CERAMIC INDUSTRIES

.
INTRODUCTION

HISTORY .. INTRO TO CERAMICS.. ITS

PROPERTIES, TYPES AND USES,,
OCCURRENCES
History
Pottery as one of the ancient
human industry
Burnt clayware found about
15, 000 B.C before
Demanded because of its
broad application even in
technology
Sustainable brickmaking
from inorganic wastes such
as fly ash, mine tailings, etc
Ceramics
Referred to as clay products or silicate
industries
Inorganic, non-metallic solid prepared from the
action of heat and cooling
A wide-ranging group of materials whose
ingredients are clays, sand and feldspar.
Some are sensitive to thermal shock (T)
Classification of Ceramics
Oxides

CERAMICS Nonoxides

Composite

Oxides: Alumina, Zirconia, Magnesia

Non-oxides: Carbides, borides, nitrides, silicides
Composites: Particulate reinforced, combinations of oxides
and non-oxides
 Classification of Ceramics
Oxide Ceramics:

Oxidation resistant

chemically inert

electrically insulating

generally low thermal conductivity

slightly complex manufacturing

zirconia
 Classification of Ceramics
Non-Oxide Ceramics:

Low oxidation resistance

extreme hardness

chemically inert

high thermal conductivity

electrically conducting

difficult energy dependent Silicon carbide cermic foam filter (CFS)

manufacturing and high cost.

 Classification of Ceramics
Ceramic-Based Composites:

Toughness

low and high oxidation resistance

(type related)

variable thermal and electrical

conductivity

complex manufacturing processes

high cost. Ceramic Matrix Composite (CMC) rotor

Types of Ceramics
Whitewares
Structural clay products sewer pipe, building bricks, roof/floor tiles
Refractories
Specialized ceramic products
Enamels and enameled metal
Glasses
Dealt in
Abrasives different
Cements industries
Whitewares
White, and fine texture
Vitreous ware (containing
glass), Earthenware
(Pottery), Porcelain
(Translucent), Stoneware
(Opaque, semi-vitreous).
Structural Clay Products

Low cost and durable, some are

porous
Can be formed into shapes
Refractories

Have high Si, Mg, or Al oxide

content.
resist 538 C and above (e.g kilns,
furnace, reactors, ovens) to
provide thermal protection of other
materials
 Specialized Ceramic Products
Advanced Ceramics
Include artificial raw materials, exhibit
specialized properties, require more
sophisticated processing.
Applied as thermal barrier coatings to
protect metal structures, wearing
surfaces,

bioceramic implants
 Specialized Ceramic Products
Advanced Ceramics
 PORCELAIN
MANUFACT URING
BRICK MANUFACT URI NG
(SLIP CASTING)
 BASIC RAW MATERIALS
Clays, Feldspar, and Sand/Flint

Kaolinite [Al2Si2O5(OH)4] Sand for light colored Feldspar as fluxing constituent

mined from hot, tropical
rainforest areas;
Clays give favorable
result
ceramic products (lowers high melting point for
efficing kiln firing)
Hardness, Good
Potash-Soda-Lime feldspar
Polish, and Glassy [K2Al2SiO6 Na2Al2Si6O16
luster CaAl2Si6O16]
PORCELAIN MANUFACTURING
Mixing DRYER

Flint, Feldspar, China Clay, Ball Clay

Trim fins or excess

Blunger DRYER
Addition of water to the mixture
GLAZED THEN
LOADED IN TUNNEL
KILNS
Crushing, Screening, Pulverizing of
QUALITY
Dried Slabs CONTROL

Hydraulic Press
Testing and
Moulding into shapes or parts (human-controlled
machine)
inspection
PORCELAIN MANUFACTURING
Some of the filtered clay
are mixed in Pugg mills
and cut in desired
length.
Remolded by skilled
workers (as shown on
the picture) on a
potters wheel.
Dried, glazed, and
loaded at tunnel kilns all
at once
MANUFACTURING OF REFRACTORIES
Grinding - coarse and fine particles
Mixing provides lubricant during molding;
functions for distribution of material
Molding
Drying remove moisture but causes
shrinkage and strains
Burning placing in kilns; permanent bond
BRICK MANUFACTURING (Slip
Casting)

Also applied for other ceramic products

Slip is poured into a porous plaster mold
Water from the mix is absorbed into the plaster to form a firm layer of clay at the mold
surface
BRICK MANUFACTURING (Dry
Press)

MATERIAL PREPARATION
Manufacturing
Manufacturing
Setting
Firing Process
Packaging