CHUYEN OI CONG NGHE SAN XUAT TS. LNG C LONG - Vien Trng Vien Vat lieu xay dng Gch t st nung (SN) l loi vt liu xy dng c t rt lu i. Nhiu ti liu nghin cu cho rng gch SN xut hin khong nm 7000 -7500 trc cng nguyn. Hin nay, ngay nhng nc tin tin nh cc nc chu u v Nht Bn, ngi ta cng vn sn xut v s dng gch SN. nc ta, gch t SN (cn gi l gch ) cng c t rt sm. Ngi ta tm thy gch trong trong nhng cng trnh c cch y hng ngn nm. Nm 2011, c nc sn xut khong trn 22 t vin gch . Theo d bo ca Vin VLXD, nhu cu gch xy vo nm 2020 nc ta l khong 42 t vin quy tiu chun. Tuy l vt liu xy truyn thng, c nhiu u im nhng t l sn xut v s dng gch trn th gii ngy cng gim v cc l do: ngun nguyn liu cho sn xut ngy cng cn kit, cng ngh sn xut gy ra nhiu cht thi c hi, vic tip tc khai thc st cho sn xut gch lm gim din tch trng lng thc, nh hng nghim trng ti mi trng sinh thi,...Ngy nay, ngi ta sng to ra nhiu loi vt liu thay th gch vi nhng u im vt tri c v tnh nng k thut, m thut v cng ngh sn xut, ng thi t nh hng n mi trng sinh thi. l cc loi vt liu khng nung khc nhau. pht trin sn xut v s dng vt liu xy khng nung (VLXKN) thay th gch SN, tit kim t nng nghip, gp phn bo m an ninh lng thc quc gia, gim kh thi gy hiu ng nh knh v nhim mi trng, gim chi ph x l ph thi ca cc ngnh cng nghip, tit kim than, em li hiu qu kinh t cho x hi, ngy 28/4/2010, Th tng Chnh ph ban hnh quyt nh s 567/Q-TTg ph duyt Chng trnh pht trin vt liu xy khng nung n nm 2020. Theo , nm 2020, t l sn xut v s dng VLXKN thay th gch SN nc ta s l 30-40% v tin ti xa b hon ton cc c s sn xut gch SN bng l th cng.
Thc hin Quyt nh s 567/Q-TTg, nhiu a phng trong c nc tch cc pht trin VLXKN v hn ch sn xut v s dng gch SN. nhiu a phng, vic sn xut gch SN bng l th cng c chm dt t nm 2010, 2011 (v d: Hng Yn, Bc Ninh,...). Trong qu trnh hn ch sn xut v s dng gch SN, xa b cng ngh sn xut gch SN bng l th cng, ny sinh mt s cch hiu khng ng v cc loi cng ngh sn xut gch SN, gy kh khn cho vic qun l, iu hnh ca c quan qun l Nh nc a phng, c nguy c tip tc pht trin mt s loi cng ngh lc hu, c tn gi mp m, khng r rng. Trong bi vit ny, chng ti s phn tch mt s vn c bn lin quan n cng ngh sn xut gch SN hin nay nc ta. I. Mt s loi hnh cng ngh sn xut gch SN hin nay Vit Nam: Cng ngh sn xut gch SN c gi theo tn ca l nung trong dy chuyn cng ngh. Hin nay, nc ta c nhng loi cng ngh sn xut gch SN chnh sau: cng ngh tuynel, cng ngh l hoffman (hay cn gi l l vng), cng ngh l ng lin tc, cng ngh l ng th cng. 1.1. Cng ngh sn xut gch SN bng l tuynel: Cng ngh sn xut gch bng l tuynel l loi cng ngh tin tin. Nhng thit b chnh trong dy chuyn sn xut gm: my n p lin hp c ht chn khng, my nho, my cn, hm sy lin hp, l nung gch l l tuynel. L tuynel l mt hm (tuynel) thng, c vm l c nh, h thng ca vo - ra hai u, h thng np nhin liu, iu khin gi vm l v c ray a xe gong vo, ra l. Theo chiu di l, c 3 vng (zn) chc nng c nh: sy, nung v lm ngui. Vt liu nung di chuyn dc thn l qua cc zn chc nng trn xe gong cn ngn la ng yn (zn nung c nh mt vng xc nh ca l). Sn lng gch tuynel nc ta hin nay chim khong 60% - 65% tng sn lng gch SN. Cng ngh sn xut gch nung bng l tuynel c nhng u im sau: Quy m sn xut ln, lin tc; iu chnh c nhit nung bng cch tng gim lng than qua l tra than; Mc c gii ha cao, nng sut cao;
