KHOA HOC-CONG NGHE
Nghien CLTU xay dung guy trinh san xuat go nhya theo cong nghe Co-extrusion ung dung
trong tuong chan cac cong trinh giao thong
• TS. N G U Y I N PHAN ANH - TrUdng Dgi hoc Hdng hdi Viet Nam
TOM TAT: Go nhya (WPC) dang dupc nghien cuu thanh cong va ap dung tai rat nhieu nudc phat tnen tren the giai Mpt so nha may nuoc ta cung da dau tu sin xuat nhung v6i chat lupng khong deu, sSn lupng khong nhieu, chi chiem Irnh dupc mgt phan nho nhu cau cua thi trudng vdi chu yeu sd dung cong ngh# ep dun truyen thong Cong nghe Co- extrusion la mot cong nghe mdi se tgo ra nhung s^n ph^m VV'PC vdi nhung uu diem hon han cong nghe truyen thong Vigc xay dung dupc quy trinh san xuat lam chu cong nghe nay se giup ich cho viec tang chat lupng s^n pham trong nuoc, chiem ITnh thj truong va g i i m nhgp khau Go nhpa da va dang dupc sii dyng nhieu trong cac cong trinh xay dung va dan dung, nhung voi nhung uu diem noi troi hoan toan co the ung dung vao cac cong trinh giao thong
TL/ KHOA: Go nhpa, cong nghe Co-extrusion, polymer nhiet d^o PP, nhpa HDPE,
ABSTRACT: Wood plastic composites (WPC) is being successfully researched and applied in many developed countnes in the world Some of our factories have also invested in production with the process by the extrusion technology but with uneven quality, not much output, only occupying a small part of the market demand The co-extrusion IS a new technology that will create WPC products with advantages over traditional technologies Building this production process in success will help increase the quality of domestic products, dominate the market and reduce imports WPC has been used extensively in construction and civil works, but with outstanding advantages, it can be applied in traffic works
KEYWORDS: WPC, Co-extrusion, Polypropylene, HDPE in WPC-
I . D A T V A N D i
^ ^ Vat lieu composit go - nhua la loai vat lieu composit 4 H C to hpp tU cac loai nhUa nhiet deo nhu PE, PP, PVC...,
^ ^ K vdi cot la cae loai bpt go, spi go hay eae loat soi thUe
^ ^ B h a e . Ngoai ra, trong qua trinh che tao eo the co them
^ ^ B s o chat phu gia nhu phu gta trptUPng hpp, phu gia
T
lien ket, phy gia ch6ng ehay va cac loai phu gia khac SSn pham WPC CO cd tinh tot, eb do on dinh kieh thUdc cao va eb the ehe tao ra cac loai s^n pham eo hinh dang phUc tap. Cae san pham lam tU WPC rat giong cac san pham lam t u go t u nhien va khac phuc dupe nhUng diem yeu eua go tU nhien la du da dUpc XLT ly thi van bt hay cong venh hoac ntft ne, nhat la dot v6i dieu kien khi hau nong am nhu 6 nU6c ta. Nhd nhQng iJfng dung thay the go tu nhien, sis dung loai vat lieu than thien vdi irioi trUdng, viec sCf dung cac san pham co nguon goc tUgo nhi/a WPC dang va rat pho bien hien nay, tuy nhien sSn pham tren thj trudng Viet Nam neu tU cae nUde tU bSn vdi chat lUOng d£im bao nhUng gia thanh cao hon 25 - 30%. Con vdi cac san pham nhap khau tCrTrung Quoc hay Malaysia cf^nhieu eong trinh qua sii dung mpt thdi gian ngSn da xuat hien sU cong venh hay phai mau va thUe te nhieu ehu dau t u nhu Vingroup hay Sungroup da yeu eau don vj cung cap phai bao hanh thay the. Mot yeu to quan trpng nOa khi ehiing ta tU san xuat dupe san pham vdi chat lUpng tUOng duong vdi san pham t i / eae nUde tU ban va gia thanh r& thi se giup thi trUdng chii dpng nguon eung cap san pham trong nUde, han ehe phu thupc vao san pham nhap khau.
