WO2014122461A1 - Method and apparatus for forming a ceramic product - Google Patents
Method and apparatus for forming a ceramic product Download PDFInfo
- Publication number
- WO2014122461A1 WO2014122461A1 PCT/GB2014/050341 GB2014050341W WO2014122461A1 WO 2014122461 A1 WO2014122461 A1 WO 2014122461A1 GB 2014050341 W GB2014050341 W GB 2014050341W WO 2014122461 A1 WO2014122461 A1 WO 2014122461A1
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- slurry
- unit
- foaming
- ceramic
- product
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B38/00—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof
- C04B38/10—Porous mortars, concrete, artificial stone or ceramic ware; Preparation thereof by using foaming agents or by using mechanical means, e.g. adding preformed foam
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B1/00—Producing shaped prefabricated articles from the material
- B28B1/50—Producing shaped prefabricated articles from the material specially adapted for producing articles of expanded material, e.g. cellular concrete
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28B—SHAPING CLAY OR OTHER CERAMIC COMPOSITIONS; SHAPING SLAG; SHAPING MIXTURES CONTAINING CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28B3/00—Producing shaped articles from the material by using presses; Presses specially adapted therefor
- B28B3/20—Producing shaped articles from the material by using presses; Presses specially adapted therefor wherein the material is extruded
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C3/00—Apparatus or methods for mixing clay with other substances
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/08—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing
-
- B—PERFORMING OPERATIONS; TRANSPORTING
- B28—WORKING CEMENT, CLAY, OR STONE
- B28C—PREPARING CLAY; PRODUCING MIXTURES CONTAINING CLAY OR CEMENTITIOUS MATERIAL, e.g. PLASTER
- B28C5/00—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions
- B28C5/08—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing
- B28C5/0881—Apparatus or methods for producing mixtures of cement with other substances, e.g. slurries, mortars, porous or fibrous compositions using driven mechanical means affecting the mixing having a stator-rotor system with intermeshing teeth or cages
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- C04B2111/00—Mortars, concrete or artificial stone or mixtures to prepare them, characterised by specific function, property or use
- C04B2111/00034—Physico-chemical characteristics of the mixtures
- C04B2111/00129—Extrudable mixtures
-
- Y—GENERAL TAGGING OF NEW TECHNOLOGICAL DEVELOPMENTS; GENERAL TAGGING OF CROSS-SECTIONAL TECHNOLOGIES SPANNING OVER SEVERAL SECTIONS OF THE IPC; TECHNICAL SUBJECTS COVERED BY FORMER USPC CROSS-REFERENCE ART COLLECTIONS [XRACs] AND DIGESTS
- Y02—TECHNOLOGIES OR APPLICATIONS FOR MITIGATION OR ADAPTATION AGAINST CLIMATE CHANGE
- Y02P—CLIMATE CHANGE MITIGATION TECHNOLOGIES IN THE PRODUCTION OR PROCESSING OF GOODS
- Y02P40/00—Technologies relating to the processing of minerals
- Y02P40/60—Production of ceramic materials or ceramic elements, e.g. substitution of clay or shale by alternative raw materials, e.g. ashes
Definitions
- This invention concerns a method of forming a ceramic product, a product made by such a method, and also apparatus for forming a ceramic product.
- Refractory brick are generally either produced via extrusion or pressing. They are pre-fired prior to sale and are then bonded together using refractory cement by refractory brick layers to form rigid fixed wall kiln linings. Once brick linings are installed, they usually last for many years if not decades. However, by virtue of them being bricks they are relatively dense and have relatively higher thermal mass/conductivity, in comparison to ceramic fibre.
- High temperature ceramic fibre has a lower thermal mass/conductivity than refractory bricks.
- the main benefit of fibre is that it fires much more quickly than brick lined kilns.
- the lower thermal mass lining allows the kiln to heat up and cool down quicker than kilns lined with refractory bricks. This lends itself to lower energy costs per firing and increased capacity as the kiln can be fired quicker.
