Abstract: This invention is related to the oil and gas production industry and more particularly to a proppant that can be used to enhance oil and gas production in hydraulic fracturing. Most particularly, the invention is a composition and a manufacturing process for making ceramic proppant: a ceramic matrix composition formed from a precursor of the matrix and a reinforcing additive, in which the reinforcing additive is in the form of numerous elongated inorganic crystals; or one or more than one precursor may be pre-fired (pre-calcined).

Abstract: The present invention relates to a composition for forming a friable-resistant dielectric porcelain material. The present invention also relates to a friable-resistant dielectric porcelain material formed from the composition of the present invention, a method of making a friable-resistant dielectric porcelain material, a friable-resistant dielectric porcelain material formed by the method of the present invention, a dielectric porcelain material comprising a particular composition, and a system for producing ozone using the dielectric porcelain material of to the present invention.

Abstract: The invention relates to synthetic hybrid rock compositions, articles of manufacture and related processes employing mineral waste starting materials such as mine tailings, mine development rock, ash, slag, quarry fines, and slimes, to produce valuable articles of manufacture and products, which are characterized by superior physical and structural characteristics, including low porosity, low absorption, increased strength and durability, and retained plasticity. The resulting materials are compositionally and chemically distinct from conventional synthetic rock materials as demonstrated by scanning electron microprobe analysis, and are useful in a wide variety of applications, particularly with respect to commercial and residential construction.

Abstract: The invention provides novel paving stones and construction block composite materials and methods for preparation thereof. The paving stones and construction block composite materials can be readily produced from widely available, low cost precursor materials by a production process that involves compacting in a mold that is suitable for large-scale production. The precursor materials include calcium silicate, for example, wollastonite, and particulate filler materials which can comprise silicon dioxide-rich materials. Additives can include calcium carbonate-rich and magnesium carbonate-rich materials. Various additives can be used to fine-tune the physical appearance and mechanical properties of the composite material, such as colorants such as particles of colored materials, such as, and pigments (e.g., black iron oxide, cobalt oxide and chromium oxide).

Abstract: A useable particulate nepheline syenite having a grain size to provide an Einlehner Abrasive Value of less than about 100 is described. The particulate nepheline syenite is generally free from agglomeration and moisture free. At least 99% of the nepheline syenite particles have a size less than 10 microns. In practice, the nepheline syenite grain size is less than about 5 microns and the distribution profile of the particulate system is generally 4-5 microns.

Abstract: The present invention relates to a composition for forming a friable-resistant dielectric porcelain material. The present invention also relates to a friable-resistant dielectric porcelain material formed from the composition of the present invention, a method of making a friable-resistant dielectric porcelain material, a friable-resistant dielectric porcelain material formed by the method of the present invention, a dielectric porcelain material comprising a particular composition, and a system for producing ozone using the dielectric porcelain material of to the present invention.

Abstract: An ultra-lightweight, high strength ceramic proppant made from mixture of naturally occurring clays, preferably porcelain clay, kaolin and/or flint-clay, earthenware clay or other naturally occurring clays having an alumina content between about 5.5% and about 35%. The proppant has an apparent specific gravity from about 2.10 to about 2.55 g/cc, and a bulk density of from about 1.30 to about 1.50 g/cc. This ultra-lightweight proppant is useful in hydraulic fracturing of oil and gas wells, and has greater conductivity than sand at pressures up to 8,000 psi as measured by Stim-Lab after 50 hours and 275° F. on Ohio Sandstone, in the presence of deoxygenated aqueous 2% solution of KCI.

Abstract: The ceramic clay is provided by kneading a forming raw material containing a ceramic forming material. The forming raw material contains, in addition to the ceramic forming material, a layered double hydroxide represented by a predetermined chemical formula in an amount of from 0.01 to 5 mass % based on the total amount of the layered double hydroxide and the ceramic forming material. The layered double hydroxide turns into a gel when dispersed in water, and when the layered double hydroxide is dispersed in water at a concentration of 6 mass %, the layered double hydroxide has a viscosity of from 1000 to 20000 mPa·s.

Abstract: Sintered, substantially round and spherical particles and methods for producing such sintered, substantially round and spherical particles from an alumina-containing raw material and a metal oxide sintering aid. The alumina-containing raw material contains from about 40% to about 55% alumina. Methods for using such sintered, substantially round and spherical particles in hydraulic fracturing operations.

