Ceramics

Industries
Table of contents

01 Introduction
Manufacturing
of Ceramics 03
Economic and
02 Ceramic Materials,
Properties, and
Products
Environmental
Standard 04
I. Introduction
Definition
Also sometimes called clay products or silicate industries, have as
their finished materials a variety of articles that are essentially
silicates.
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.
History
human-made ceramics were Ceramic products, such as
found in Czechoslovakia (Czech vases, bricks, and tiles,
18,000
Republic) and were in the form of become popular in the
animal and human figurines, BCE
Middle East and Europe.
slabs, and balls

Chinese pottery
28,000 9,000
appears.
BCE BCE
 High-temperature refractory
materials are introduced to
build furnaces for making
steel, glass, ceramics, and
Mid
1400s cements, leading the way to
the industrial revolution. 1800s

Porcelain electrical
High-temperature insulators and
furnaces are developed 1500s incandescent light bulbs
in Europe for are invented.
metallurgical use.
 High-strength quartz-enriched
porcelain for insulators, alumina The robocasting process for
spark plugs, glass windows for 1940s 3D printing of ceramics is
automobiles, and ceramic developed.
capacitors are introduced.

Research on oxide
magnetic materials
1920s (ferrites) and Late
ferroelectric materials 1990s
begins.
Traditional ceramic raw materials include clay minerals such as kaolinite, whereas more
recent materials include aluminum oxide, more commonly known as alumina. Modern
ceramic materials, which are classified as advanced ceramics, include silicon carbide
and tungsten carbide.
II. Ceramic
Materials,
Properties, and
Products
Basic Raw Materials

Clays Feldspar Sand

clays are plastic and - called Spar in - called Flint in industry
moldable when industry
sufficiently pulverized - for the light-colored
and wet, rigid when - is of great ceramic products, sand
dry, and vitreous importance as a with a low iron content
when fired at a fluxing constituent in should be chosen.
suitably high ceramic formulas.
temperature
Properties of Ceramics
 Hard  Electrical Insulator

 Wear – resistant  Nonmagnetic

 Brittle  Noncorrosive

 Refractory  Oxidation Resistant

 Thermal Insulator  Chemically Stable

Products of Ceramic Industries

Whitewares Heavy Clays Refractories Frits

ceramic ware that is Low-cost but very those materials which are are thin layer of
white, ivory, or light durable products. used to withstand the ceramic or glass
gray in color after firing. Usually bricks for effect of thermal, applied to a substrate of
structures. chemical, and physical metal
effects that are met with
in furnace procedures
Glasses
III. Manufacturing
of Ceramics
Manufacturing of Whitewares

1. Raw Material Procurement

- to begin the process, raw materials are transported and stored at the
manufacturing facility. The raw materials used in the manufacture of ceramics range from
relatively impure clay materials mined from natural deposits to ultrahigh purity powders
prepared by chemical synthesis. Naturally occurring raw materials used to manufacture
ceramics include silica, sand, quartz, flint, silicates, and aluminosilicates (e. g., clays and
feldspar).
2. Beneficiation
- Although chemically synthesized ceramic powders also require some
beneficiation. The basic beneficiation processes include comminution, purification, sizing,
classification, calcining, liquid dispersion, and granulation. Naturally occurring raw
materials often undergo some beneficiation at the mining site or at an intermediate
processing facility prior to being transported to the ceramic manufacturing facility.
a. Comminution
- entails reducing the particle size of the raw material by crushing,
grinding, and milling or fine grinding
b. Purification
- several procedures are used to purify the ceramic material which
includes washing, acid leaching, magnetic separation/ float flotation.
c. Sizing and Classification
- separate the material into size ranges using vibrating screens and are
available for isolating particles down.
e. Calcining
- consists of heating a ceramic material to a temperature well below its
melting point to liberate undesirable gases or other material and to bring about
structural transformation to produce the desired composition and phase product.
f. Liquid Dispersion
- Liquid dispersion of ceramic powders sometimes is used to make
slurries.
g. Granulation
- dry powders often are granulated to improve flow, handling, packing,
and compaction.
3. Mixing
- The purpose of mixing or blunging is to combine the constituents of a

