Abstract: A method of making ceramic articles includes compounding ceramic precursor batch components that include hydrous clay. The hydrous clay includes particle components having a platy geometry. The crystallite size of the platy hydrous clay particle components is greater than a predetermined amount. Controlling such crystallite size can result in reduced shrinkage of green ware during the clay dehydroxylation stage of firing.

Abstract: A method of making ceramic articles includes compounding ceramic precursor batch components that include hydrous clay. The hydrous clay includes particle components having a platy geometry. The crystallite size of the platy hydrous clay particle components is less than a predetermined amount. Controlling such crystallite size can result in fired ceramic articles with a lower coefficient of thermal expansion and improved thermal shock resistance.

Abstract: There is provided an apparatus and process for manufacturing a brick or paver with a high content of coal ash (ranging from 60% to 100% coal ash or fly ash) so that a waste product (coal ash, and more particularly Class F coal ash) from a coal-fired power plant is incorporated into a building product (high content fly ash brick or paver). Also provided is a variable firing tray to support the dried, high content coal ash bricks/pavers as the dried products are sent through a tunnel kiln, to improve circulation around the individual bricks/pavers and thereby result in reduced firing time in the kiln.

Abstract: A process of manufacturing a sulfoaluminate or ferroaluminate cement, and an apparatus for the manufacture. The cement is manufactured from a mixture containing CaCO3, Al3 and/or Al(OH)3, CaSO4, SiO2 and/or a product containing silica or silicates such as clay, these compounds being present in the anhydrous or hydrated form. In this process, the mixture is treated up to clinkering by movement in a center of a kiln, in a sheet with approximately constant thickness, at approximately constant speed, along a treatment path having a positive temperature gradient, and for a treatment time during which the mixture remains below its melting temperature. The mixture is clinkered to produce a clinkered mixture that is cooled upon exit from the treatment path.

Abstract: A novel process for manufacturing fully vitrified flat extruded ceramic glazed, unglazed tiles and profiles includes the following steps: mixing of raw materials in predetermined ratios; wet milling in ball mills; mechanical filter pressing to get cakes; shredding of cake to obtain noodles like structure; using a de-airing pug mill machine to produce proper mixing by removing of air the body; drawing a column of clay body through a die for required shapes; drying in three layer horizontal drier and chamber drier; coloring in a appropriate glazing line; firing in a appropriate roller kiln; sorting line; packing and palletizing machine; and using a sawing and glueing machine for smaller size tiles to make patterns and for border tiles. The invention also includes a system for carrying out the invented process so as to achieve high quality fully vitrified ceramic tiles and profiles.

Abstract: FIGS. 25 and 26 show in sequence a 270° bending of a tile predisposed on a bottom surface thereof in which surface a straight groove has been made at a position where a bend is to be performed. FIG. 5 is a detailed illustration showing the groove after having been filled following bending. In the illustrated example, the bend of the tile is obtained, after making the groove in the opposite surface to the upper surface, by subjecting the tile to overall or localized heating as it is resting on a support made of refractory material which support has two surfaces which are reciprocally perpendicular and inclined with respect to a vertical, at a suitable angle for the tile to be stable thanks to a part thereof resting on the surface, and a projecting part of the tile to be able, when softened, to fall by gravity until it reaches and rests perfectly on the other surface 10″ of the support.

Abstract: A method of making a product which is generally impervious to water including the steps of making a generally homogenous mixture of slate particles and clay, setting the mixture as necessary to produce a formable composition, forming the wet mixture to a desired configuration, at least partially drying the formed mixture and subjecting the dried formed mixture to a temperature of at least 1145° C. for a time sufficient for at least some of the clay to convert into a binder to bind together the slate particles.