Raising the quality of calcium silicate unitswith simultaneous reduction of production costs using Statistical Design of Experiments (DoE)

As part of the investigations carried out, a mathematical model with which the brick compressive strength can be predicted was built up, examplarily on the basis of raw materials from a calcium silicate unit plant. All the relevant production parameters were varied using the methods of statistical design of experiments (DoE). The calculations carried out are based on the data records for the raw materials, generated from 72 experiments in the pilot plant, the process-related manufacturing parameters and the measured brick properties. The energy required for a set of manufacturing parameters and the associated CO2 emissions can be calculated, so that the desired approaches for reducing energy consumption and environmentally relevant emissions as well as maintaining the quality for implementation in calcium silicate unit plants are available. These are - as far as technically possible - especially the - Reduction of energy consumption - Reduction of environmentally relevant emissions - Reduction of production costs by reducing the input of lime - Reduction of the manufacturing time by shortening the hardening time in the autoclave - Maintaining or increasing product quality, e.g. by optimizing the CSH phase constitution