ceramic powder to produce a more chemically and physically homogenous

material for forming.
4. Forming
- In the forming step, dry powders, plastic bodies, pastes, or
slurries are consolidated and molded to produce a cohesive body of the
desired shape and size.
5. Green Machining
- After forming, the ceramic shape often is machined to eliminate
rough surfaces and seams or to modify the shape. The methods used to
machine green ceramics include surface grinding to smooth surfaces,
blanking and punching to cut the shape and create holes or cavities, and
laminating for multilayer ceramics.
6. Drying
- After forming, ceramics must be dried. Drying must be carefully
controlled to strike a balance between minimizing drying time and avoiding
differential shrinkage, warping, and distortion. The most commonly used
method of drying ceramics is by convection, in which heated air is circulated
around the ceramics.
7. Presinter Thermal Processing
- Prior to firing, ceramics often are heat-treated at temperatures well
below firing temperatures. The purpose of this thermal processing is to provide
additional drying, to vaporize or decompose organic additives and other
impurities, and to remove residual, crystalline, and chemically bound water.
Presinter thermal processing can be applied as a separate step, which is referred
to as bisque firing, or by gradually raising and holding the temperature in several
stages.
Thermal Processing Equipments
8. Glazing
- For traditional ceramics, glaze coatings often are applied to dried or
bisque-fired ceramic ware prior to sintering. Glazes consist primarily of oxides
and can be classified as raw glazes or frit glazes.
9. Firing
- is the process by which ceramics are thermally consolidated
into a dense, cohesive body comprised of fine, uniform grains. This
process also is referred to as sintering or densification. In general:
(1) ceramics with fine particle size fire quickly and require lower firing
temperatures;
(2) dense unfired ceramics fire quickly and remain dense after firing
with lower shrinkage; and
(3) irregular shaped ceramics fire quickly.
Industrial Kiln Equipments
10. Final Processing
- Following firing, some ceramic products are processed further to
enhance their characteristics or to meet dimensional tolerances.
- Surface coatings are applied to traditional clay ceramics to create a
stronger, impermeable surface and for decoration. Coatings also may be applied
to improve strength, and resistance to abrasion and corrosion.
Manufacturing of Heavy Clays

1. Mining

- The raw materials used in the manufacture of brick and structural clay

products include surface clays and shales, which are mined in open pits.
2. Grinding and Screening
- The material is then conveyed to a grinding room, which
houses several grinding mills and banks of screens that produce a fine
material that is suitable for forming brick or other products.
3. Forming and Cutting Or Shaping
- The screened fine bricks are formed using stiff mud extrusion
process. Stiff mud extrusion lines begin with a pug mill, which mixes the
ground material with water and discharges the mixture into a vacuum
chamber then shaped and cut into desired products mechanically or
handset.
4. Drying and Firing
- From the dryer, the bricks enter the kiln. The most common
type of kiln used for firing brick is the tunnel kiln. During firing, small
amounts of excess fuel are sometimes introduced to the kiln atmosphere,
creating a reducing atmosphere that adds color to the surface of the bricks.
5. Cooling and Storage
- After firing, the bricks enter the cooling zone, where they are
cooled to near ambient temperatures before leaving the tunnel kiln. The
bricks are then stored and shipped.
Manufacturing of Refractory Ceramics

1. Raw Material Processing

- Raw material processing consists of crushing and grinding
raw materials, followed, if necessary, by size classification and raw
materials calcining and drying.
2. Forming
- Forming consists of mixing the raw materials and forming
them into the desired shapes. This process frequently occurs under wet or
moist conditions.
3. Firing
- Firing involves heating the refractory material to high
temperatures in a periodic (batch) or continuous tunnel kiln to form the
ceramic bond that gives the product its refractory properties.
4. Final Processing
- The final processing stage involves milling, grinding, and
sandblasting of the finished product. This step keeps the product in
correct shape and size after thermal expansion has occurred.
Manufacturing of Enamels (Frits)

1. Weighing
- To begin the process, raw materials are shipped to the
manufacturing facility by truck or rail and are stored in bins. Next, the raw
materials are carefully weighed in the correct proportions.
2. Mixing
- The raw batch then is dry mixed and transferred to a hopper
prior to being fed into the smelting furnace.
3. Smelting
- Smelting is carried out to melt the clays into molten material.
Depending on the application, frit smelting furnaces operate at
temperatures of 930° to 1480°C (1700° to 2700°F).
4. Quenching
- When smelting is complete, the molten material is passed
between water-cooled metal rollers that limit the thickness of the material,
and then it is quenched with a water spray that shatters the material into
small glass particles called frit.
IV. ECONOMIC AND ENVIRONMENTAL
STANDARDS
Top Ceramic Producers
Top Ceramic Consumers
Top Ceramic Companies Locally and Internationally

Worldwide Philippines

 Saint – Gobain  Saint – Gobain

 3M  3M

 Lixil Group Corp.  Lixil Group Corp.

