at the important Alina Group, one of the country's largest companies producing raw materials.

The first plant which came into operation a few months ago is the result of commercial agreements signed in 2016.

The plant is located in the city of Karatau and is a grinding and screening plant for the production of approximately 20 tons/h of calcium carbonate and is equipped with MAXI-PIG hammer mills, MOLOMAX MS6/190 and screening system business suit.

The second, much smaller plant, located in the city of Taraz, is equipped with a MOLOMAX MS3/120 Pendulum Mill and produces approximately 10 tons/h of calcium carbonate and calcined gypsum.

The third plant, with an agreement signed between the parties in 2017, is located in the city of Semey, which came into operation at the end of 2018 and is equipped with a MOLOMAX MS6/190 finishing mill complete with a series of three-story batteries from Vagli high MS performance while, as a pre-grinder, there is always the MAXI-PIG. The plant in question produces calcium carbonate and calcite with an estimated flow rate of approximately 18-20 tons/h.

A new commercial agreement was recently signed with the Alina Group which provides for the supply of a "twin" plant to the one currently operating in Semey for the new factory, about to be completed in the city of Aktobe.

Thanks to these profitable and satisfying collaborations with the Alina Group, Manfredini and Schianchi is today confirmed as a leading company in Kazakhstan in the supply of plants for the grinding and screening of calcium carbonate.

Alina Calcium carbonate


IN MEMORY OF UMBERTO MANFREDINI


Umbeto Manfredini

The Manfredini & Schianchi Group is sad to announce that the Chairman and founding partner, Umberto Manfredini, passed away on Sunday, May 5, 2019, at 10.30 pm.

Umberto Manfredini was born in Sassuolo (MO) on January 26th, 1938. He has been a leading figure in the ceramic industry of Sassuolo and Italy. In 1960 he decided to establish his own business so he built an individual mechanical workshop with only a cutter and a lot of good will.

At the beginning, instead of working for customers of the ceramic district, Umberto had as main customer Fiat Agri of Modena (now New Holland), company specialized in the production of agricultural machines.

The meeting with future partner Gianfranco Schianchi was the decisive turning point: in fact in 1962, thanks to the union between the two, MANFREDINI & SCHIANCHI was born, and is today a leading company that has specialized in the production of milling plant and plant for the preparation of raw materials for the ceramic and brick industry, as well as the coal, calcium carbonate, bentonite industries.

The company is also one of the world's leading companies to supply salt processing technology. Anyone who has had the good fortune to meet Umberto Manfredini in person knows that he was an energetic, combative and dynamic person, always full of new ideas. A person who had the ability to sense the changes in the ceramic industry of the future and, consequently, to understand new needs.

Strong supporter of dry milling technology, even when the ceramic world insisted on the wet method, Umberto has always believed that in the world, especially in those countries where water is considered a precious commodity, dry technology could have important margins of development. And he was right, especially when Manfredini & Schianchi began to export more and more outside national borders and to expand into new markets and countries such as North Africa, the Middle East, Iran and especially South America. Brazil has been one of the countries in which, over the last 30 years, tiles produced with the dry method have experienced an incredible growth. In fact, whilst visiting the South American giant towards the end of the 80s in the ceramic district of San Paolo (Santa Gertrudes, Cordeiropolis, Rio Claro), Umberto immediately realized its potential.

He therefore founded Manfredini and Schianchi do Brasil, which for years has been one of the largest Brazilian companies to locally manufacture raw material milling plant. In addition to being a great entrepreneur, Umberto Manfredini, during his 81 years of life, has held many other positions in the social life of Sassuolo. He was both chairman of the CNA of Sassuolo and Councilor for Sport and Culture of the Municipality of Sassuolo in the 70s.

He also had different roles within the Sassuolo Football Association in the 70s, 80s and 90s and was one of the founding members, along with Manfredini & Schianchi, of the ceramic machinery trade association, ACIMAC in 1989, which at that time was headquartered in Milan.

