INTERNATIONAL JOURNAL OF ARTIFICIAL INTELLIGENCE
ISSN: 2692-5206, Impact Factor: 12,23
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УДК 678.8
PRODUCTION OF COMPOSITE GYPSUM MIXTURES FOR THE PRODUCTION
OF HEAT-INSULATING MATERIALS USING ALUMINOSILICATE ASH
MICROSPHERES
Talipov N.Kh.
Doctor of Engineering Sciences, Professor,
State Unitary Enterprise "Fan va Tarakkiyot", Uzbekistan, Tashkent.
Kattakhodjaev D.Yu.
Applicant, State Unitary Enterprise "Fan va Tarakkiyot",
Uzbekistan, Tashkent.
Panjiev O.Kh.
Doctoral candidate, State Unitary Enterprise "Fan va Tarakkiyot",
Uzbekistan, Tashkent.
Eshkulov N.U.
Applicant, State Unitary Enterprise "Fan va Tarakkiyot", Uzbekistan, Tashkent.
Annotation:
The paper presents the results of selecting the composition of composite gypsum
materials using inorganic fillers - ash microspheres, which are formed during the combustion of
coal at thermal power plants. Based on the laboratory studies, composite compositions have
been developed for obtaining heat-insulating building products with low bulk density. The
rheological properties and physical and mechanical properties of mortar mixtures have been
studied and the optimal compositions of composite gypsum mixtures for the production of heat-
insulating materials using aluminosilicate ash microspheres have been determined.
Key words:
mineral binders, filler, aluminosilicate microsphere, low bulk density,
superplasticizer, composite composition, density, thermal insulation materials.
Introduction.
Modern trends in the development of competitive production require the creation
of new promising thermal insulation materials for various purposes, consisting of mineral
binders, organic and inorganic porous mineral fillers with low bulk density. The use of inorganic
and organic lightweight fillers in the production of thermal insulation materials based on
gypsum binders allows you to adjust and improve the construction and technical and thermal
insulation properties of mineral binders and materials based on it to specified quality criteria.
Currently, new thermal insulation materials using inorganic porous fillers with low bulk density
are increasingly used in construction. All this requires the development of the most effective
compositions of thermal insulation materials with a low thermal conductivity coefficient.
Currently, the use of non-traditional porous fillers in the production of heat-insulating materials
with low bulk density is becoming widespread, for example, aluminosilicate ash microspheres
with various mineral binders and water-soluble polymers [1], which also act as a binder. The use
of ash microspheres as a component in cement or gypsum mixtures gives the material heat-
insulating properties and has increased physical and mechanical characteristics [1,2].
Aluminosilicate ash microspheres are a unique material with a wide range of applications. These
are hollow glass-crystalline aluminosilicate balls, which have a number of names: light fraction
of fly ash, ash microspheres, microspheres. Aluminosilicate microspheres are formed during
high-temperature flare combustion of coal at thermal power plants, as a result of granulation of
INTERNATIONAL JOURNAL OF ARTIFICIAL INTELLIGENCE
ISSN: 2692-5206, Impact Factor: 12,23
American Academic publishers, volume 05, issue 04,2025
Journal:
https://www.academicpublishers.org/journals/index.php/ijai
page 1043
the melt of the mineral part of the coal by crushing it into individual small drops and swelling of
the latter due to an increase in gas inclusions.
Object and methods of research.
During laboratory research on the development of thermal
insulation material compositions for partition purposes, composite gypsum binders were used as
a binder and aluminosilicate ash microspheres were used as a lightweight filler. To reduce the
water:solid ratio and increase the spreadability of solution mixtures, a water-reducing additive
was used - superplasticizer Polyplast SP-1. Polyplast SP-1 is manufactured according to TU
5870-002-58042865-05 in the form of dry powder and aqueous solution at the production sites
of Polyplast OJSC [3].
Composite gypsum compositions for the production of thermal insulation materials with low
bulk density were prepared in laboratory conditions. The homogenization process of the original
materials was carried out in a laboratory ball mill for 20 minutes [2,3]. The physical and
mechanical properties of the developed compositions were studied according to GOST 23789-
2018 in standard samples of beams measuring 4x4x16 cm molded from mortar mixtures of
normal density, the thermal conductivity coefficient of the samples was determined according to
GOST 17177-94, “Building thermal insulation materials and products. Test methods”.
The results obtained and their discussion.