- a method of forming a ceramic product comprising producing a ceramic forming mixture in the form of a slurry, causing the slurry to foam, extruding the foamed slurry to form a product, and thereafter drying and firing the extruded product.
- the ceramic product may be extruded as a continuous length, and cut into required lengths immediately following extrusion.
- air may be fed into the slurry, and the air and slurry mixed together to entrain the air within the slurry.
- the air may be fed into the slurry as compressed air, and the compressed air may be at a volume of between 0.2 and 2 litres/min.
- a foaming agent may be added to the slurry to aid foaming, and the foaming agent may be an organic amine oxide.
- the foaming agent may be drip dosed into the slurry, and may be drip dosed at a rate of between 2 and 15ml/mins.
- the slurry and air may be fed into a foaming unit, which unit may comprise a plurality of relatively rotating rotors and stators, which may rotate at a speed of between 200 and 500rpm.
- An increased pressure will be developed in the foaming unit, which increased pressure may be between 20 and 80 psi.
- a feed pipe may be provided extending from the foaming unit to an extruding unit. If the cross sectional size of the product to be formed is greater than the cross sectional size of the feed pipe, then a chamber may be provided between the feed pipe and a die of a required size and shape, which chamber is of greater cross sectional size than the die.
- the extruded product may be fired at a temperature above 1200°C.
- a setting agent may be added to the slurry.
- the setting agent may be any of gypsum, calcium aluminate cements, Portland cements, PVA plus cross linking polymer additives, alginates or starches.
- the ceramic forming mixture may be mixed together by a high speed blunger.
- the ceramic forming mixture may include:
- the ceramic forming material may be any of alumina which may be calcined, fused or tabular, silica, magnesium oxide, silicon carbide, zirconium silicate, silliminite, mullite, steatite or cordierite.
- the additives may include any of organic binders, methyl cellulose, starches or polyvinyl acetate.
- the additives may include an organic deflocculant, which may be sodium tripolyphosphate.
- the ceramic forming mixture may also include up to 50% clay to form a slurry, which may be ball or china clay.
- a ceramic product made by a method according to any of the preceding fourteen paragraphs.
- apparatus for forming a ceramic product including a mixing unit for mixing together components of a ceramic forming mixture, the mixing unit being connected to a foaming unit for causing the slurry to foam, the foaming unit connecting to a die unit for extruding foamed mixture therethrough.
- a support unit may be provided arranged to receive extruded lengths of material from the die unit.
- the support unit may be in the form of a conveyor, which may be a roller conveyor.
- the mixing unit may be in the form of a high speed blunger.
- a pump may be provided for pumping slurry from the mixing unit to the foaming unit, and the pump may be a fixed displacement pump.
- a sieve may be provided between the mixing unit and the foaming unit to remove particles above a predetermined size such as for instance 2mm.
- the foaming unit may include an inlet for compressed air to be mixed with the slurry.
- the foaming unit may include an inlet for a foaming agent, and may permit drip dosing of the foaming agent.
- the foaming unit may comprise a plurality of relatively rotating rotors and stators for entraining the air in the slurry, and the rotors and stators may rotate at a speed of between 200 and 500 rpm.
- a feed pipe may be provided extending from the foaming unit to the extruding unit.
- Fig. 1 is a diagrammatic side view of apparatus according to the invention.
- Fig. 2 is a more detailed diagrammatic side view of part of the apparatus of Fig. 1 .
- Fig. 1 shows an apparatus 10 according to the invention for producing ceramic products by a method of the invention.
- the apparatus 10 comprises a mixing unit 12 which includes a high speed blunger.
- the mixing unit 12 also includes a conventional fixed displacement pump (not shown) which pumps material through a magnet and a sieve to remove any solid or unmixed particles of say greater than 2mm.
- the pump connects to a pipe 14 which leads to a foaming unit 16.
