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Materials & Equipment/Whitewares: Ceramic Engineering and Science Proceedings, Volume 12, Issue 1/2 PDF

397 Pages·1991·25.406 MB·English
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Ceramic Engineering & Science Proceedings JANUARY-FEBRUARY1 991 Materials 81 EauiomentMlhitewares A Collection of Papers Presented at the 92nd Annual Meeting and the 1990 Fall Meeting of the Materials & Equlpment and Whitewares Divisions Russell Wood Proceedings Committee April 23-26, 1990 Dallas, TX and September 30-October 3 Nashville, TN Tile A Collection of Papers Presented at the 92nd Annual Meeting Barbara Jacoby Tile Symposium Program Co-Chair April 23-26,1990 Dallas, TX Published by The American Ceramic Society, Inc. 757 Brooksedge Plaza Drive Westenrille, OH 43081-6136 Copyright@1 991, The American Ceramic Society, Inc. ISSN 01 96-621 9 Executive Director Editor W. Paul Holbrook John 6. Wachtman Director of Publications Production Manager Linda S. Lakemacher Alan Hirtle Committee on Publications: David W. Johnson, Jr., chair; Delbert E. Day; Richard E. Tressler; George MacZura, exofficio; W. Paul Holbrook, exofficio; Carol M. Jantzen; John B. Wachtman, ex officio. Editorialand SubscriptionO ffices: 757 Brooksedge Plaza Drive, Westerville, Ohio, 43081-6136. Subscription $69 a year; single copies $15 (postage outside U.S. $5 additional). Published bimonthly. Printed in the United States of America. Allow four weeks for address changes. Missing copies will be replaced only if valid claims are received within four months from date of mailing. Replacements will not be allowed if the subscriber fails to notify the Society of a change of address. CESPDK Vol. 12, NO.1 -2, pp. 1-392, 1991 The American Ceramic Society assumes no responsibility for the statements and opinions advanced by the contributors to its publications, or by the speakers at its programs. Copyright 0 1991, by the American Ceramic Society. Permission to photocopy for personal or internal use beyond the limits of Sections 107 and 108 of the US. Copyright Law is granted by the American Ceramic Society for libraries and other users registered with the Copyright Clearance Center, provided that the fee of $2.00 per copy of each article is paid directlytoC CC, 21 Congress Street, Salem, MA01970. The fee for articles published before 1991 is also $2.00 per copy. This consent does not extend to other kinds of copying, such as copying for general distribution, for advertising or promotional purposes, or for creating new collective works. Requests for special permission and reprint requests should be addressed to the Reprint Dept., The American Ceramic Society (0196-6219/91 $2.00). Each issue of Ceramic Engineering and Science Proceedings includes a collection of technical articles in a general area of interest, such as glass, engineering ceramics, and refractories. These articles are of practical value for the ceramic industries. The issues are based on the proceedings of a conference. Both The American Ceramic Society, Inc., and non-Society conferences provide these tech- nical articles. Each issue is organized by an editor who selects and edits material from the conference proceedings. There is no other review prior to publication. Table of Contents Materials & Equipment/Whitewares ........................................ Preface vii ......... Steps in the Development of Floor Tile Technology 1 H. Reh ............................ Solving Firing Problems 13 J. Richard Schorr and Dale A. Fronk Utilizing SPC for Raw Materials to Improve Pigment ...................................... Quality.. 22 John A. Clark, I11 The Use of Montmorillonites as Extrusion Aids for ....................................... Alumina 33 M. Miller and R. A. Haber ................... Optimization of Color in Body Tiles 49 Felipe Lamilla Microwave Drying of Slip Casting: Out of the ...................... Laboratory and Into the Factory 54 Bruce A. Freed, Hank Dusseldorp, Jack Klieb, Brian Woods, and Steve Oda ......... Zircon Iron Corals: Improved Corals for the 1990s 62 Christopher T. Decker Prediction of Gel Structures in Slips Using Computer .............................. Modeling Techniques 68 G. Crume and D. R. Dinger Dewatering and Particle-Size Distribution Studies of ............ Fast-Casting, High Void Volume Kaolin Clays 80 J. J. Callahan, W. L. Garforth, W. J. Polestak, and E. J. Sare ... 