FIRECLAY

The United States Environmental Protection Agency defines fire clay very generally as a

"mineral aggregate composed of hydrous silicates of aluminium (Al2O3·2SiO2·2H2O) with or
without free silica.

Fire clay is a range of refractory clays used in the manufacture of ceramics, especially fire brick.

Fireclay consists essentially of kaolinite, a hydrous aluminum silicate that is usually combined
with bentonites in molding sand. It is highly refractory, but has low plasticity. It improves the hot
strength of the mold and allows the water content to be varied over greater ranges. Because of its
high hot strength potential, it is used for large castings. It is also used to improve sieve analysis
by creating fines whenever the system does not have an optimum wide sieve distribution of the
base sand. However, because of its low durability, its use is generally limited. In addition, the
need for fireclay can usually be eliminated through close control of sand mixes and materials.

PROPERTIES
High-grade fire clays can withstand temperatures of 1,775 °C (3,227 °F), but to be referred to as
a "fire clay" the material must withstand a minimum temperature of 1,515 °C (2,759 °F).[2] Fire
clays range from flint clays to plastic fire clays, but there are semi-flint and semi-plastic fire
clays as well. Fire clays consist of natural argillaceous materials, mostly Kaolinite group clays,
along with fine-grained micas and quartz, and may also contain organic matter
and sulphur compounds.
Fire clay is resistant to high temperatures, having fusion points higher than 1,600 °C (2,910 °F);
therefore it is suitable for lining furnaces, as fire brick, and for manufacture of utensils used in
the metalworking industries, such as crucibles, saggars, retorts and glassware. Because of its
stability during firing in the kiln, it can be used to make complex items of pottery such as pipes
and sanitary ware.
EXTRACTION
Unlike conventional brick-making clay, some fire clays (especially flint clays) are mined at depth,
found as a seatearth, the underclay associated with coal measures.

C0MPOSITION
The chemical composition typical for fire clays are 23-34% Al2O3, 50-60% SiO2 and 6-27% loss on
ignition together with various amounts of Fe2O3, CaO, MgO, K2O, Na2O and TiO2. Chemical analyses
from two 19th-century sources, shown in table below, are somewhat lower in alumina [3][4] although a
more contemporary source quotes analyses that are closer.

CELLULOSE

Cellulose is a molecule, consisting of hundreds – and sometimes even thousands – of carbon,

hydrogen and oxygen atoms. Cellulose is the main substance in the walls of plant cells, helping
plants to remain stiff and upright. Humans cannot digest cellulose, but it is important in the diet
as fibre.

Cellulose is added to control sand expansion and to broaden the allowable water content range. It
is usually added in the form of wood flour, or nut shells.
Cellulose reduces hot compressive strength and provides good collapsibility, thus improving
shakeout.
At high temperatures, it forms soot (an amorphous form of carbon), which deposits at the
mold/metal interface and resists wetting by metal or slags.

It also improves the flowability of the sand during molding. Excessive amounts generate smoke
and fumes and can cause gas defects. In addition, if present when the clay content drops too low,
defects such as cuts, washes, and mold inclusions will occur in the castings.