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.
Aceramicis aninorganicnon-metallic
solid made up of eithermetal or non-
metalcompounds 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 ceramicsand 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 asbonesubstitutes 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 1785C 1150C 1710C
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 (700C -
2000C)
 Chemical conversions and basic
ceramic chemistry
Chemical conversions:
Dehydration: chemical smoking 150 -
650C
Calcination: 600 - 900C
Oxidation of ferrous iron and organic
matter: 350 - 900C
Silicate formation: 900C 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 -
650C)
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 940C to a
crystalline form of alumina, -alumina,
with the evolution of considerable heat
 Chemical conversions and basic
ceramic chemistry
At 1000C, 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 1300C