Bai bao tap trung nghien etru xay dUng quy trinh sSn xuat thU nghiem theo cdng nghe Co-extrusion thay the edng nghe ep dun truyen thdng, tao ra nhUng san pham WPC CO ehat luong dam blio vdi gta thanh hpp ly, giup chu ddng nguon cung cap san pham trong nUde, han eh^
phu thupevao san pham nhap khau; kiem dinh sSn pham dam bao theo tieu ehuan hien hanh.
Nghien cUu nay dat duoc vdi sU tro giiip va hpp tae tU Cong tyTNHH Go nhUa Composite Viet Nam.
2. CdNG NGHE CO-EXTRUSION
Co-extrusion la sU phun ra eua nhieu Idp vat lieu dong thdi. Loai ep dijn nay sif dung hai hoae nhieu may diin de lam ndng ehay va eung cap lUu lUpng the tich on djnh eua cac loai nhUa deo khac nhau cho mdt dau ep phun don (die) ma se ep cac vat lieu d dang mong mudn [1]. Hpp chat dun eho phep mpt vat lieu pha trpn dUOc ip dun, nhUng co-extrusion giU lai cae vat lieu rieng biet nhU cac ldp khac nhau trong san pham dun, cho phep bo tri thieh hop cSc vat lieu vdi eae tinh chat khac nhau nhu dp th^m oxy, dp cong venh, phai mau, dp cirng va tinh ehiu mai mon.
Ldp phu dim sif dung qua trinh thoi hoac due casi de phu them mdt Idp de eai thien dac tinh cCia s§r pham tao ra nhu phu mdt Idp PE (polyethylene) hoac Pf
KHOA HOC-C6NG NGHE. .So 04/2019
(polypropylene) lam tang dac tinh khang nUdc, chong thcim, dp bdng sang be mat va dac biet la tang cudng dp ben (xe ddt va keo).
IVlpt Uu diem cita edng nghe ep dun nhu vay se tao dupe ra sSn pham vdi nhieu hinh dang, tiet dien phu thudc vao khudn mau ditc (profile) va ed the thUe hien vdi chieu dai bat ky.
3. XAY DtiNG QUYTRlNH C 6 N G NGHg SAN XUAT Trong edng nghe san xuat WPC, dieu quan trpng nhat la nghien eifu xae djnh dupe thanh phan cap phdi eija nguon nguyen lieu dau vao. Vdi nghien cUu nay, thanh phan cap phoi duoe sif dyng chu yeu la bpt go, bpt da, PP, HDPE, bpt mau va mdt sd hpp chat phu gia. Ciing vdi sU trp giUp kinh nghiem thUc ti&n tU Cong ty TNHH Gd nhua Composite Viet Nam, ket hpp vdi nhdng yeu cau ti^ khach hang, nghien edu nay da de xuat mot quy trinh nhu ndi dung dUdi day de thd nghiem:
3.1. LUU do
Bing 3.1
Luu dd quy trinh sin x u i l
3.2. Thi^tbjsilir dung 3.2.1. Dde tinh mdy
Qua trinh san xuat sd dung may cd dac tinh sau:
- May trdn: Bao gom may trpn ndng va lanh co tae dung trdn deu cac nguyen vat lieu vdi nhau sao eho deu va on djnh nguyen lieu. Cae nguyen lieu duac can theo ti le (cdng thdc).
- May bam: Diing de bam nguyen lieu dim bj loi va cho dim lai thanh san pham hoan chinh.
- May dim hai true vit: May ehinh tao ra san pham hoan chinh, khi su' dung ket hop vdi cae khudn de dinh dang ra san pham theo mot hinh dang (profile) nhat dinh.
- May lam hat: Nguyen lieu tU may trdn ehuyen qua lam hat, tao ddng deu hat de khi eho vao may dim chi sir dung mdt che do nhiet dd, tde dd true vit...
- May gia edng be mat bao gdm may mai be mat, eao xUde be mat va tao van vdi hoa van san ed va dUOc gia edng b i n g nhiet.
- Cae may phu trp nhU may nen khi, may bum phue vu cho lam mat, may lam mat nude...
3.2.2. Che dp bdo dUong
Chu ky bao dudng may dupe thUe hien theo quy djnh eua nha may va eiia nha san xuat may. Viec thUc hien bao dudng ed the do can bp ky thuat cita nha may hoae nha eung cap dieh vu bao dudng (ben thir 3) tien hanh.