Aluminosilicate microspheres obtained from ash
and slag are a mineral expanded finely dispersed bulk product of light gray color, consisting of
hollow spherical particles of regular shape with a diameter of 5 to 500 microns with solid non-
porous walls with a thickness of 5 to 10% of the particle diameter, and in chemical composition
corresponds to the main composition of impurities of burnt coals. The internal cavity of the
particles is filled with nitrogen and carbon dioxide.
Laboratory studies have shown that aluminosilicate ash microspheres have the lowest density
and are several times less than the density of water, which is the basis for effective gravitational
separation of microspheres from fly ash in an aquatic environment. Tables 1 and 2 show the
chemical composition and physical characteristics of aluminosilicate ash microspheres.
Table 1
Chemical composition of aluminosilicate ash microspheres.
Oxide content, mass. %
SiO
2
А1
2
О
3
Fe
2
О
3
СаО
MgO
TiO
2
R
2
O
Р
2
O
5
52,0-64,0
23,0 -29,0 1,5-6,0
0,1-5,8
0,5-2,0 0,6-1,0 1,0-2,3
0,2-1,0
Table 2
Physical characteristics of aluminosilicate ash microspheres
№
Characteristics
Indicators
1
Particle size, mm
0,04-0,125
0,1-0,3
0,25-0,5
2
Bulk density, kg/m
3
610
400
340
3
Average pressure
indicator, kN
24
24
24
4
Thermal conductivity,
W/mK
0,10
0,09
0,08
INTERNATIONAL JOURNAL OF ARTIFICIAL INTELLIGENCE
ISSN: 2692-5206, Impact Factor: 12,23
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5
Moisture content, %
Less than
0.5
Less than
0,5
Less than
0,5
6
Fraction content, %
22,3
31,8
45,9
Based on the laboratory studies, composite compositions were developed to obtain heat-
insulating building products with low bulk density. In the work, when selecting modifying
additives, the entire range of requirements for heat-insulating composite materials was taken
into account. The content of the modifier additive was established experimentally.
When selecting the optimal composition of composite materials, we first determined the
rheological properties of mortar mixtures at different ratios of the initial components, then
determined the effect of additives on the construction and technical properties and performance
indicators of thermal insulation materials. During the laboratory studies, the mechanism of
action of the superplasticizer on the properties of the developed compositions of composite
thermal insulation mixtures and products based on them was investigated.
The results of the study showed that the spherical shape and a wide range of granulometric
composition are ideal factors for a bulk filler, since the material in this form has increased
fluidity and, due to the effective ratio of surface area to occupied volume, ensures the most
compact packing, which allows to minimize the shrinkage deformation of finished products
based on microspheres compared to fillers of other shapes [3,4].
Laboratory studies of the physical and mechanical properties of composite gypsum materials
have shown that finely dispersed ash microspheres in the amount of 7.5-10% improve the
rheological properties of mortar mixtures and increase the strength characteristics of the
composition by 15-18%. The increase in the strength indicators of composite thermal insulation
mixtures is explained by the fact that highly dispersed particles of ash microspheres fill the
voids between coarser grains in the process of forming the structure of calcium sulfate dihydrate
in hardened materials.
The study of the physical characteristics of samples made from normal density composite
thermal insulation mixtures showed that depending on the amount of lightweight filler, it is
possible to regulate the thermal and physical and mechanical properties of materials. The results
showed that with the introduction of 7.5-10% ash microspheres into the composition of gypsum
mixtures, it is possible to obtain building products with an average density of 475 - 700 kg / m
3
.
Conclusion.
Based on the conducted laboratory studies, it was established that, depending on
the amount of lightweight filler, it is possible to regulate the thermal and physical-mechanical
properties of composite materials with low bulk density used in construction. The results
showed that the thermal conductivity coefficient of the developed composite materials with an
average density of 475 - 700 kg / m³ with a content of aluminosilicate microspheres of 7.5 -
10.0% is equal to 0.170 - 0.190 W / m K [5].
Based on the conducted studies, it was established that for the production of thermal insulation
materials with high strength and low thermal conductivity, the use of aluminosilicate
microspheres in the compositions of composite gypsum binders is promising.
INTERNATIONAL JOURNAL OF ARTIFICIAL INTELLIGENCE
ISSN: 2692-5206, Impact Factor: 12,23
American Academic publishers, volume 05, issue 04,2025
Journal:
https://www.academicpublishers.org/journals/index.php/ijai
page 1045
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