CERAMIC INDUSTRIES, PORTLAND CEMENTS, & GLASS INDUSTRIES

Janine Bernadette A. Pontanar BS Chemistry III Report in Industrial Chemistry Lec

OUTLINE..
o Chapter 9 CERAMIC INDUSTRIES o Chapter 10 PORTLAND CEMENTS, CALCIUM, & MAGNESIUM COMPOUNDS o Chapter 11 GLASS INDUSTRIES

CHAPTER 9 CERAMIC INDUSTRIES

Outline.. Introduction Types of Ceramic products Basic Raw materials Uses

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION Ceramic industries Greek keramos, 'potter's clay'), originally the art of making pottery now the (clay products or silicates industries) science of manufacturing articles prepared from pliable, earthy materials that are made rigid by exposure to heat. Ceramic materials are nonmetallic, inorganic compounds primarily compounds of oxygen, but also compounds of carbon, nitrogen, boron, and silicon. Ceramic products withstand higher temperatures, resists greater pressures, have superior mechanical properties, posses mechanical properties, possess special electrical characteristics, and can protect against corrosive chemicals.

Pictures of some Ceramic products

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION Types of ceramic products: 1. White wares China, earthenware, pottery, porcelain, stoneware, and vitreous ware 2. Refractories - like glass and steel building crucibles, gas fire radiant and kiln linings. 3. Enamels and enameled metal 4. Structural clay products bricks, face brick, terra cotta, sewer pipe, and drain tile 5. Specialized ceramic products

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION 1. WHITE WARES - any of a broad class of ceramic products that are white to off-white in appearance and frequently contain a significant vitreous, or glassy, component. Including products as diverse as fine china dinnerware, lavatory sinks and toilets, dental implants, and spark-plug insulators, whitewares all depend for their utility upon a relatively small set of properties: imperviousness to fluids, low conductivity of electricity, chemical inertness, and an ability to be formed into complex shapes.

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION 2. REFRACTORY material is one that retains its strength at high temperatures. ASTM C71 defines refractories as "non-metallic materials having those chemical and physical properties that make them applicable for structures, or as components of systems, that are exposed to environments above 1,000 F (811 K; 538 C)".[

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION 3. ENAMELS & ENAMELED METAL or porcelain contains a large proportion of fluxes applied and fused to metals at moderate red heat. One of the applications of enamel is in gold, silver, and copper.

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION 4. STRUCTURAL CLAY PRODUCTS

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION 5. SPECIALIZED CERAMIC PRODUCTS  CERAMIC COMPOSITES Cermets consist of an intimate mixture of ceramic and metallic components. They are used in linings for brakes and clutches because of the greater weight and higher speeds involved and also non-lubricating bearings in temperature range 370 oC-815 Oc

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION Ceramic Fibers for resistance to thermal shock conditions and useful in hypothermal envi. It can be made to roving, yarn, cloth, braid, wicking, rope, % hollow sleeving. Also used for thermal insulation; for zone curtains in annealing surfaces, and for high-temperature-low-voltage wiring circuits of space and aircraft equipment.  FERROELECTRIC AND FERROMAGNETIC CERAMICS most common is BaTiO3. Used in TV sets, computers, magnetic switches, wideband transformers, recorders, and memory devices such as FD, etc.

CHAPTER 9 CERAMIC INDUSTRIES

INTRODUCTION  PYROCERAM AND FOTOFORM are first manufactured as glass then converted to a ceramic with predominantly crystalline body.

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS Clay Feldspar Sand

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS Clay earth that is plastic, moldable when finely pulverized and wet; tenacious when dry; and that becomes permanently vitreous hard when baked or fired.

Clay extraction

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS important clay minerals: kaolinite (Al2O3.2SiO2.2H2O), montmorillonite (Mg,Ca)O.Al2O3.5SiO2.nH2O, and illite (K2O, MgO, Al2O3, SiO2, H2O

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS Feldspar a mineral that is used as fluxing agent in ceramic formulas; it may exist in the clay or may be added as required. - composed of aluminosilicates of potassium, sodium, calcium, or occasionally barium. Feldspar; the most abundant mineral in the world found in igneous and metamorphic rocks.

