Utilizing more of the raw materials from your mining operations

By Bill Daidone 12. October 2017

raw materials

The raw materials used to make bricks are the most important part of the process. The quality of the brick and the success or failure of the brick plant can often be traced to the raw materials. The planning and implementation of a raw materials program is the backbone of a well-run brick plant. Brick plants are often built in close proximity to the primary raw materials to be used for decades. The quality and consistency of these raw materials normally vary throughout the mine property. When the characteristics of some mined materials are too far out of specifications it may be necessary to avoid these raw materials thus reducing the raw material reserves. Some of the characteristics and some of the ways to optimize the usage of raw materials are described below.

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Temaer: Structural, Refractory, raw materials

How to extend the working life of parts in brick and tile forming equipment

By Jonathan Savage 5. October 2017

In today’s heavy clay market there is becoming a push for more product in faster lead times. This need is putting extra pressure on manufacturers especially to increase throughput times. Although kilns and sometimes driers can be the bottleneck, there is added pressure on the moulding equipment to produce clay products quicker.

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Temaer: Structural

How to improve Lubrication of the molds during your ceramic process

By Miguel Ten 28. September 2017

The pressing stage is one of the most demanding in the production of ceramic bodies. Therefore, gaining any improvements here is directly translated into savings along the production process. These improvements will help to optimize the total costs of the manufactured products by reducing losses whilst improving the quality of the shaped materials.

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Temaer: Decorative, Refractory, Plasticity, lubrication

How to deal with efflorescences in Structural bricks

By Yaiza Paños 21. September 2017

Why does an efflorescence appear?

In chemistry, efflorescence is defined as the migration of a salt to the surface of a porous material, where it forms a coating. The essential process usually involves the dissolving of an internally held salt in water. The water, with the salt now held in solution, migrates to the surface, then evaporates, leaving a coating of the salt. These efflorescent salt deposits tend to appear at the worst times, usually about a month after the building is constructed, and sometimes as long as a year after completion.

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Temaer: Structural

How to optimize brick production through faster drying

By Jonathan Savage 7. September 2017

Before bricks and tiles can be fired the majority of water used in its moulding needs to be removed from the clay product. Any excess residual water or moisture left in the article as it enters the kiln to be fired will be removed very quickly leading to major problems such as blow out, warpage or in the extreme – as has been seen on numerous occasions – to explode causing serious damage to the kiln and production.

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Temaer: Structural

Reduction of plastic clays usage on the production of tiles - is it possible?

By Miguel Ten 10. August 2017

One of the main challenges of the Ceramic Industry is related to the lack of good quality plastic clays. Though there are many reliable sources, its cost is banning industrial usages, especially in a moment when tiles are becoming larger and larger. Furthermore, if we consider how market is moving towards higher performance requirements, this situation is not showing any ways of changing

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Temaer: Decorative, Plasticity

How to select the perfect binder for shaped refractory bricks manufacturing

By Jack Pongdet 3. August 2017

Generally, refractories are classified as basic, high alumina/silica, fireclay and insulating. There are also classes of “special refractories” which include Silicon Carbide, Silicon Nitride, Graphite, Zircon, Zirconia, fused cast and several others. Most refractory materials are supplied as preformed shapes. However, they also are manufactured in the form of special purpose clays, bonding mortars and monolithic such as castable, plastic refractories, ramming mixes and gunning mixes. In fact, many  refractories materials have been developed specifically to meet the service conditions of a particular process. The characteristic properties of each refractory class are a function of both their raw material base and the methods used to manufacture the refractory products.

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Temaer: Structural, Refractory

Different methods for plasticity measurement of a ceramic material

By Rosa Mediavilla 27. July 2017

Plasticity is the characteristic behaviour of a ceramic material to become permanently deformed after the application of an external force. This property is the most characteristic one in clays, and there are some factors that influence the plasticity and they should be considered in plasticity measurements:

  • Water physical characteristics like, viscosity, surface tension…
  • Particle size distribution of the solid sample and its specific surface
  • Chemical and mineralogical composition of samples
  • Effect of the additives added to the clay/water system
  • Sample temperature
  • The way to prepare the sample, particularly the energy used to mix and to process clay, water & additives

Plasticity is defined as the capacity to be deformed without being broken. Many methods available to measure it, and they are classified into two groups: direct and indirect methods.

Table1. Direct and indirect plasticity methods.

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Temaer: Decorative, Structural, Plasticity

Clay conditioning without souring

By Jonathan Savage 20. July 2017

The first process required to begin the production of clay bricks or roof tiles is to make available the raw materials required for the process. The major material used in manufacture are clays and as such brickworks will have been built as close to a clay quarry as possible although some clays are still trucked in to aid in varying colours and technical characteristics.

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Temaer: Structural

Clay formulation improvement for a better decorative tile production

By Miguel Ten 13. July 2017

Clay body formulation has been in a continuous evolution since the modern-day tile industry trended towards large and more aesthetic in appearance. This evolution is calling for adjustments to achieve required performances whilst optimizing production costs.

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Temaer: Decorative

BioKeramAdditive-A

A blog from BioKeram

BioKeram is a new range of products from Borregaard, the world's leading supplier of high performance biopolymers to the ceramics industry, with more than 50 years experience in the ceramics market. With this blog we aim to share our knowledge regarding ceramic process optimization.


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