Cac may thudng xuyen dupe ve stnh b i n g khi hang ngay theo ea lam viec. Bom dau md dinh ky theo yeu cau ky thuat cita nha san xuat hoae 7 ngay bdm md va 3 thang thay dau mdt lan eho tat ea eae may. Bao dUdng may djnh ky do ben thU 3 thuc hien theo tieu ehuan ky thuat eiia nha san xuat.
3.3. Yeu cau ky thuat 3.3.1. Nguyen lieu
- Hat nhua: Sir dung nhua tat ehe lan mdt, ky hop ddng lau dai, bao gom nhua PP/PE mau xam. NhUa hat PP tai sinh polypropylene dupe tai sinh tir bao bi, van phdng pham, dyng eu thi nghiem, npi that d to... NhUa hat PE tai sinh tUtui nilon, mang phii edng nghiep, cd tinh ehat deo dai.
- Bdt go phai ddng nhat, ed dp mjn dam bao khdng cdn nhin thay bpt go tren be mat san pham. Cac thdng so ky thuat nhU sau: Kieh thUde: 180p; dp phan bo hat:
Dudi 250p ed tren 60%; dp ngam nudc dudi: 8%; mau sic:
vang, nau; tap ehat: khdng.
- Bpt da cd dp mjn theo tieu chuan va gde da vdi (CaC03): Dang bdt Tale, san xuat theo tieu ehuan Cdng ty Cd phan Khoang san Cdng nghiep mien Bac, bao bi ddng gdi theo tieu ehuan eiia nha san xuat.
- Chat lien ket sd dung chuyen cho nganh gd nhua bao gdm:
+ Chat lien ket dang TPPP8112 GA, carboxylated (maleie anhydride) PP (homopolymer);
+ Boi tron PYK - 4102 hydroxyl (san xuat tai DUc, nhap khau true tiep ve Viet nam)
- Bdt mau: Vd co gdc Fe203, pha trdn bpt mau vdi Ti02 theo ti le 1:5; cac bpt mau deu tan trong nUdc, dd tham thau dau t d 0.3 den 2.1 va dp PH 0.05 den 2.5. Khi d nhiet dp ISCC dp bay mau tUO.4 den 0,8%; dp min eua bdt duoe lpe eiia sang 45 mesh.
- Phy gia khae (khi can thiet) bao gdm ehat chong UV, oxy hoa, bdi tron...: Nguyen lieu tren deu cd ehdng nhan tieu ehuan dupe nhap khau true tiep hoac mua qua dai ly chinh hang tai Viet Nam.
3.3.2. Chi tiiu ehdt luang cua sdn pham Bing 3.2. Cac chi tieu chat luong eua sin pham
va phuong phip thd nghiim Ten chi lieu
Ktioi tuang the tich OohSpttiu nuac Bo ben uon M6-dun dSn tioi uon Ba ben keo
DmvJ g/cm^
%
MPa MPa MPa
Yeucaukythual JIS A 5741:2012 TirO,aaen 1,5 Ktiong tdn lion 100 Khong nh6 hon 15,0
PhiiOngph^pthA JISK7n2,1999 JIS A 5905 2003 J1SK7171 2008 ASTM 0638:2010
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KHOA HOC - CONG NGHE _
Cae ehi tieu ve an toan moi trUdng dupc tuan theo lEC 62321:2008 [2] va thUe hien bdi edng nghe phan tieh ICP-OES (may quang pho) cho cac cht tieu Cd, Pb, HG;
phuang phap trac quang UV - VIS cho Crdm hda tri 6 duoc the hien Bdng 3.3:
Bing 3.3. Cie chi tiiu ve an toan moi trudng Unchltiau
C a d m i u m ( Cdi Chi (Lead - Pb|
Thuy ngan (Mercury - HG) C r o m h o a t r i e
Y£u cau ky thuat ( m g / k g ) K f t q u S (mg/kg) 100 4 2
1000 106
1000 N.D ( n o t detected]
1000 N D
3.4. Ket qua mau san pham thijr nghiem 3.4.1. Mpt so hinh dnh sdn xudt thd nghiem
Hinh 3.7: Kiem tra hoan thien sin pham
KHOA HOC - CONG NGHE . _ So 04/2019
Hinh 3.B: Sin pham thd nghiim tao ra theo cac profile khie nhau 3.4.2. Ket qud thinghiem