- the foaming unit 16 includes a chamber 18 with a unit 20 connected thereto.
- the unit 20 permits compressed air to be fed into the slurry at a volume of between 0.2 and 2 litres/min.
- the unit 20 also permits a foaming agent to be dripped dosed into the mixture.
- the foaming unit 16 also includes a mixing head 22 to receive the air rated slurry incorporating the foaming agent.
- the mixing head includes a series of relatively rotating rotors and stator blades nesting together which spin around at 200 - 500 rpm to entrain and fully mix the air into the slurry in a whisking like action. This produces foam air bubbles in the ceramic slurry which stay embedded within the slurry without bursting or slumping.
- the foaming agent provides temporary green strength to maintain the bubbles in the foam structure.
- a natural increased pressure of between 20 and 80psi will build up in the mixing head 22. This increased pressure is sufficient to push material through a feed pipe 24 into a die unit 26.
- the die unit 26 permits a selection of interchangeable dies 28 to be fitted of a required size and shape, to permit products of different sizes and shapes to be formed.
- a die chamber 30 is provided between the feed pipe 24 and the die 28, which chamber 30 is of greater cross sectional area than the die 28.
- the die chamber 30 ensures that material passes out through the die 28 consistently and at a constant speed.
- the die unit 26 is located such that material 32 passing thereoutof will land on a roller conveyor 34. Where a continuous length of material is being extruded from the die unit 26, a cutting arrangement may be provided adjacent thereto to enable cutlets to be located on the conveyor 32.
- a high alumina ceramic with approximately 70% alumina silica and other materials is mixed in the mixing unit 12 to form a slurry with a solids content of approximately 70%.
- the slurry is then pumped through the pipe 14 into the foaming unit 16. Any solid or unmixed particles greater than 2mm are removed by the sieve or magnet.
- Compressed air is fed into the slurry at a required volume of between 0.2 and 2 litres/min, and an organic amine oxide foaming agent is drip dosed into the slurry at a rate of between 2 and 15ml/min.
- This mixture is then mixed at high speed in the mixing head 22 to entrain the air and create foam air bubbles in the ceramic slurry.
- An increased pressure of between 20 and 80 psi develops in the foaming unit 16.
- the foaming agent provides temporary green strength to these bubbles prior to firing.
- a setting agent such as gypsum, calcium aluminate cements, Portland cements, PVA plus cross linking polymer additives, alginates or starches may be injected into the slurry to aid the forming process.
- the setting agent may include accelerants or retardants.
- the foamed mixture is then passed under pressure through the feed pipe 24 into the die unit 26 and as show in Fig 1 can be extruded into lengths 32.
- the lengths 32 can be cut as required to at least rough lengths, and dried and then fired at a temperature above 1200°C.
- the products thus formed can be cut further if required into precise shapes for use for instance in lining a kiln or in other refractory applications. These products have a 65-75% alumina content. This method enables mixes with little or no clay to be used, which previously has not generally been possible, as a clay content has been required to give the foamed material some strength.
- This apparatus and/or method can be used with a wide range of ceramic materials, other than the above described example.
- alumina may be calcined, fused or tabular.
- Other ceramic forming materials may be used alone or in combination, such as silica, magnesium oxide, silicon carbide, zirconium silicate, silliminite, mullite, steatite or cordierite.
- Clay of up to 50% may be added, which may be ball or china clay.
- Additives in the mixture may include organic binders, methyl cellulose, starches, polyvinyl acetate or other suitable binders.
- the additives may include an organic deflocculant, which may be sodium tripolyphosphate.
- a different mixing unit could be used to entrain the air in the slurry.
- the die unit may take a different form.
- the firing conditions for the final product will depend on the nature of the material. An after burner will generally be required in the process due to the combustion products produced from the binders.
