Urgency
One of the most pressing challenges of the new construction and
maintenance of existing buildings and structures is a hydroprotection and restoration of the bearing capacity of building
structures. Water acts on structures in the outer or inner side
(atmospheric and groundwater).
In the spring thaw raises the groundwater level (GWL), which
interact with mineral and organic particles, change their chemical
composition and concentration. Groundwater level fluctuations
activate the leaching of lime in concrete structures. Rainwater
captures from the atmosphere of a large number of gaseous
industrial emissions. Is converted to the acid rain solution
destroying concrete, marble, silicate bricks, this increases the
number of pores, capillaries, and cracks.
For protection of various constructions from surface wear and
cracking, i.e. from the harmful effects of water and aggressive
environment use various waterproofing materials (based on cement,
bitumen, polymer).
Urgency
Relevant environmental, technical and
economic problem in many countries is
the utilization of sulfur formed as
waste oil and gas, the amount of
which is increasing every year,
reaching several million tons.
The pollution of the environment
sulfur dust, which in windy weather
spreads over long distances. Are often
sulfur dust explosions occur.
Processing of low-cost sulfur is
economically viable and could
solve the environmental problem
in any region.
LLC «Gubkin E & TC» has developed a unique product
- a waterproof coating on the basis of polymeric sulfur,
which would solve two problems at once:
1
• - the problem of new construction and operation
of existing buildings and structures associated
with waterproofing and repair of building
structures (foundations, etc.) exposed to
groundwater, surface water and industrial waste
waters, adverse climatic factors
2
• - problem of disposal of the
sulfur formed as a departure of
oil and gas processing, the
amount of which is increasing
every year
The application of waterproofing coatings
based on highly polymerized sulfur
The lining and protection
of underground facilities
Waterproofing
underwater, waterworks
Waterproofing of building
structures in the disposal of
chemical waste
Waterproofing dams,
bridge piers, quays
Waterproofing pools,
reservoirs, ponds
Examples of constructions which can be used for
waterproof coating on a highly polymerized
sulfur:
Hydraulic facilities:
•
•
•
•
•
•
Civil engineering structures:
Reservoirs (open, diked etc.)
Swimming pools (open and closed)
Manholes
Docks
Berths
The design of treatment facilities
(aeration tanks, septic tanks,
sewers, pumping, etc.)
• concrete seawall
• Dams, etc.
•
•
•
•
•
Foundations
Basements
Underground facilities (parking
lots, garages, transitions, etc.)
Balconies
Lift shafts
Examples of constructions which can be used for
waterproof coating on a highly polymerized
sulfur:
Industrial and agricultural
facilities:
•
•
•
•
•
•
•
Industrial premises
Pools of cooling towers
Vaults
Chimneys
Mines
Bins
Concrete structures exposed to
aggressive action, etc.
Objects of energy sector:
•
•
•
•
•
•
Spent nuclear fuel pools
Pumping stations
Storage of spent nuclear fuel
Canals
Overpass of fuel
Cable tunnels
Examples of constructions which can be used
for waterproof coating on a highly polymerized
sulfur:
Concrete structures exposed to
radiation, etc. Transport
infrastructure :
Objects of Defense and Emergencies :
•
•
Seekers
Fire tanks, etc.
•
•
•
Tunnels (road, rail, walking, etc.)
Subways
The elements of bridges and roads,
etc.
The benefits of an innovative product :
Economic efficiency
Efficiency, reliability,
durability
Safety and
environmental
The opportunity to work
with a variety of
construction materials
(concrete, brick, etc.)
Ability to work under
the negative ambient
temperatures
No pretreatment step
of building materials
Market
• Construction is one of the most important sectors of the
national economy. Its condition largely determines the level
of development of society and its productive forces.
• Along with the development of the construction industry is
growing demand for high-performance waterproofing
coating. Existing on the market waterproofing materials
have a number of drawbacks, such as high cost, low
efficiency, fragility, low resistance to aggressive media, etc.
• Thus, an innovative product - the waterproof coating on the
basis of a highly polymerized sulfur will be worthy
competition to existing waterproofing materials on the
market and the demand is expected to be high.