>> VN HM NAY S 1 2012 NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012 1S Ch ng sn xut, do c hm sy lin hp nn tn dng c ti a lng nhit khi nung sn phm; Sch, gii quyt c vn mi trng sinh thi, gim pht thi kh CO 2 , hn ch nhim mi trng; C th nung a dng cc sn phm nh gch ngi, gch p lt, gch th, c bit l nhng sn phm c rng t 16 - 60%; Mc tiu hao nguyn liu st gim t 15 40% (ty thuc vo rng ca sn phm), than cm 6 gim t 20 35%, nng sut lao ng tng gp 2 3 ln so vi sn xut gch c trong l th cng. 1.2. Cng ngh sn xut gch nung bng l vng Hoff- man (l vng): L vng c dng mt hm (tuynel) hnh vnh khn khp kn, c: vm l; cc ca ra - vo sn phm bn cnh hm; h thng van khi v knh khi trc tm theo chiu di hnh vnh khn. Theo chu vi l, khng c cc vng chc nng c nh. Cc vng sy, nung v lm ngui di chuyn vng quanh chu vi l. Thng thng mi l c 12 n 36 bung. Mi bung c mt li ra - vo kch thc khong 1,2m x 1,3 m. Vt liu nung c xp trc tip vo l, trn nn l v nm c nh trong l t khi cn dng mc n khi c nung thnh gch, cn ngn la di chuyn lin tc vng quanh l (zn nung di chuyn lin tc theo chu vi l). Nh vy, phng thc sn xut ca loi l ny l lin tc nhng ch nhit li gin on i vi vng nung. i vi tng khoang l, ch nhit ng ca l tng t nh l ng th cng hoc l ng lin tc. Do ch kh ng hc trong l l ngn la chy quanh theo vng l nn ngn la chy c th cn phi s dng ng khi cao, khong 60m to lc ht hoc s dng qut ht cng sut ln. Gn y, mt s c s u t xy dng mt loi l gi l l Hoffman ci tin. y l mt bin th ca l Hoffman. Loi l ny c nguyn l cu to nh l Hoffman nhng c mt s ci tin v h thng knh khi, van khi v vm l. Vm l ca l Hoffman ci tin c th l loi di ng hoc n gin hn, c th khng c vm xy m ch ph pha trn bng mt lp x than. V bn cht, y l l Hoffman (l vng). L Hoffman (l vng) c chi ph nhit nung ln, do phi chi ph nhit cho tng l, vm l, nn l mi ln ngn la i qua. Ni cch khc, zn nung c hnh thnh theo chu k chuyn ng ca ngn la nn mi ln mt vng l chuyn thnh zn nung u phi chi ph nhit t nng vng t nhit mi trng ln n nhit zn nung, nhit nung gch mc, nhit cn bng vi nhit tn tht ra mi trng (i vi l tuynel - v zn nung c nh nn ch cn cung cp nhit cn bng vi lng nhit tn tht ra mi trng v nhit nung gch mc). Vic xp mc vo l v d gch ra l u c thc hin trong thn l nn iu kin lm vic ca ngi lao ng rt nhim (nng v bi). Tuy nhin, do chi ph xy dng l Hoffman ci tin rt thp nn mt s ch u t la chn loi l ny. 1.3. Cng ngh sn xut gch SN bng l ng nung lin tc: L lin tc kiu ng c xut s t Trung Quc, c du nhp vo Vit Nam t nm 2001. L lin tc kiu ng khi ng mt ln, c th vn hnh lin tc trong sut qu trnh sn xut. L lin tc kiu ng c bung t t theo chiu thng ng, gch di chuyn t trn xung di. Mc c gii ho tng i cao, gim c lao ng nng nhc; tit kim nhin liu n 45% so vi l th cng truyn thng, gim thiu nhim mi trng. Quy m sn xut v vn u t ph hp vi nng