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS Three common types of Feldspar: 1. Potash (K2O.Al2O3.6SiO2) 2. Soda (Na2O.Al2O3.6SiO2) 3. Lime (CaO.Al2O3.6SiO2)

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS Some common fluxing agents(refers to a material employed to lower the melting point of more refractory materials): Borax Boric acid Soda ash Sodium nitrate Pearl ash Nepheline Syenite calcined bones flourspar cryolite iron oxides antimony oxides lead oxides lithium minerals barium minerals

CHAPTER 9 CERAMIC INDUSTRIES

BASIC RAW MATERIALS Sand or flint

CHAPTER 9 CERAMIC INDUSTRIES

USES Mechanical applications valves and turbocharger rotors for high-temperature diesel and gas-turbine engines Electrical & Magnetic applications insulators, semiconductors, conductors, and magnets. Aerospace space shuttle tiles

CHAPTER 9 CERAMIC INDUSTRIES

USES Bioceramics dental specialists use this ceramic to make hip joints, dental caps, and dental bridges. calcium hydroxyl phosphates are compatible with bone and are used to reconstruct fractured or diseased bone Nuclear Power uranium ceramic pellets to generate nuclear power.

CHAPTER 9 CERAMIC INDUSTRIES

USES Building & Construction bricks, tiles, piping, and other construction materials. Household fixtures such as sinks and bathtubs are made from feldspar- and clay-based ceramics. Coatings household appliances, such as refrigerators, stoves, washing machines, and dryers, are often coated with ceramic enamel.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

Outline.. Introduction Types of Portland Cement Uses of Portland Cement Industrial Applications Economics Environmental effects

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

INTRODUCTION Cements are used for various purposes, such as binding sand and gravel together with portland cement to form concrete, for uniting the surfaces of various materials, or for coating surfaces to protect them from chemical attack. Portland cement is a material which consist of at least two-thirds by mass of calcium silicates (3CaOSiO2 and 2CaOSiO2), the remainder consisting of aluminium- and iron-containing clinker phases and other compounds. The ratio of CaO to SiO2 shall not be less than 2.0. The magnesium oxide content MgO shall not exceed 5.0% by mass.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

INTRODUCTION Five component system of PC: CaO MgO Al2O3 Fe2O2 SiO2

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

TYPES OF PORTLAND CEMENT 1. TYPE I Regular PC for general concrete construction. The typical compound compositions of this type are: 55% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 2.8% MgO, 2.9% (SO3), 1.0% Ignition loss, and 1.0% free CaO. 2. TYPE II Moderate-heat-of-hardening and Sulfate-resisting PC used for moderate heat of hydration is required or for concrete construction exposed to moderate sulfate action. Heat evolved must not exceed 70 & 80 cal/g after 7-28 days. Its typical compound composition is: 51% (C3S), 24% (C2S), 6% (C3A), 11% (C4AF), 2.9% MgO, 2.5% (SO3), 0.8% Ignition loss, and 1.0% free CaO.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

TYPES OF PORTLAND CEMENT 3. TYPE III High-early-strength (HES) made fro lime-to-silica ratio higher that type I and finer than type I. Contains high C3S than type l. it hardens quicker and evolution of heat is faster. Its typical compound composition is: 57% (C3S), 19% (C2S), 10% (C3A), 7% (C4AF), 3.0% MgO, 3.1% (SO3), 0.9% Ignition loss, and 1.3% free CaO.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

TYPES OF PORTLAND CEMENT 4. TYPE IV Low-heat PC contains lower % of C3S and C3A lowers evolution. Gen known for its lw heat of hydration. C4AF is increased because of the addition of Fe2O3, heat should not exceed to 60 and 70 cal/g after 7-28 days. Its typical compound composition is: 28% (C3S), 49% (C2S), 4% (C3A), 12% (C4AF), 1.8% MgO, 1.9% (SO3), 0.9% Ignition loss, and 0.8% free CaO.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