111 Characteristics of Large Extensions in the Size ....................... Distribution for Alumina Slips 93 P. A. Smith and R. A. Haber Effects of Moisture on the Firing Characteristics of ...................... Glasses Used in Ceramic Glazes 97 E. J. Pawlicki, W. Bowser, V. Grebe, D. Sproson, and E. Sadd ........ Use of Polyphosphates as Deflocculants of Alumina 106 J. Faison and R. A. Haber Effects of Ball-Clay Processing on Suspension ...................................... Rheology 116 Chris B. Maxwell and Dennis R. Dinger X-Ray Spectrometry-A Potent Tool in the Quality .............................. Control of Ball Clays 123 M. J. Stentiford ......................... Particle-Size Measurements 133 John J. Cooper ............... Particle-Size Analysis of Whiteware Clays 144 J. M. Woodfine Chemical Manufacturers Association: CHEMSTAR ............................ Crystalline Silica Panel 146 Joseph C. Shapiro Use of Ceramic Coatings to Enhance Performance of .......................... Metal Furnace Components 152 John Hellander How High Emissivity Ceramic Coatings Function ................. Advantageously in Furnace Applications 162 John Hellander Computer-Controlled Weighing Systems for the Production of Colored Glazes, Using Easily .......................... Dispersible Ceramic Stains 170 Alan Sefcik ................... Application of Spersastain Pigments 173 Alan Sefcik iv ........................................ Preface 177 .................................. Tile Glossary.. 179 George Gehringer ................. Porous and Vitrified Single-Fired Tiles 183 Loris Lorici and August0 Brusa ................................... Color Figures 185 A Professional Approach to Objective Color ...................................... Language 222 Claudio Marcello Monari ................... Directions in Tile Color and Texture 229 Barbara Ann Jacoby and Iris Florath ........ The Technology in Whitewares is Changing Rapidly 233 H. Reh ................. Machinery Update: Matching the Needs 243 M. Masini Technical Developments in Ceramic Tile Glazes and .............................. Related Applications 261 Bruno Burzacchini ........................... Dry Dispersible Pigments 275 Terry D. Wise, Stephen H. Murdock, and Richard A. Eppler The Role of Basic Oxides in Leadless Frits for Fast- ..................................... Fire Glazes 282 S. T. Blachere Glazing and Decorating Aids for the Manufacture of ................................ Single-Fired Tiles 293 Bruno Guski Continuous Wet Grinding in the Floor and Wall Tile ....................................... Industry 308 G. Nassetti and C. Palmonari V ....... Granulation of Powders for Whitebody Ceramic Tiles 328 G. Nassetti and G. Timellini ............. Save Fuel and Energy by Firing 300°F Lower 343 William M. Jackson I1 .............. Practical Solutions for Fast-Fire Tile Faults 350 Barbara Ann Jacoby and Maurice Pare ................ Mechanical Performance of Ceramic Tile 357 G. Carani and G. Timellini Abrasion Resistance of Glazed Tile: Characterization of the Quality and Prediction of Performance in ............................... Working Conditions 369 G. Carani, G. Timellini, C. Palmonari, and A. Tenaglia IS0 Standards for Ceramic Floor and WaII Tile: ........................ Present Situation and Outlook 382 C. Palmonari and A. Tenaglia vi Materials & Equipment/Whitewares The group of papers in this section was presented at the national meeting of the American Ceramic Society in Dallas, April 23-26, 1990, and at the Materials & Equipment/Whitewares Divisions meeting in Nashville, September 304ctober 3, 1990. These papers represent work ranging from laboratory studies to plant process investigations, from raw materials to finished products. In many instances, the report will have direct application to whitewares production, either by giving the reader a better understanding of raw material preparation and quality control procedures, or by learning the results of analyses of specific operating problems. We are appreciative of the effort by the authors of these papers, not only for the time involved in the actual work, but for the effort required for the preparation of the paper, and, in many instances, considerable travel to reach the meeting place. These Proceedings serve as a permanent record of their presentations. Russell K. Wood American Standard, Inc. vii Ceramic Engineering & Science Proceedings Editor by John B . Wachtrnan Copyright@ 1991, The American Ceramic Society, Inc. Ceram. Eng. Sci. Proc. 12[1-2] pp. 1-12 (1991) Steps in the Development of Floor Tile Technology H. REH Verlag Schmid GMBH Freiburg, Germany