Copper Slag: Consumption Of Abrasive Powder For Sandblasting Per 1 / M2 Of Metal Structures (metal), Hazard Class, Copper Slag From The Karabash Plant And Other Russian Manufacture

2024 Author: Beatrice Philips | [email protected]. Last modified: 2023-12-16 05:33

For normal work with copper slag, you need to know what is the consumption of abrasive powder for sandblasting per 1 / m2 of metal structures (metal). It is also necessary to understand the hazard class of this substance, with other features of its use. A separate topic is the choice of the kuperslag of the Karabash plant and other manufacturers in Russia.

What it is?

There is a huge amount of goods and products around people. Along with widely used in everyday life or simply known in general terms, those things that only narrow specialists know about can play a significant role. This is exactly what the copper slag is (occasionally there is also the name cup slag, as well as mineral shot or grinding grain). This product is now widely used for abrasive blast cleaning.

Nickel slag is partly similar to it, distinguished only by its increased hardness.

How is kuperslag made?

You can often read that copper slag is copper slag. However, in fact, it belongs to the number of synthesized materials. To obtain such a product, first the slags obtained after copper melting are actually taken. The semi-finished product is mechanically crushed in water, then dried and screened out . As a result, the final composition does not contain copper at all, since they try to extract it as fully as possible from the ore and use it in production.

Abrasive workpieces based on copper slag are usually labeled as Abrasive ISO 11126 . Separate markings are assigned for non-metallic products. The designation / G may also occur, which indicates the shape of the abrasive particle. Further numbers show what the cross section is.

The established standard says that cooper-slag particles cannot be larger than 3, 15 mm, however, and dust, that is, fragments less than 0.2 mm, should account for a maximum of 5% . It is worth noting that in a number of cases they try to reuse already spent copper slag. This saves many valuable resources. Practice has shown that it is possible to restore working capacity for 30-70% of the spent abrasive, depending on a number of circumstances.

A complex apparatus for pumping recyclable materials is usually not needed . It can also move through the pipes to the roar due to the force of gravity. But this is typical mainly for semi-handicraft installations.

Industrial grade machines often use pneumatic or mechanical abrasive collection systems, from which the recyclable material goes to the sorting unit.

Characteristics and properties

A quality certificate must be issued for the supplied copper slag (both primary and secondary series). It reflects the main parameters of the supplied product. The composition of the abrasive complex includes the following chemical fractions:

• silicon monoxide from 30 to 40%;
• aluminum dioxide from 1 to 10%;
• magnesium oxide (sometimes referred to as burnt magnesia for simplicity) 1 to 10%;
• calcium oxide also from 1 to 10%;
• iron oxide (aka wustite) from 20 to 30%.

Kupershlak is composed of dark, acute-angled particles . Its bulk density is from 1400 to 1900 kg per 1 m3. In this case, the indicator of the true density varies from 3, 2 to 4 grams per 1 cm3. The moisture content normally does not exceed 1%. The share of extraneous inclusions can account for up to 3% maximum. According to GOST, not only the specific gravity is normalized, but also other technical indicators of the product. So, the share of grains of lamellar and acicular species can account for a maximum of 10%. Specific electrical permeability is up to 25 mS / m, and exceeding this parameter is not recommended.

The standard hardness according to the Moos scale is up to 6 conventional units . The entry of water-soluble chlorides is also normalized - up to 0, 0025%. Other important parameters: level of abrasive ability from 4 and dynamic strength not less than 10 units. Many people naturally take an interest in the copper slag hazard class. Sandblasting is accompanied by the release of fine suspended matter into the air, and it has the potential to harm living organisms. And in this regard, kupershlak pleases: it belongs to the 4th hazard class, that is, to the category of practically safe substances.

According to GOST, the following MPCs are established for such reagents and abrasives:

• concentration in the air at the place of work over 10 mg per m3;
• lethal dose if swallowed 5 grams per 1 kg of body weight;
• a lethal dose in contact with unprotected skin is 2.5 grams per 1 kg of body weight;
• critically dangerous concentration in the air, threatening life - over 50 grams per 1 cubic meter. m;
• the coefficient of air poisoning is less than 3.

Gas analyzers are used to monitor the presence of copper slag in the air. Sampling for detailed laboratory studies should be carried out at least once every 90 days. This rule applies both in production facilities and in open work sites.

It is advisable to use personal protective equipment during cleaning work. Switching to closed-loop sandblasting helps dramatically reduce the hazard.

Comparison with quartz sand

The question "Which abrasive is better" worries many people. It can only be answered with a careful analysis of the technological nuances . When quartz grains of sand hit the surface, a large number of small dust grains are formed. Their dimensions are from 15 to 30 microns. Along with quartz, these dust particles can be both clay and impurities after the destruction of the rock. Such inclusions can be hammered into the gaps by the peak of the machined surface. It is possible to remove them from there with brushes, but this procedure, causing a significant waste of money and time, does not allow achieving ideal quality. Even the smallest quartz residue provokes rapid corrosion of steel. Attempts to solve the problem by staining give only a short-term fragile effect.