Abstract: The invention relates to a composition, which comprises a particulate mixture of: (i) 25 to 80% calcined clay; (ii) 5 to 70% fluxing component; and (iii) 5 to 70% filler component.

Abstract: A glaze composition which makes it possible that a base material for an inorganic calcined substance containing a lot of vitreous material is glazed without having corrosion. The glaze composition comprises a plastic material, a non-plastic material, and a solvent material, wherein the plastic material comprises at least one material selected from the group consisting of Gairome clay, Kibushi clay, kaolin and talc; the non-plastic material comprises at least one material selected from the group consisting of silica, calcined kaolin, pottery stone, pyrophyllite, pottery shards, chamotte and zircon; and the solvent material comprises at least one material selected from the group consisting of feldspar, lime stone, dolomite, zinc oxide and lithium carbonate.

Abstract: The invention relates to synthetic hybrid rock compositions, articles of manufacture and related processes employing mineral waste starting materials such as mine tailings, mine development rock, ash, slag, quarry fines, and slimes, to produce valuable articles of manufacture and products, which are characterized by superior physical and structural characteristics, including low porosity, low absorption, increased strength and durability, and retained plasticity. The resulting materials are compositionally and chemically distinct from conventional synthetic rock materials as demonstrated by scanning electron microprobe analysis, and are useful in a wide variety of applications, particularly with respect to commercial and residential construction.

Abstract: An improvement in a mixture for forming into a body that is to be fired into a “whiteware ceramic product” wherein the mixture is a compound of clay and other minerals with a ferric oxide content of less than about 5.0% by weight of the dry mixture. The improvement includes adding to the mixture a binder in the form of a combination of protein and a vegetable flour with an equivalent gram strength of at least 30 grams and a protein content of 20-50% of the binder, where the binder is in the range of 0.05% to 0.50% by weight of the dry mixture.

Abstract: A clay plaster formulation and application. The clay plaster is a mixture of various clays, and aggregate. This plaster is both functional and decorative and is for use on new and existing construction.

Abstract: A useable particulate nepheline syenite having a grain size to provide an Einlehner Abrasive Value of less than about 100 is described. The particulate nepheline syenite is generally free from agglomeration and moisture free. At least 99% of the nepheline syenite particles have a size less than 10 microns. In practice, the nepheline syenite grain size is less than about 5 microns and the distribution profile of the particulate system is generally 4-5 microns.

Abstract: A clay plaster formulation and application. The clay plaster is a mixture of various clays, and aggregate. This plaster is both functional and decorative and is for use on new and existing construction.

Abstract: 0.5 to 30 parts by weight of a hexagonal celsian powder is added to 100 parts by weight of a ceramic raw material powder to give a mixture. The mixture is sintered to give a ceramic porcelain so as to precipitate monoclinic celsian in the ceramic porcelain.

Abstract: A batch mixture including ceramic-forming ingredients, a pore former, a binder comprising an ammonium salt of an alkylated cellulose binder, and a liquid vehicle, as defined herein. Also disclosed is a method for producing a ceramic precursor article as defined herein having excellent extrusion properties.

Abstract: A precursor composition for the production of granulated ceramic material to be used as hydraulic fracture proppant, comprises 20 to 55% pyroxene, and 15 to 50% olivine. The remaining component is quartz and/or feldspar. The precursor composition can be sintered in a broader temperature range. The resulting proppant material shows high mechanical strength and resistance to acids, and also higher stability under hydrothermal conditions than the prior art.

Abstract: A composite article includes a substrate and a layer attached to the substrate. The layer includes a metal phase, a first ceramic phase, and a second ceramic phase.

Abstract: A clay plaster formulation and application. The clay plaster is a mixture of various clays, and aggregate. This plaster is both functional and decorative and is for use on new and existing construction.

Abstract: There is disclosed a ceramic clay obtained by kneading a forming material containing a ceramic forming material, wherein the forming material contains layered double hydroxide, in addition to the ceramic forming material, at a ratio of 0.5 to 50% by mass with respect to a total with the ceramic forming material, and hardness measured by an NGK clay hardness meter is set to 4 to 18 mm. A high-strength honeycomb structure can be obtained capable of preventing or inhibiting pollution and global warming when used in manufacturing a ceramic structure, and having few defects such as cracks.