The most important global technological innovations in jbor tile production since I960 are viewed in light of the enhancements of capacities and their effects on production costs and quality. The participation of t k m r t ile industry in the world’s ceramic production is discwsed. The development in the past few decades is described in detail. In this contat, dry pressing and wet exlrusion are discussed. The expected technological developments are given jiml consideration. Introduction Floor tiles have been around for centuries. In Europe, the first mention of floor tiles appeared in 1020 when ceramic tiles were laid in the A.D. floor of a monastery near Regensburg. They may have originated from bricks-ven the Ancient Romans clad their floors with not only mosaics of natural stones but also relatively rustic ceramic tiles. At that time ceramics’ capacity to store heat well was its essential virtue, which is the reason why ceramics were mainly used in the baths. Ceramic tiles first became interesting for floors when it became possible to produce denser bodies that were consequently more resistant to abrasion. In Europe, this occurred sometime after the 14th century. Modern tile production has its industrial roots in the beginning of the 19th century when the first experiments with dry pressing were conducted. In the middle of the 19th century, extrusion machines had reached the point where plastic compounds could be shaped mechani- cally. One can well suppose that the upswing in the second half of the 19th century proceeded accordingly. At that time, larger factories appeared, particularly in Great Britain and Germany, which produced floor tiles using the dry-pressing techniques. One Product-Two Manufacturing Techniques From the beginning, floor tiles were shaped from both powder and plastic bodies. For different reasons, wet-shaped tiles were, for the most part, transported through the production processes in a vertical 1 position on the narrow cant. As the bodies became increasingly thinner and the individual tile could no longer remain standing on its edge, split tiles developed. The term is deceiving. It simply refers to a pair of tiles that are attached to one another on the reverse side, while the outer surfaces can, for example, be glazed. The result is a broader supporting area. According to experience, these kinds of double tiles require a total thickness of at least 32 mm in the wet state if falling tiles are to be avoided. Only after firing are the double tiles separated. The most widely used variants today are presented in Fig. 1. It is estimated that approximately 10% of all floor tiles are extruded in the wet process. That is also and especially due to the fact that the necessary raw materials for this purpose are quite rare. Plastic clays with a suitable sintering behavior are in demand. Dry pressing, in contrast, gets by with far less plastic clays. During the molding cycle, workability is almost negligible. The particularly advantageous green strength of plastic clays can also be "artificially" achieved by means of the appropriate additives; this is done frequently. When two different processes can simultaneously hold their own for so long, there must be a reason. It has to do with the various advantages that, due to the particular technology, enter into the tiles. Table I makes this compari- son. Certain demands can sometimes only be fulfilled by one of the two methods. Table I. Advantages of Dry- or Wet-Shaped Floor Tiles Dry Wet Close tolerances (no dry shrinkage) Thin pieces Thick pieces (coarse-grained structure) Easy to decorate "Natural" look (plane surface) (if fired in tunnel kiln) Fine-grained structure Surface profiles Floor Tiles Are an Important Sector in Ceramics If one takes aside bricks, then the current production of ceramics in the Western world is an estimated $50 billion/year. The distribution is shown in Table I1 (the required raw materials are likewise indicated). 2 1 Diminution Crushing /I BY 2a Batching By volume nass 2b (Brox feeder) 2C (Dker) I Milling Screen pan Fine I 111 3 mill grinding mill/ Fine roll 1 11 Blunger mill I 4 Classi- one Sieving CY fication , 5 Storing Clay silo, 0 Storage etc. arc 6 Mixing h! - 7a Drying Dry- Fluid bed, 7b Milling Pan Pan mill 8 Storing Clay silo, Silo "i' etc. 9 Shaping Extruder Extruder Dry Dry Db -----------------Pr-ess --Pr-ess- -P-res-s -Route A B C D E F Granulates Fig. 1. Flow sheet of typical preparation in the tile industry 3

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