Kupershlak is guaranteed to remove the very likelihood of harmful dust . On impact of this abrasive, only partial destruction occurs. The likelihood of the formation of a somewhat pronounced dust layer is minimized. If, however, there are dust grains, grains of sand, then they are very easily removed due to the supply of compressed air. For such an operation, no additional specialists are needed, and you can get by with minimal labor costs. Leading experts and companies report that it is the copper slag that is optimal for working with surfaces. The expected warranty period for coatings cleaned in this way is up to 10 years. In some cases, it is even twice as long. But there is another fact that is often overlooked. Namely, back in 2003, by the decision of the chief sanitary doctor of Russia, sandblasting with dry ordinary sand was officially prohibited. It is too dangerous for your health.

Quartz dust includes pure quartz and silicon dioxide. Both components, to put it mildly, can hardly be called beneficial to health. They cause such a formidable disease as silicosis. The danger concerns not only those directly employed in the sandblasting industry (they are usually protected by special suits, respiratory protection), but also those who are nearby. A serious risk applies to everyone who is within a radius of 300 m (taking into account the direction and speed of air currents).

Silicosis is not cured even by modern medical interventions. It is not for nothing that in a number of states the cleaning of surfaces with jets of quartz sand was banned in the last century. Therefore, the use of copper slag is also an important guarantee of safety. Its increased cost is fully justified yet:

• almost three times faster cleaning of surfaces;
• decrease in consumption per unit surface;
• the possibility of secondary and even triple use;
• less wear and tear of the equipment used;
• reduction in labor costs;
• the ability to clean the surface according to the international standard Sa-3.

Main manufacturers

In Russia, the dominant position in the production of copper slag is occupied by the Karabash abrasive plant in the city of Karabash. A full cycle of production of a finished product is deployed there. The company is also engaged in the sale of its own products through the trading house "Karabash Abrasives ". The shipment is usually in bags. The company also sells a lot of sandblasting and painting equipment operating on the same principle, consumables for such devices.

Uralgrit (Yekaterinburg) also has significant positions in the market . There is a complete set of everything you need for corrosion protection. Uralgrit has been producing abrasive powders and equipment for their use for over 20 years. The presence of warehouses throughout the Russian Federation allows you to quickly receive the necessary goods. The supplied products allow you to immediately deploy sandblasting.

Sending goods is possible both by rail and by highway.

Application

Abrasive powder for sandblasting is very important when you need to get rid of rust and signs of scale. The same composition is used in the preparation of various surfaces for painting, treatment with anti-corrosion mixtures. Kupershlak is suitable for pure concrete, reinforced concrete, metal, natural stone, ceramic and silicate bricks. You can use abrasive from copper production waste:

• in the oil and gas sector;
• in work with other pipelines;
• in construction;
• in various branches of mechanical engineering;
• cleaning bridges and other extended metal structures (and these are just the most common and obvious examples).

It should be borne in mind that Cooper Slag cannot be used in an aquarium. Meanwhile, some unscrupulous sellers are selling it for this very purpose. Aquarists note that backfilling of copper slag inevitably leads to poisoning of all inhabitants of the vessel . Even the toughest fish can die. The main reason is excessive metallization.

The abrasive can also be used for processing river and sea vessels . This composition is suitable for the treatment of walls in residential and non-residential premises. It is used to clean damaged and defrosted parts of objects during repairs. Very fine powder fractions are suitable for cleaning aluminum. It will be possible to successfully remove the remains of rubber, paint and varnish coatings, grease, fuel oil and many other unwanted components.

Cleaning is possible both in everyday mode and to combat old dirt.

Consumption

The consumption rate of copper slag in various situations varies from 14 to 30 kg per 1 cubic meter. m of the surface to be cleaned. Much, however, depends on the requirements. So, if you just need to bring the metal surface to the state Sa1, and the pressure does not exceed 7 atmospheres, from 12 to 18 kg of the composition will be consumed . When the pressure rises to more than 8 atmospheres, the cost per 1 / m2 of metal structures will already fluctuate from 10 to 16 kg. If cleaning to Sa3 is required, then the recommended figures are 30-40 and 22-26 kg, respectively.

We are talking about the recommended indicators because there are no strict regulatory requirements at all. The standards cannot regulate also the consumption of abrasive per m3. The fact is that practical work is faced with a large number of influencing factors. An important role is played by the degree of surface contamination and the specific type of metal, the copper slag fraction, the equipment used, and the qualifications of the work performers. To cut costs, you need:

• purchase only a flawless product;
• use professional equipment and monitor its serviceability;
• to stimulate material saving by sandblaster;
• monitor the order of storage of abrasive raw materials;
• equip the equipment with remote control systems for abrasive flow.