lc ca cc doanh nghip va v nh. T nm 2002 n nay, l ng nung lin tc thay th cho cc l th cng ci thin c cht lng gch, gim nhim mi trng, gim bt mt s khu lao ng nng nhc cho ngi lao ng, nng sut v cht lng sn phm c nng ln. Cng ngh ny cng c ci tin ph hp vi cc doanh nghip va v nh nn c kh nhiu tnh pht trin thay th cho gch nung th cng. Vi cng ngh ny, cc tnh pha Nam sn xut c gch c rng ti 50%, mc tiu hao nhin liu thp hn l tuynel v mi trng c ci thin nhiu. Tuy nhin, nhn v chin lc lu di th vic pht trin l ny vn cha ph hp ch trng cng nghip ha, hin i ha ca ngnh VLXD, sn xut theo hnh thc ny vn mang tnh nh l, gy kh khn cho cng tc qun l trung ng v a phng. y c th coi l gii php trc mt, c th p dng cho nhng a phng thiu t, cho nhng huyn min ni c iu kin kh khn v giao thng, cho vic thay th cc cm l th cng lc hu (nhng c s khng c vn pht trin l tuynel). 1.4. Cng ngh sn xut gch nung bng l th cng truyn thng: L th cng truyn thng c s dng ph bin Vit Nam t lu i. y l loi hnh cng ngh sn xut n gin, lc hu nht. Hin nay sn lng gch SN c sn xut bng l ng th cng chim khong 35 - 40% tng sn lng gch SN. c im ni bt ca loi hnh sn xut th cng l thit b my mc, nh xng rt n gin. Cng tc gia cng, to hnh ch yu c thc hin bng cc loi my n lento loi EG2 hoc EG5 khng c chn khng. Kh nhiu h t nhn mt s a phng sn xut gch hon ton th cng. Cc quy trnh k thut trong sn xut khng c thc hin, khun mu to hnh sn phm khng m bo v kch thc, cha ph hp vi co nguyn liu, nn kch >> VN HM NAY 14 NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012 thc sn phm thng thiu ht, mu m sn phm n iu. Gch mc sau khi to hnh c phi trn cng th cng khng c mi che, sau c nung trong l gin on. Nhn chung, cng ngh sn xut ch yu l th cng, hao ph nguyn, nhin liu ln, gy nhim mi trng, cht lng gch cn hn ch, c bit l v kch thc, hnh dng. C th lit k hng lot nhc im ca cng ngh sn xut gch SN bng l th cng nh sau: Nung gin on, khng c h thng kim tra nhit , th t l kim tra nhit bng kinh nghim; Tn tht nhit nng ln, pht thi kh CO 2 nhiu, gy nhim mi trng cao; Qu trnh nung ko di, kh nng tn dng nhit km, nhit tch trong v l ln; Cht lng gch thp, khng ng u, mu m n iu, ph thuc nhiu vo kinh nghim ca ngi t l, t l gch ph phm cao (trn 10%); Nng sut lao ng thp, iu kin lao ng nng nhc. gim nhim mi trng, hin nay, mt s a phng ci tin b phn ng khi ca l nung theo hng: nng cao ng khi pht tn kh thi ra mt vng rng hn, gim nng nhim khu vc gn l nung; dng nc vi hp th bt kh CO 2 v SO 2
chn ng khi hoc trn thm mt lng nh vi vo nhin liu hp th bt kh SO 2 ngay trong vng nung (gii php ny cng c s dng cho l tuynel). Tuy nhin, vic u t h thng x l thng khng y , khng vn hnh h thng u t (u t mang tnh i ph) nn khng gim thiu c cc kh c. Ton b quy trnh cng ngh sn xut c bn vn khng c g thay i. iu kin lao ng ca ngi lao ng vn rt km v cht lng sn phm vn thp, khng n nh v cc chi ph vn cao. Trong bng 1. Nu nhng c im c bn ca cc loi cng ngh sn xut gch SN ch yu nc ta hin nay: Bng 1: Nhng c im ch yu ca cc loi cng ngh sn xut gch t st nung. c im ch yu Cng ngh sn xut L