TYPES OF PORTLAND CEMENT 5. TYPE V Sulfate-resisting PC that resist sulfates than the other 4 types. C3A is lower and as a result C4AF is higher than reg. cements. Its typical compound composition is: 38% (C3S), 43% (C2S), 4% (C3A), 9% (C4AF), 1.9% MgO, 1.8% (SO3), 0.9% Ignition loss, and 0.8% free CaO. Recently added type of Portland Cement: TYPES Ia, IIa, and IIIa - have recently been added to ASTM C-150 in 2009with a similar composition as types II and IIa but with a mild heat.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

USES OF PORTLAND CEMENT Production of concrete Mortars Plasters Grouts

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

ECONOMICS OF CEMENT In 2008, the United States consumed 93.6 million metric tons of portland cement, reflecting a -15.2% decrease over 2007 levels. The industry down turn was first linked to the mortgage foreclosure crisis which decreased residential construction spending activity by -18.5% in 2007 and -29.9% in 2008. Cement consumption is dependent on the time of year and prevalent weather conditions. Nearly two-thirds of U.S. cement consumption occurs in the six months between May and October.

CHAPTER 10 PORTLAND CEMENTS, CALCIUM & MAGNESIUM COMPOUNDS

ENVIRONMENTAL EFFECTS Portland cement manufacture can cause environmental impacts at all stages of the process. These include emissions of airborne pollution in the form of dust, gases, noise and vibration when operating machinery and during blasting in quarries, consumption of large quantities of fuel during manufacture, release of CO2 from the raw materials during manufacture, and damage to countryside from quarrying. An independent research effort of AEA Technology to identify critical issues for the cement industry today concluded the most important environment, health and safety performance issues facing the cement industry are atmospheric releases (including greenhouse gas emissions, dioxin, NOx, SO2, and particulates), accidents and worker exposure to dust

CHAPTER 11 GLASS INDUSTRIES

Outline Introduction Basic raw materials Types of Glass Methods of preparation Industrial application Economics

CHAPTER 11 GLASS INDUSTRIES

INTRODUCTION Glass has many uses because of its transparency, high resistance to chemical attack, effectiveness as an electrical insulator, and ability to contain a vacuum. Glass is an amorphous brittle material and characteristically exhibit compressive strength much greater than its tensile strength. It is composed of about 75% silica (SiO2) plus Na2O, CaO, and several minor additives.

CHAPTER 11 GLASS INDUSTRIES

BASIC RAW MATERIALS Sand Soda Feldspar Borax Salt cake Cullet Refractory blocks

CHAPTER 11 GLASS INDUSTRIES

TYPES OF GLASSES Fused silica or vitreous silica made by high-temperature pyrolysis of silicon tetrachloride very resistant chemically and thermally. Alkali silicates soluble glasses used as solutions Soda-lime glass Used for windows, transparent fixtures, and all manner of containers

CHAPTER 11 GLASS INDUSTRIES

TYPES OF GLASSES Lead glass For decorative and optical effects borosilicate glass For optical and scientific work and for utensils Glass ceramic For cook-serve-freeze utensils

CHAPTER 11 GLASS INDUSTRIES

TYPES OF GLASSES Fiber glass For textile and reinforcing Alumino-silica glasses For higher temperatures Special glasses Colored glass, opal glass, translucent glass, safety, laminated , and tempered glass; photosensitive glass; and special chemical and industrial use

CHAPTER 11 GLASS INDUSTRIES

METHODS OF PREPARATION 1. Melting (2900oF) Pot furnace 2 tons or less ; crucibles made of clay or platinum Tank furnace 1,500 tons ;

CHAPTER 11 GLASS INDUSTRIES

METHODS OF PREPARATION 2. Shaping By machine or by hand 3. Annealing a process of slowly cooling glass to relieve internal stresses after it was formed. Not annealed glass is liable to crack or shatter when subjected to a relatively small temperature change or mechanical shock. 4. Finishing Cleaning, grinding, polishing, enameling, grading, gaging cutting, sandblasting,

CHAPTER 11 GLASS INDUSTRIES

INDUSTRIAL APPLICATION