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Ceramic Industry

Banda, Bautista, Catarata


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INTRODUCTION
Introduction
• The traditional ceramic industries, have
as their finished materials a variety of
products that are essentially silicates.
• In recent years, new products have been
developed as a result of the materials
that withstand higher temperatures,
resist greater pressures, etc.
What are Ceramics?
• pots and other articles made from
clay hardened by heat.
• A ceramic is an inorganic non-metallic
solid made up of either metal or non-
metal compounds that have been
shaped and then hardened by
heating to high temperatures. In
general, they are hard, corrosion-
resistant and brittle.
What are Ceramics?
• Ceramic comes from the Greek word
meaning ‘pottery’. The clay-based
domestic wares, art objects and building
products are familiar to us all, but pottery
is just one part of the ceramic world.
• Nowadays the term ‘ceramic’ has a more
expansive meaning and includes materials
like glass, advanced ceramics and some
cement systems as well.
How about Pottery?
• pots, dishes, and other articles made
of earthenware or baked clay. Pottery
can be broadly divided into
earthenware, porcelain, and
stoneware.
• Pottery is generally considered to be
containers made from clay. "Pot" is a
term used for any number of container
forms. 
Introduction
• In this particular discussion, we will
tackle about:
– Whitewares
– Structural Clay Products
– Refractories
– Specialized Ceramic Products
– Enamels and Enameled metal
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HISTORY
History
• Burnt clayware has been found
dating from about 15,000 BC
• Well developed in Egypt in 5, 000 BC
• Various ancient races were found to
have created clay products
independently of each other
History
• The advent of cross-fertilization of
silicate chemistry, metallurgy, solid-
state physics, computer-controlled
processes, and advanced automation
modernized methods of fabrication.
• It is now possible to produce
ceramics with superior qualities.
History
• Recently, new process have been
developed for brickmaking from
inorganic wastes (fly ash, foundry
sand, mine tailings, furnace slag,
etc.)
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HUMAN UTILIZATION
Human Utilization
• Building brick
• Sewer pipe
• Drain tile
• Filler in paper
• Filler in rubber
• Filler in plastics
• Filler in paint
• Filler in fertilizers
Human Utilization
• Fridge magnets
• Metals production
• Aerospace
• Electronics
• Automotive
• Personal protection
Human Utilization
• In modern medicine, advanced ceramics –
often referred to as bioceramics – play an
increasingly important role. Bioceramics
such as alumina and zirconia are hard,
chemically inert materials that can be
polished to a high finish. They are used as
dental implants and as bone substitutes in
orthopaedic operations such as hip and knee
replacement.
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BASIC RAW MATERIALS


Basic Raw Materials
• Classic Ceramic Products:
– Clay
– Feldspar
– Sand
Clay
• Impure hydrated aluminum
silicates
• Resulted from the weathering of
igneous rocks in which feldspar
was a noteworthy component
Clay
•  
Potash feldspar:
Kaolinite:
Silica:
Clay
•  Clay minerals:
– Mixture of:
• Kaolinite:
• Montmorillonite:
• Illite: K2O, MgO, Al2O3, SiO2, H2O (in
varialble amounts)
Clay
• Plastic and moldable when
pulverized and wet
• Rigid when dry
• Vitreous when fired at a suitably
high temperature
Clay
• Accompanied by varying
amounts of feldspar, quartz, and
other impurities (oxides of iron)
• Kaolinite – the basic clay mineral
present in nearly all the clays
used in the ceramic industry
Clay
• Chosen for particular properties
• Frequently blended to give the
most favorable result
• Physical Properties and impurities
vary from clay to clay
• It is necessary to upgrade them
by beneficiation process
Feldspar
•  Common types:
– Potash:
– Soda:
– Lime:
• Fluxing constituent in ceramic
formulas
Sand
• “Flint”
• the skeletal structure upon which
clays and flux components attach
•  used to modify thermal
expansion, regulate drying and
shrinkage, and improve structural
integrity and appearance
Basic Raw Materials
Kaolinite Feldspar Sand or
Flint
Formula SiO2
Plasticity Plastic Nonplastic Nonplastic
Fusibility Refractory Easily fusible Refractory
binder
Melting Point 1785°C 1150°C 1710°C
Shrinkage on Much Fuses No Shrinkage
burning shrinkage
Additional Raw Materials
• Fluxing agents – lower vitrification
temperature, melting temperature,
reaction temperature
• Refractory ingredients – retains the
strength of the material at high
temperatures
Common fluxing agents
• Borax
• Boric Acid
• Soda Ash
• Sodium nitrate
• Pearl ash
• Nepheline syenite
• Calcined bones
• Apatite
• Fluorspar
• Cryolite
• Iron oxides
• Antimony oxides
• Lead oxides
• Lithium minerals
• Barium minerals
Common refractory ingredients
• Alumina
• Olivine
• Chromite
• Magnesite
• Lime and limestone
• Zirconia
• Titania
• Hydrous magnesium silicates
• Aluminium silicates
• Dumortierite
• carborundum
• Mullite
• Dolomite
• thoria
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CHEMICAL CONVERSIONS AND