Abstract: The present invention relates to a decorative refractory tile and it's method of use. This decorative tile utilizes a specially formulated clay body that undergoes dehydration and vitrification by firing in a specific manner with respect to temperature, time and rate of temperature increase. This thin, refractory tile has a high thermal conductivity, high structural strength able to maintain a minimal of cracking, distortion and spalling under rapid temperature changes and possesses a high resistance to erosion from ash-laden gases encountered in a conventional fireplace. This tile can be colored with heat resistant glazes, stains and oxides and sized or shaped within certain dimensional ranges, so as allow it to present patterns, designs or even pictures on the sides, floor and back of the firebox. When this tile is crafted by one with an artistic flair, and affixed to the walls, floor or sides of a firebox, aesthetically favorable fireplaces can be created.

Abstract: Methods and compositions are provided for making low temperature sintering ceramic bodies that have very low thermal expansion and low porosity.

Abstract: A brick additive and methods for using the brick additive are disclosed. The additive may include an internal porosity. The internal porosity may display an intra-granular internal porosity in which at least some of the pores are interconnected via an open network of pore spaces. In some embodiments, the additive is capable of maintaining its internal porosity after undergoing thermal modification via calcination, for example. In addition, brick additives of the present invention may display a large surface area.

Abstract: Methods and compositions are provided for making low temperature sintering ceramic bodies that have very low thermal expansion and low porosity.

Abstract: A clay composition comprises, in parts by weight on oxide basis, 10-15% Al2O3, 50-85% SiO2, 0-12.5% B2O3 and 10-20% metal oxides of the form RO or R2O.

Abstract: A brick additive and methods for using the brick additive are disclosed. The additive may include an internal porosity. The internal porosity may display an intra-granular internal porosity in which at least some of the pores are interconnected via an open network of pore spaces. In some embodiments, the additive is capable of maintaining its internal porosity after undergoing thermal modification via calcination, for example. In addition, brick additives of the present invention may display a large surface area.

Abstract: Ceramic media made using ceramic components comprising from 5 to 60% by weight of spodumene and 95 to 40 wt % of other ceramic-forming components comprising clay and feldspar have a reduced tendency to shrink upon firing to form the media and improved physical properties.

Abstract: Support material from porous ceramic granulate, produced from a mixture of 45 to 80 parts by weight clay, 0 to 50 parts by weight calcite, quartz sand, dolomite, feldspar, chamotte and/or sepiolite, 15 to 30 parts by weight water, 0.01 to 0.03 parts by weight deflocculant, 0.001 to 0.01 parts by weight surfact and optionally agents counteracting the deflocculant and foamed under an overpressure of at least 0.3 bar prior to baking and filled or charged with at least one volatile substance.

Abstract: The present invention involves the use of fired clay, in particular flint clay, as a filler particulate and substitute for standard polymeric particulate commonly used in solid surface products. As well, it is also a substitute for ground stone as used in engineered stone products.

Abstract: A process is described for producing porcelain, in particular high-strength porcelain and a ceramic insulator. To produce the porcelain, calcined bauxite is used instead of alumina. The simultaneous addition of clay and kaolin, in each case containing more than 5% by weight of foreign metal oxide inclusions, results in a porcelain which, compared to an alumina porcelain of the same mechanical strength, can be produced at significantly lower cost. The porcelain is suitable in particular for applications for highly mechanically loaded components used in electrical insulation.

Abstract: This invention provides a light-weight pottery article with lower specific gravity than that of general pottery as well as a process for producing the same. The light-weight pottery article of the invention is produced by adding a lightening agent to clay based on silica and alumina, forming the resulting kneaded material into a desired form and calcinating the formed material, wherein the lightening agent is microspherical hollow ceramic powder having a hollow structure based on silica and alumina, the surface of said hollow ceramic powder is coated with an inorganic coating layer based on a silicate compound (e.g. sodium silicate, potassium silicate etc.), said hollow ceramic powder is contained in such a state as to be uniformly dispersed at a proportion of 20 to 80% by weight in the base materials, and in said base materials there is a structure in which the neighboring hollow ceramic powders have been integrated with one another via said inorganic coating layer.

Abstract: A composition for ceramic tiles, the composition having being formulated from materials including granite and comprising the following components, given in weight percent, based on the total weight of the composition:______________________________________ SiO.sub.2 56-64 wt % Al.sub.2 O.sub.3 15-17 wt % K.sub.2 O 2-3 wt % Na.sub.2 O 0.5-1.5 wt % CaO 5-5.7 wt % MgO 0.5-0.6 wt % L.O.I. 6-7 wt %.