Nhufng mau san pham thif nghiem san xuat deu da dupc mang di thi nghiem tai Trung tam Vat lieu hdu eO va Hda pham xay dung - Vi&n VM lieu Xay dUng, Bp Xay dung,
Bing 3.4. Ket qui thinghiim
TenchltHu Khoi liTong t h l tich Ob hap thu nu6c e o b i n u d n maun ahn hii \i6n M b ^ n h t e
lUnits) g/cm'
MPa tA?i MP^
T £ n c h l t i e u C a d m i u m { Cd) Chi [ L e a d - P b ) ThCiy ngSn (Mercury - HG) Crom h6a tri 6
Y £ u c i u k ; t h u i t 1 K f l q u i JiSA5741:20l'2 1 t h i n q h K m
TuO,Baerl5 13
Khong nh6han 15 0 O.J 36,8 29476
15.3
Phuang phdp IhA , J I S K 7 I U I 9 9 9
JIS K 7171.21)08 ASTM 0638 3010 Y ^ u c S u k y t h u a t
( m g / k g ) 100 1 0 0 0 1000 1000
K e t q u S ( m g / k g ) 4 2 106 K h 6 n g p h a t h i e n K h 6 n g p h a t h i e n
4. K^T LUAN
Tren co sd nghien cdu xay dung quy trinh san xuat thCf nghiem vdi day dCi va ehi tiet cae budc, ket hpp vdi thi nghiem theo tieu chuan ASTI\/1 va JIS, san pham thCf nghiem kh^c phuc dUOc nhdng nhupe diem cua san pham sin co hoac san pham tuong tunhap khau nhusau:
- l a n g dd lien ket giiJa thanh phan nhUa va bdt go, dan den ket cau san pham chac, ben va dac biet khdng binut;
- Gi^m he so gian nd nhu vay lam Scin pham se ed kich thudc on djnh hon nen han che toi da su cong venh cDa sSn pham;
- Mau sic cua san pham on dinh trong thdi gian dai;
- Sd dyng edng nghe sSn xuat mdi Co-Extrusion.
Hinh 4.1: Hinh inh dng dung MPC vio tudng chin giao thdng Vdi nhijfng khuon mau (profile) khac nhau, nhdng san pham WPC tao ra theo tinh toan cd gia thanh san pham tuong dUong vdi sSn pham nhap khau cua Trung Quoc, Malaysia va r^ hon 20 - 30% gia thanh nhap khau
t d mdt so nudc nhU Indonesia, Australia, Thailand... Bay la mpt CO sd rat Idn giup ehu ddng ngudn eung cap san pham trong nudc, han che phu thude vao san pham nhap khau. Dac biet, san pham thd nghiem nay se khic phuc dupc nhuoc diem cua ddng san pham xuat xd t d Trung Quoc hoac Malaysia va ed chat lUOng tuong duong thi trudng chau Au.
Hien nay, vdi sU trp giijp eija Cdng ty TNHH Go nhua Composite Viet Nam, nhdng san pham thd nghiem theo quy trinh san xuat nay da va dang dUa vao dupe thj trudng trong nUde, tieu bleu nhU nhdng edng trinh trong eae khu nghi dUdng cija Tap doan Vingroup tai Phu Quoc, Nha Trang... Dac biet, vdt nhdng chi tieu cO ly da dUclc xae djnh thong qua thi nghiem, loat WPC theo de xuat hoan toan cd the Ung dung vao he thdng tUdng ch^n am thanh (do tao dupe cac tiet dien rong) trong cac cdng trinh giao thdng qua khu vUe ddng dan eU.
Tai lieu tham khSo
[1 ]. Andrew high Precision Machinery Co, Ltd.
[2].IEC 62321:2008.
[3]. Anatole A.KIyosov (2007), Wood Plastic Composites, John Wiley & Son.
Ngay nhan bai: 15/02/2019 Ngay ch^p nhan dang: 10/3/2019 NgUdri phSn bien: TS. Tr^n DOc Phuc
TS. Nguyen Hoang
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