Tuynel L ng lin tc L Vng (Hoffman) L th cng Quy m sn xut Va v ln Nh v va Va v ln Nh v va Cng on to hnh thng thng My nho n p lin hp, ct gch t ng My nho n p lin hp, ct gch t ng My nho n p lin hp, ct gch t ng My n p, ct gch th cng Cng on phi, sy mc Hm sy, nh knh Phi t nhin Phi t nhin, hm sy Phi t nhin Cng on nung Lin tc, zn nung c nh Lin tc, zn nung c nh L vn hnh lin tc, zn nung thay i, gin on theo khoang l Gin on Tiu hao nhin liu TB (kg than/ 1000 vin gch QTC) 100 - 120 100 - 80 120 - 140 180 - 220 Vn chuyn ra vo l Xe gong Vo l: Vn thng Ra l: h thng vtme, thy lc Vo - ra: th cng Vo - ra: th cng Mi trng xp d Nhit thng Nng, bi Nng v bi cao Nng v bi cao nhim mi trng Pht tn rng, c th x l trit Pht tn tng i rng, kh x l Pht tn rng, kh x l Pht tn tp trung, kh x l Chng loi sm phm Ph hp vi sn phm mng, gch rng Nung c c gch c v rng Nung c gch c (min Bc) v gch rng (min Nam) Nung c gch c (min Bc) v gch rng (min Nam) S 1 2012 NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012 15 II. Cn nhn dng ng v cng ngh u t theo xu hng tin tin, ph hp vi ch trng ca Nh nc: Hin nay, do phi xa b cng ngh sn xut gch SN bng l ng th cng nn mt s ch l gch mun chuyn i sang cng ngh khc khng b cm vi mc chi ph thp, ph hp vi iu kin ca mnh. p ng nhu cu ca cc ch l gch th cng, trn th trng xut hin mt s tn gi cng ngh mi, i khi gy lng tng, kh hiu cho ngi dn v cc c quan qun l nh nc a phng. C th nu mt vi loi cng ngh thuc dng ny, nh sau: L th cng ci tin (c ni gi l l p vung): Thc cht y vn l l th cng. Loi l ny ch khc l th cng mt im duy nht l cu to ng khi v x l khi. Tuy nhin, vic x l khi khng c thc hin thng xuyn nn hiu qu mi trng rt thp. c im ca loi l ny c phn tch k mc 1.4 ca bi vit ny. L Hoffman ci tin: Thc cht y vn l loi l Hoff- man. S ci tin ch yu c ngha i vi ch u t v chi ph u t thp hn so vi l Hoffman c in. c im ca loi l ny c phn tch k mc 1.2 ca bi vit ny. Cng ngh Hoffman - tuynel ci tin: y l cch gi mp m, kh chp nhn. Thc cht ca cng ngh ny l l Hoffman ci tin. Trong dy chuyn cng ngh ny, ngi ta c s dng hm sy tuynel. Tuy nhin, hm sy tuynel c xy tch ri l vng (l Hoffman). y l cch lch lut, i vi nhng a phng khng ng h vic u t cng ngh l vng (l Hoffman). Nu khng xem xt k, c th c quan qun l d nhm hm sy tuynel vi cng ngh sn xut gch SN tuynel. Ngoi nhng bin tng trn, mt s a phng, cc ch u t cn thu cc cng ty t vn nh, thiu chuyn nghip lp d n, thit k cc d n mang tn D n u t cng ngh sn xut gch tuynel nhng ni dung k thut li khng phi l cng ngh tuynel m l: hoffman ci tin hoc hoffman - tuy- nel ci tin...Mt s t cn b lm cng tc qun l Nh nc cc a phng nghe c cc thng tin rt hp dn v l th cng ci tin, l p vung lng tng trong vic iu hnh, qun l. Chng ti hy vng rng, bi vit ny s gip bn c c thm mt s thng tin c th hn nhn dng ng v cng ngh u t sn xut theo xu hng tin tin, ph hp vi ch trng ca Nh nc trong vic sn xut gch SN Vit Nam hin nay./.
M hnh l Tuynel M hnh l vng Hoffman M hnh l ng lin tc M hnh l gch th cng >> VN HM NAY 16 NGHN CUU VA PHAT TRN VT LU XY DUNG S 1/2012