Areas of use of an innovative
product
Waterproofing at during
manufacture of building
materials
Waterproofing on
stage repair of
finished
constructions
Thus, the implementation of technology applied waterproofing
coating can be carried out at the plants by entering additional
workshops, as well as at the location of the object, using
compact equipment necessary for the application of a
waterproofing coating.
Technologies of drawing of waterproofing coating
based on a highly polymerized sulfur on building
materials:
Complete impregnation
•
In the first method the impregnation is carried
out by dipping the product in the chamber with
the melt impregnation of polymeric sulfur. This
flow chart is best suited for permanent
installation, for example, at an operating plant of
concrete products as a complementary
technology unit in which part of the products
produced by the plant can be processed in the
melt of polymeric sulfur. Possible to use this
method for operating a mobile unit in which the
impregnation products operate on site
immediately before installation (for example,
prior to impregnation pile elements clogging or
zero cycle before their installation). The first
method is used when processing prefabricated
usually new, not yet assembled products. The
depth of infiltration is provided and monitors the
flow rate of the solution in the bath for
impregnation cycle.
Surface impregnation
• By the second method the melt
polymeric sulfur applied to the
surface of structures by
brushing, rolling, spraying, or
by another similar device. The
method can be used for precast
have not yet mounted
structures and elements for
existing buildings, including at
their repair or reconstruction.
Embodiments of an innovative
product
1
• Construction of the production of polymeric sulfur and
sales of waterproofing material as to the factories that
manufacture building materials, as to individuals willing
to repair the building structures.
2
• Construction of the production of polymeric sulfur and
maintenance of commercial production of a new product
at the plant, produces building materials, and,
accordingly, sales of a new product - "a building
material with a waterproofing coating."
The calculation of the construction unit for production
of polymeric sulfur capacity - 6000 tons / year. This will
get the following amounts of development of
technology:
The impregnation of concrete
• Complete impregnation requires the
consumption of a building material
for 1m3 approximately 6kg, which
will handle about 1 000 000 m3 of
building products.
• A melt flow of polymeric sulfur per
1m2 for surface treatment is 0.8-1.0
kg. It will handle more than 6000000
m2 of surface.
The impregnation of bricks
• Complete impregnation of one
brick requires the consumption of
0.11 kg of polymeric sulfur, which
will handle nearly 54 mln bricks.
• In 1m2 masonry contains 51 brick,
hence the polymer sulfur flow rate
per 1m2 at full treatment is 51 *
0.11 = 5.61 kg.
• A flow of polymeric sulfur per 1m2
for surface treatment is 0.8-1.0 kg.
It will handle more than 6 000 000
m2 of surface.
• In 1m3 masonry contains 394
bricks, from here on 1m3 brick
masonry with full treatment takes
about 394 * 0.11 = 43.34 kg.
Technological scheme of the unit for
the preparation of polymeric sulfur in
3D
Overview of the equipment needed to
produce polymeric sulfur
1. Storage tanks and sulfur stabilizer, equipped with electric
paddles and heating jacket, coolant - superheated steam.
2. Reactor-mixer for preparing a composition of liquid sulfur and
stabilizer: equipped with a paddle stirrer with electric and
heating jacket, Heat carrier - superheated steam.
3. Fridge-crystallizer scraper, refrigerant: cooling water or liquid
propane from propane refrigeration cycle.
4. Heater - heat exchanger scraper, Heat carrier - superheated
steam;
5. Pumps;
6. Dispensers.
Safety and environmental project
On this innovative product is designed MSDS
•
•
•
•
•
In the solid polymeric sulfur (polymerization degree 75-80%) - fire
resistant material, non-toxic, hazard class 4. Liquid sulfur is non-toxic.
Melting point-120°C, the temperature of spontaneous combustion 575
°C.
Solid polymeric sulfur is in the glassy state and does not generate sulfur
dust.
Liquid polymeric sulfur in the overflow and storage (in direct contact
with oxygen in air) generates sulfur dioxide (SO2) in a small amount
(within the maximum allowable concentration). The maximum
permissible concentration (MPC) for airborne concentrations are: for
sulfur dioxide - 10 mg/m3. Monitoring the MPC is the local branch of
environmental control.