 Kyocera Corporation  Kyocera Corporation

 AGC Ceramics Co., LTD  AGC Ceramics Co., LTD

INTERNATIONAL EMISSIONS AND CONTROL SPECIFICATION

Emissions from ceramics manufacturing facilities include particulate matter (PM), PM less than or
equal to 10 microns in aerodynamic diameter (PM-10), PM less than or equal to 2.5 microns in
aerodynamic diameter (PM-2.5) sulfur dioxide (SO ), sulfur trioxide (SO ), nitrogen oxides (NO ),
carbon monoxide 2 3 x (CO), carbon dioxide (CO ), metals, total organic compounds (TOC)
(including methane, ethane, volatile 2 organic compounds [VOC], and some hazardous air
pollutants [HAP]), hydrochloric acid (HCl), and fluoride compounds. Factors that may affect
emissions include raw material composition and moisture content, kiln fuel type, kiln operating
parameters, and plant design. The pollutants emitted from the manufacture of other structural clay
products are expected to be similar to the pollutants emitted from brick manufacturing, although
emissions from the manufacture of glazed products may differ significantly.
 Glass
Industries
Flow of Presentation

01 03
Raw materials for
Introduction the Production

Economics and Manufacturing

02 Glass Industries
in Philippines
of Glass
04
I. Introduction
Definition of Glass

It is a non-crystalline, often transparent, amorphous

solid that has widespread practical, technological, and
decorative use like in windowpanes, tableware, and
optics.
History

Egyptians were making sham jewels of hand-blown window-glass

glass which were often of fine workmanship Medieval
cylinder was invented.
and marked beauty Time

Venice enjoyed a
Early 6,000 monopoly as the center of 12th century
or 5000 BC glass industry.
 17th century Present

first glass works in Advance technology is

America were founded use in the production of
at Jamestown in 1608. glass
II. Economics and Glass
Industries in Philippines
 According to Ronilo Matas, Executive Director of
the Flat Glass Alliance of the Philippines (FGAPI),
GLASS
the local flat industry is worth $80 million. It
INDUSTRY
IN THE shows that the total number of constructions rose

PHILIPPINES from 29, 424 to 32, 729 in the second quarter of

2014.
 CONTAINER
GLASS

The Philippines container glass industry is

dominated by large food and beverage
companies, setting up their own units to meet
captive requirements of glass bottles.
 SAN MIGUEL
YAMAMURA GLASS It is the largest glass container glass producer
CORP. in the Philippines. It is owned 65% by the San
Miguel Corp and 35% by leading Japanese
container glass and technology provider,
Nihon Yawamura Glass Co Ltd.
 Commenced the commercial production of
float glass in 1991 at Pasig City with a 400
ASAHI FLAT GLASS
tons/day plant and is the only float glass
PHILIPPINES
producer in the Philippines.
 CHALLENGING CONDTIONS

Philippine glass industry is plagued by a lack of raw materials and high

energy cost. For example, locally available silica sand is a major
concern when it comes to raw materials.

Consequently, local producers are forced to import vast quantities of

this key component from Indonesia.
III. RAW MATERIALS FOR THE PRODUCTION
Imporatant Raw Materials

Limestone Sand Soda

- called Flint in industry - It is a vital component in glass as it
clays are plastic and reduces the melting temperature of
moldable when - it impacts key features of the sand, and significantly cutting
sufficiently pulverized down energy use and related CO2
its final products like
and wet, rigid when emissions. .
transparency, strength,
dry, and vitreous
and durability of glass.
when fired at a
suitably high
temperature
Basic Raw Materials

Feldspars Borax
Cullet
they are cheap, pure, and
it lowers expansion it is the crushed glass from imperfect
fusible and are composed
coefficient but increases articles, trim of otherwise waste glass.
entirely of glass forming
chemical durability. It facilitates the melting and utilizes
oxides.
waste.
IV. Manufacturing of
Glass
FOUR MAJOR PHASES IN PRODUCTION

1. Melting
2. Fabrication
3. Annealing
4. Finishing
1. MELTING

Glass melting furnaces are designed to melt

raw materials into glass. It uses different power
sources, mainly fossil fuel or fully electric
power.