Umberto left his wife Pasquina, his sons Alessandro and Andrea and all staff of Manfredini & Schianchi, a great memory of himself and his teachings. By virtue of his generosity, loyalty, respect and will to believe in his ideas of him. "If a thing is right, ... it is right to believe in it and carry it forward! Always! Never fall before the first difficulties, but keep fighting to keep your beliefs and your faith in that idea ... "

Thank you, Umberto, for your invaluable lesson.


MS-DRYTECH AND FUSION GRANULATION: THE GREEN ALTERNATIVE TO DRY GRINDING


Fusion

The results obtained from the dry body preparation process using MS-DryTech grinding technology followed by patented Fusion dry granulation confirm that it is possible to produce glazed porcelain tiles with the same characteristics as those made using conventional wet technology. It is an extremely eco-friendly process that ensures significant reductions in energy and water consumption while also allowing for major savings in terms of production costs.

Drawing from its unique experience in the dry process raw materials preparation sector, Manfredini & Schianchi is able to propose the most suitable technologies according to the type of raw materials available and the required ceramic product quality.

The following are the results of a study conducted at the Manfredini & Schianchi Technology Center in collaboration with the University of Modena and Reggio Emilia and the ITC (Institute of Ceramic Technology) of Castellón.

The aim of the study was to test the suitability of bodies ground with MS-DryTech and granulated with Fusion for the production of tiles with technical characteristics similar to porcelain. For this purpose, the composition of the dry grinding body was formulated in keeping with the classic criteria of ceramic body formulation, in other words without making any changes with respect to the formulations used for wet grinding.

This was followed by an investigation of the quality parameters of ceramic product obtained with dry ground bodies and a comparison with those of a typical porcelain tile body produced by wet grinding and spray drying.

The study investigated the mineralogical, chemical, morphological and particle size characteristics and sinterability of the resulting ceramic bodies, as well as the macroscopic and normative characteristics of products (linear shrinkage, water absorption, mechanical strength and incidence of black core defect). The following laboratory tests were conducted:

  • Measurements of particle size distribution of body powders;
  • Chemical analysis of body powders
  • Mineralogical analysis of bodies
  • Morphological analysis of body powders after granulation and spray drying and corresponding in-press behaviour
  • Characteristics after firing (linear shrinkage, water absorption) of products obtained from powders produced using the two different technologies
  • Comparison between the consumption levels and savings obtained with the two technologies;
  • Comparison between the environmental impacts of the two technologies. .

results

The diffractometric and particle size analyzes confirmed that there are no substantial differences between the results of the two grinding technologies. A comparison between the two technologies reveals that in both the dry and wet process the residue stands at about 5% at the grinding particle size of 44 micron.

The powder morphology obtained with Fusion granulation was more compact and completely free of internal air pockets

Table 1 compares the two granulates (one a Fusion granulate, the other a spray dried body), which despite their slight differences in morphology proved to be virtually identical in terms of particle size distribution and pressing parameters.

The slightly higher in-mold density of the Fusion granulate confirms the much more uniform moisture content between the coarser fractions (>600 micron) and the finer powder (<100 micron).

This does not affect the die cavity loading parameters and instead makes for a much smoother and more uniform green tile surface.

The analysis of the behavior of the two bodies during firing (fired with 38 minute cycles at 1210°C) likewise reveals no differences.

In detail, table 2 shows the technical and quality parameters of porcelain tiles of size 60x120 cm and thickness 10 mm manufactured from a body produced with the MS-DryTech process and Fusion granulation using easily-sourced low-cost raw materials.

conclusions

The experimentation shows that the dry formulations granulated with Fusion technology can be used to create products with equivalent characteristics to ceramic materials obtained with traditional wet grinding technology followed by spray drying.

In particular, the process developed by Manfredini & Schianchi allows for excellent reactivity, which is ideal for the production of porcelain tiles.

If we also take into account the big difference in environmental sustainability between the two processes (tables 3 and 4 show a comparison between their energy and water consumptions and emissions), it will be evident that the dry process is superior to the wet process and is a particularly valid solution for ceramic tile producers wishing to focus on increasingly eco-sustainable production.

Fusion

Fusion

Fusion

Fusion

Fusion

Fusion

 

 




 

 


Via GM Dallari, 2 - 41049 Sassuolo (MO) - Italy
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Email: plants@min-ind.it