Polymeric sulfur is not more toxic compounds forms in the air and waste
waters in the presence of other substances and it has no cumulative
properties.
Safety and environmental project
Qualified personnel must be trained
Knowledge check on industrial safety and
labor protection, safety at work with polymer
sulfur, as well as familiar with the relevant
sections of the instructions and emergency
response plans.
When working with polymer modified sulfur
staff must be provided with personal protective
equipment (PPE) and protective equipment
Respiratory Equipment (RPE) (special clothing,
safety goggles, rubber gloves, respirators).
Calculation of income from the sale of
polymeric sulfur
Item name
Amount , in
tons / year
Unit price of,
EUR / ton
Overall,
EUR / year
Sulfur Polymer, including:
6 000
- sulfur from the gas processing
5 940
37.5
222750
60
1875
112500
- stabilizator
Total raw materials
6 000
Sulfur Polymer
6 000
Total income
335250
200
1200000
864750
Technical and economic characteristics of the
installation for the production of polymeric
sulfur capacity of 6000 tons / year
№
data
module
units of
1
Annual operating mode
час.
8 000
2
Commercial products in
natural units:
2.1
Polymeric sulfur
tons / year
6 000
3
Commodity output
EUR
1 200 000
4
Growth of commodity products
EUR
864750
EUR
350000
EUR
103000
6
Additional operational
expenses
Profits tax
7
Net income for the year
EUR
411875
8
Capital expenses
EUR
432497,5
9
Payback period
year
1,05
5
The dynamics of growth of tariffs for raw
materials, wages, operating costs and the
cost of commodity product
data
wages
the cost of electric
power
operating costs
(transport, replacement
materials, service)
raw material costs
commodity price of
the product
normative,
%
module today
EUR /
8
year
254671
EUR /
2,5
year
78000
2
1,5
2,3
EUR /
year
EUR /
year
EUR /
year
after 1
year
after 2
year
after 3 after 4 year after 5
year
year
275045
297049
320812
346477
374960
79950
81949
83998
86098
88250
14178
14462
14751
15046
15347
15654
335250
340279
345383
350564
355822
361160
200
204,5
209,25
214
219
224
The dynamics of growth of wages,
insurance premiums and tax
payments
тыс. руб.
Technology of production of
building materials with a
waterproofing coating
• This technology is to fully melt impregnation of
building materials, and polymeric sulfur can be
carried out directly on plants producing building
materials.
• Below are the results of calculations of this
technology for the impregnation of concrete and
brick. The calculation for each construction
material is kept separately.
The calculation of the capital cost of the
introduction of the installation for applying a
waterproofing coating for building materials
№
Name of equipment and costs
Number Required
of units. Ratio% of
the cost
Unit price
of, .EUR
Sum, EUR.
1
basic equipment:
1.1
Heated tank for liquid polymeric sulfur
1
16250
16250
1.2
The conveyor-belt
1
50 000
50 000
1.3
Other
Total capital equipment
Iinstrumentation
Shut-off and control and relief valves
Total equipment
Transportation, harvesting and storage costs
2
3
4
5
6
Dismantling, assembly
Project work
Total capital expenditures
20
30
10
15
50
2500
68750
13750
20625
34375
10313
15469
51563
180469
Calculation of income from the sale of building
materials with a waterproofing coating of
polymeric sulfur.