BASIC CERAMIC CHEMISTRY
Chemical conversions and basic
ceramic chemistry
• All ceramic products are made by
combining various amounts the
aforementioned materials, shaping
and firing to temperatures (700°C -
2000°C)
Chemical conversions and basic
ceramic chemistry
• Chemical conversions:
– Dehydration: “chemical smoking” 150 -
650°C
– Calcination: 600 - 900°C
– Oxidation of ferrous iron and organic
matter: 350 - 900°C
– Silicate formation: 900°C and higher
Chemical conversions and basic
ceramic chemistry
• Phase-rule studies have been of
importance in interpreting empirical
observations in the ceramic
industries and in making predictions
for improvements
Chemical conversions and basic
ceramic chemistry
Chemical conversions and basic
ceramic chemistry
• Ceramic products are all more or less
refractory and the degree of
refractoriness of a given product is
determined by the relative quantities
of refractory oxides and fluxing
oxides
Chemical conversions and basic
ceramic chemistry
• The common ingredient of all
ceramic products is clay, and
therefore the chemical reactions
which occur on heating clay are
important
Chemical conversions and basic
ceramic chemistry
• The
  first effect of the heat is to drive
off the water of hydration (600 -
650°C)
• The clay absorb more heat, leaving
an amorphous mixture of alumina
and silica
Chemical conversions and basic
ceramic chemistry
• A large proportion of the alumina can
be extracted with hydrochloric acid in
this stage
• As heating is continued, the amorphous
alumina changes sharply at 940°C to a
crystalline form of alumina, γ-alumina,
with the evolution of considerable heat
Chemical conversions and basic
ceramic chemistry
•  At 1000°C, the alumina and silica
combine to form mullite (
• At a still higher temperature, the
remaining silica is converted into
crystalline cristobalite
Chemical conversions and basic
ceramic chemistry
•  Overall reaction in the heating of
clay:
Chemical conversions and basic
ceramic chemistry
• An actual ceramic body contains many
more ingredients than clay itself.
• The chemical reactions are more
involved and there will be other
chemical species besides mullite and
cristobalite present in the final clay
product
Chemical conversions and basic
ceramic chemistry
• All ceramic bodies undergo a certain
amount of vitrification, or glass
formation, during heating, and the
degree of vitrification depends upon
the relative amounts of refractory and
fluxing oxides in the composition, the
temperature, and the time of heating
Chemical conversions and basic
ceramic chemistry
• The vitreous phase imparts desirable
properties to some ceramic bodies by
acting as a bond and imparting
translucency in chinaware.
• In refractories, some vitrification is
desirable to act as a bond
• Extensive vitrification destroys the
refractory property
Chemical conversions and basic
ceramic chemistry
• As a result, any ceramic body is
composed of a vitreous matrix plus
crystals (mullite and cristobalite)
Chemical conversions and basic
ceramic chemistry
• The degree of vitrification provides
the basis for useful classification of
ceramic products
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CLASSIFICATION OF CERAMIC
PRODUCTS BASED ON
DEGREE OF VITRIFICATION
Classification of ceramic products

• Whitewares
• Heavy-clay products
• Refractories
• Enamels
• Glass
Whitewares
• Varying amounts of fluxes
• Heat at moderately high
temperatures
• Varying vitrification
Heavy-clay products
• Abundant fluxes
• Heat at low temperatures
• Little vitrification
Refractories
• Few fluxes
• Heat at high temperatures
• Little vitrification
Enamels
• Very abundant fluxes
• Heat at moderate temperatures
• Complete vitrification
Glass
• Moderate fluxes
• Heat at high temperatures
• Complete vitrification
Classification of ceramic products

Amount of Heating Vitrification


flux Temperatur
e
Whitewares Varies Moderate Varies
Heavy-clay Abundant Low Little
products
Refractories Few High Little
Enamels Very Moderate Complete
abundant
Glass Moderate High Complete
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WHITEWARES
Whitewares
• Whiteware is a generic term for
ceramic products which are usually
white and of fine texture
• Because of the different amounts and
kinds of fluxes, there is a
corresponding variation in the degree
of vitrification among whitewares.
Whitewares
• Earthenware – “semivitreous”
dinnerware. Porous and
nontranslucent with a soft glaze
• Chinaware – vitrified translucent
ware with a medium glaze which
resists abrasion to a degree. Used for
nontechnical purposes
Whitewares
• Porcelain – vitrified translucent ware with
a hard glaze which resists abrasion to the
maximum degree. Includes chemical,
insulating, and dental porcelain
• Sanitary ware – formerly made from clay,
usually porous. Prefired and sized
vitreous grog is sometimes included in
the triaxial composition
Whitewares
• Stoneware – one of the oldest
ceramic wares. Crude porcelain not so
carefully fabricated from raw material
of a poorer grade
• Whiteware tiles – generally classifid
as floor tiles. Resistant to abrasion
and impervious to stain penetration.
May be glazed or unglazed
Whitewares
• Stoneware – one of the oldest
ceramic wares. Crude porcelain not so
carefully fabricated from raw material
of a poorer grade
• Whiteware tiles – generally classifid
as floor tiles. Resistant to abrasion
and impervious to stain penetration.
May be glazed or unglazed
Glazing
• Important in whitewares and in
tableware
• A glaze is a thin coating of glass
melted onto the surface of more-
or-less porous ceramic ware
Glazing
• A glaze contains ingredients of
two distinct types in different
proportions:
– Refractory materials (feldspar,
silica, china clay)
– Fluxes (soda, potash, flourspar, and
borax)
Glazing
• “glost firing” – technical term for
the firing of the glaze
• Earthenware should be glazed
between 1050 – 1100 °C
• Stoneware – 1250 to 1300°C

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