The batch is either melted by;

a. pot furnace
b. tank furnace
 POT FURNACE

- the pots are filled with raw materials and heated by means of
producer gas.

- when the mass has melted down, it is removed from the pot,
and it is taken for the next operation fabrication.

- It is used to melt small quantities of glass

 continuous process and it is adopted to
TANK FURNACE melt large quantities of glass at a time.
 2. FABRICATION

The molten glass is given suitable shape

or form in this stage.

It can either be done by hand or by

machine. The hand fabrication is
adopted for small scale production and
machine fabrication is adopted for large
scale production.
DIFFERENT WAYS OF FABRICATION

A. Blowing
B. Casting
C. Drawing
D. Spinning
 A. BLOWING

- it is done by operator using air

compressor to blow it from the end
of the blow pipe

- blowing causes the molten mass to

assume the shape of a cylinder and it
is heated for few second and is
blown again until the required size is
formed.
 The molten glass is poured in moulds and it is
allowed to cool down slowly. The large pieces of
B. CASTING glass of simple design can be prepared by this
method. It is also adopted to prepare mirrors, lenses,
etc.
 C. DRAWING

This process consists in simply pulling the molten glass

by mechanical equipment.
 D. SPINNING

In this process, the molten

glass is spin at high speed by a
machine to form very fine
glass fibres.
 3. ANNEALING

The glass articles, after being manufactured, are to be cooled down slowly and
gradually. This process of slow and homogeneous cooling of glass articles is
known as the annealing of glass.
 TWO METHODS
OF ANNEALING

A. FLUE TREATMENT
B. OVEN TREATMENT
METHOD
A. FLUE TREATMENT METHOD
In this method, a long flue is provided, and it is constructed in such a way that
there is gradual decrease in temperature from one end of flue to the other. The
red-hot articles of glass are allowed to enter at the hot end of flue and they are
slowly moved on travelling bands. They become cool when they reach the cool
end of flue. This method is useful for large scale production.
B. OVEN TREATMENT METHOD
In this method, the red-hot glass articles are placed in ovens in which arrangement is
made to control the temperature. After articles are placed in the ovens, the
temperature is slowly brought down. This method is useful for small scale production.
 IV. FINISHING

All types of annealed glass must undergo

certain finishing operations, which,
though relatively simple, are very
important. These include cleaning,
grinding, polishing, cutting,
sandblasting, enameling, grading, and
gaging.
 ADDITIONAL INFORMATION ON
SPECIAL GLASSES

Special glasses composed of different classifications namely;

A. Colored Glass
B. Translucent Glass
C. Safety Or Laminated Glass
D. Fiber Glass
E. Phosphate And Borate Glasses
 A. COLORED
GLASSES

Colored glass was merely for

decoration and essential for both
technical and scientific purposes
and is produced in many hundreds
of colors.
B. TRANSLUCENT
GLASS
Opal or translucent glasses are clear
when molten but become opalescent as
the glass is worked into form, owing to
the separation and suspension of
minute particles in the medium which
disperse the light passing through them.
 C. SAFETY OR
LAMINATED
GLASS

It may be defined as a composite structure

consisting of two layers of glass with an inter
leaf of plastic, plasticized polyvinyl butyral
resin.
 D. FIBER GLASS

It is a material made from extremely fine fiber

of glass which is a non-crystalline material with
a short-range network structure. It can be spin
into yarn, gathered into a mat, made into
insulation, tape, air filters, and a great variety of
other products such as pipe with plastic bond.
 E. PHOSPATE
AND BORATE
GLASSES

Phosphate glass contains

phosphorous pentoxide as a major
ingredient wholly or partially
displacing silica. An important
property or phosphate glass is its
ability to resist hydrofluoric acid,
for example, in fluorinations.
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