Waterproofing concrete
Item name
Waterproofing brick
Number of
m3 / year Unit price Sum, mln
(concrete of, EUR./ EUR./
cubes)
м3
year
(S, ton/year)
Raw materials,
including:
- concrete
- polymeric sulfur
Raw materials,
including:
- brick
1 000 000
100
100
6 000
200
1,2
Total raw materials:
concrete with
1 000 000
waterproofing coating
Total income
Item name
101,2
110
Number, ths Unit price , Sum, mln
units / year
EUR/
EUR./
(S, ton/year) ths units
year
- polymeric sulfur
53 93258
300
16,1798
6 000
200
1,2
Total raw materials:
110
brick with
53 93258
waterproofing coating
8,8
Total income
17,3798
337,5
18,2023
0,8225
Technical and economic parameters of the unit for
applying a waterproofing coating for building
materials
Waterproofing concrete
№
Data
module
1
Annual operating mode
hour
2
Commercial products:
2.1
3
4
Concrete with
waterproofing coating
Cost of commodity
production
Growth of commodity
products
Waterproofing brick
U
№
Data
module
1
Annual operating mode
hour
2
Commercial products::
2.1
м3
1 000 000
ths. EUR
110 000
3
ths. EUR
8800
4
U
Brick with waterproofing
coating
Cost of commodity
production
Growth of commodity
products
ths units
53 93258
ths. EUR
18202,3
ths. EUR
822,5
5
Additional operational
expenses
ths. EUR
8388,2
5
Additional operational
expenses
ths. EUR
701,4
6
Profits tax
ths. EUR
82,36
6
Profits tax
ths. EUR
24,21
7
Net income for the year
ths. EUR
329,44
7
Net income for the year
ths. EUR
96,86
8
Capital expenses
ths. EUR
180,47
Payback period
year
0,55
Capital expenses
Payback period
ths. EUR
9
8
9
180,47
1,86
year
The dynamics of growth of tariffs
Waterproofing concrete
data
wages
the cost of electric
power
operating costs
(transport,
replacement
materials, service)
raw material costs
commodity price
of the product
normative,
%
module
today
after 1 year after 2 year after 3 year after 4 year after 5 year
Ths EUR /
254,67
year
275,05
297,05
320,81
346,48
374,20
2,5
Ths EUR /
year
8125
8328,13
8536,33
8749,74
8968,48
9192,69
2
Ths EUR /
year
7,01
7,15
7,30
7,44
7,59
7,74
1,5
Ths EUR /
101200
year
102718
104259
105823
107410
109021
1,7
Ths EUR /
year
0,1118
0,1138
0,1158
0,1178
0,1198
8
0,11
The dynamics of growth of tariffs
Waterproofing brick
data
wages
the cost of electric
power
operating costs
(transport,
replacement
materials, service)
raw material costs
commodity price of
the product
normative,
%
module
today
8
Ths EUR /
year
254,67
275,05
297,05
320,81
346,48
374,20
2,5
Ths EUR /
year
438,2
449,16
460,39
471,9
483,69
495,79
2
Ths EUR /
year
7,01
7,15
7,30
7,44
7,59
7,74
1,5
Ths EUR /
year
1738
17640,5
17905,1
18173,7
18446,3
18722,9
1,7
Ths EUR /
year
0,3375
0,34325
0,349
0,355
0,361
0,36725
after 1 year after 2 year after 3 yearafter 4 year after 5 year
The dynamics of growth of wages,
insurance premiums and tax
payments
Waterproofing concrete
Waterproofing brick
тыс. руб.
ООО «Губкинский инженернотехнический центр»
http://gubkin-etc.ru/
conclusion:
Necessary information from the customer to design the plant
for the production of polymeric sulfur:
1. Productivity of the plant;
2. Information about the initial temperature of the raw sulfur
coming to the plant;
3. Type of refrigerant (propane, ammonia, water) and
parameters (t, P);
4. Selection of shipment (packaging) of the finished product
(type, size of package).
Comparative characteristics of waterproof
materials and placement of seats in accordance
with the evaluation criteria
The evaluation criteria
Waterproofing on the basis of
polymeric sulfur
Cost-effectiveness (cost /
expense)
0,2 € /m2
Efficiency (ratio of water
absorption)
1
Type of waterproofing material
Waterproofing cement-based
Polymer waterproofing
Waterproofing bitumen-based
2
1,75 € /m2
1
3
3,2 € /m2
15 € /m2
4
3
4
2
durability
Comparable with the lifetime of
the building material
Comparable with the lifetime of
the building material
1
1
15years
20-30 years
4
2
3
The need for pre-treatment
Pretreatment is not needed
required surface preparation
1
required surface preparation
2
requires careful preparation of the
surface
3
4
Safety and environmental
-operation at elevated
temperatures
1
3
Resistance to aggressive
environments
2
1
Total:
1
operation at elevated
temperatures;
- hazardous emissions into the
atmosphere
4
3
2
2
4
4
2
3
3