Landscapes
- Engineering & Computer Science (AREA)
- Chemical & Material Sciences (AREA)
- Ceramic Engineering (AREA)
- Mechanical Engineering (AREA)
- Structural Engineering (AREA)
- Manufacturing & Machinery (AREA)
- Materials Engineering (AREA)
- Organic Chemistry (AREA)
- Dispersion Chemistry (AREA)
- Press-Shaping Or Shaping Using Conveyers (AREA)
- Compositions Of Oxide Ceramics (AREA)
Abstract
Description
Claims
Priority Applications (1)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1514444.7A GB2526961A (en) | 2013-02-08 | 2014-02-06 | Method and apparatus for forming a ceramic product |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
GB1302233.0 | 2013-02-08 | ||
GBGB1302233.0A GB201302233D0 (en) | 2013-02-08 | 2013-02-08 | Forming a ceramic product |
Publications (1)
Publication Number | Publication Date |
---|---|
WO2014122461A1 true WO2014122461A1 (en) | 2014-08-14 |
Family
ID=47998810
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/GB2014/050341 WO2014122461A1 (en) | 2013-02-08 | 2014-02-06 | Method and apparatus for forming a ceramic product |
Country Status (2)
Country | Link |
---|---|
GB (2) | GB201302233D0 (en) |
WO (1) | WO2014122461A1 (en) |
Cited By (2)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016009183A1 (en) * | 2014-07-17 | 2016-01-21 | Mantec Technical Ceramics Limited | Forming a ceramic product |
CN108312295A (en) * | 2018-04-19 | 2018-07-24 | 佛山市远方通用机械科技有限公司 | A kind of batch manufacturing method of foamed ceramic partition plate |
Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1944007A (en) * | 1933-04-01 | 1934-01-16 | Battelle Memorial Institute | Light weight ceramic material and method of making the same |
DE10111487A1 (en) * | 2001-03-09 | 2002-09-19 | Arbeitsgemeinschaft Mauerziege | Process for producing a porous foam brick for statically loaded brickwork comprises extruding a clay slurry mixture to produce an extruded length of brick which is cut into shorter lengths forming blanks |
JP2005272281A (en) * | 2004-03-26 | 2005-10-06 | Toto Ltd | Method for manufacturing porous ceramics and apparatus for manufacturing porous ceramics |
-
2013
- 2013-02-08 GB GBGB1302233.0A patent/GB201302233D0/en not_active Ceased
-
2014
- 2014-02-06 WO PCT/GB2014/050341 patent/WO2014122461A1/en active Application Filing
- 2014-02-06 GB GB1514444.7A patent/GB2526961A/en not_active Withdrawn
Patent Citations (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
US1944007A (en) * | 1933-04-01 | 1934-01-16 | Battelle Memorial Institute | Light weight ceramic material and method of making the same |
DE10111487A1 (en) * | 2001-03-09 | 2002-09-19 | Arbeitsgemeinschaft Mauerziege | Process for producing a porous foam brick for statically loaded brickwork comprises extruding a clay slurry mixture to produce an extruded length of brick which is cut into shorter lengths forming blanks |
JP2005272281A (en) * | 2004-03-26 | 2005-10-06 | Toto Ltd | Method for manufacturing porous ceramics and apparatus for manufacturing porous ceramics |
Cited By (3)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
WO2016009183A1 (en) * | 2014-07-17 | 2016-01-21 | Mantec Technical Ceramics Limited | Forming a ceramic product |
CN108312295A (en) * | 2018-04-19 | 2018-07-24 | 佛山市远方通用机械科技有限公司 | A kind of batch manufacturing method of foamed ceramic partition plate |
CN108312295B (en) * | 2018-04-19 | 2019-08-23 | 广东远方通用科技有限公司 | A kind of batch manufacturing method of foamed ceramic partition plate |
Also Published As
Publication number | Publication date |
---|---|
GB201302233D0 (en) | 2013-03-27 |
GB2526961A (en) | 2015-12-09 |
GB201514444D0 (en) | 2015-09-30 |
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