Abstract: A method for preparing high strength and high thermal shock-resistant china for ceramic whiteware which comprises the steps of molding a china-forming raw material which mainly comprises a natural ore material capable of forming corundum through firing or a material obtained by calcining the natural ore material to form corundum, a natural ore material capable of forming mullite through firing or a material obtained by calcining the natural ore material to form mullite, a clayey material and a flux such as feldspar, nepheline or dolomite; and then firing the molded china-forming raw material. The method permits the production of cheaper china for ceramic whiteware having high strength and excellent thermal shock resistance as compared with those prepared by the conventional techniques.

Abstract: This invention relates to synthetic garnite tiles made essentially from garnite sand and a process for the production of synthetic garnite tiles essentially from garnet sand which is a by-product of beach sand from rare earths extraction, said process comprising mixing beach sand garnet, feldspar and clay thoroughly; pressing the mixture using a press at a pressure in the range of 40-80 MPa to form tiles of desired shapes and sizes; drying the tiles so formed at a temperature of 100-120.degree. C.; firing the dried tiles at a temperature in the range of 1050-1250.degree. C. with a soaking for a period ranging from 1.5 to 2.5 hours, and polishing the resultant tiles.

Abstract: The use of wollastonite fibers having relatively long average fiber lengths as reinforcement agents for unfired sanitaryware bodies. The addition of refined wollastonite to sanitaryware bodies exhibited improved resistance to propagation of cracks, reduced drying and firing shrinkage, fluxing activity, an HF release inhibition upon firing. Reduced shrinkage and increased permeability improves the resistance to cracking during rapid drying and allows faster time schedules to be employed.

Abstract: A method of improving the strength and/or plasticity of a clay composition comprising a kandite clay and an organic additive comprising at least one water soluble compound having a plurality of basic groups wherein the organic additive is present in an amount of from about 0.05% by weight to about 0.5% by weight based on the dry weight of the kandite clay present, which method comprises treating the kandite clay by adding thereto a monovalent ion activated smectite clay or a monovalent ion activating agent for a smectite clay or both whereby the amount of monovalent ion activated non-calcined smectite clay present in the clay composition is adjusted to be in the range from about 1% by weight to about 5% by weight based upon the dry weight of the kandite clay present.

Abstract: A method of calcining kaolin, comprising the steps of:a) producing a clay slurry comprised of water and kaolin clay of a specific particle size;b) mixing a water insoluble potassium containing glass forming compound into the clay slurry in an amount wherein the potassium content of the slurry is equal to about 1% by weight of the kaolin clay in the slurry;c) removing sufficient water from the slurry to form a material having an extrudable consistency;d) extruding the material into elongated shapes;e) heating the shapes by continuously moving them through a furnace having a zone, wherein the material is exposed to temperatures of at least 2700.degree. C. for at least 30 minutes.

Abstract: An adsorptive monolith made by extruding a mixture of activated carbon, a ceramic forming material, a flux material, and water, drying the extruded monolith, and firing the dried monolith at a temperature and for a time period sufficient to react the ceramic material together and form a ceramic matrix. The extrudable mixture may also comprise a wet binder. The monolith has a shape with at least one passage therethrough and desirably has a plurality of passages therethrough to form a honeycomb. The monolith may be dried by vacuum drying, freeze drying, or control humidity drying. The monolith is useful for removing volatile organic compounds and other chemical agents such as ozone from fluid streams. Particularly useful applications include adsorptive filters for removing ozone from xerographic devices and other appropriate office machines and volatile organic compounds from automobile engine air intake systems.

Abstract: A method and composition of matter for balancing tire and rim assemblies of vehicles is disclosed wherein the composition of matter has rounded balancing elements of different sizes to line the interior of a tire casing and to move over the lining to offset points of imbalance.

Abstract: This invention relates to a Hall-Heroult cell for aluminum production comprising a cryolite-resistant liner comprising:i) between 75 weight percent wt % and 95 wt % alumina-silica refractory grain, andii) between 1 wt % and 10 wt % of a sealant selected from the group consisting of feldspar and nepheline.

Abstract: A honeycomb structural body is obtained by mixing 60.about.80 wt % of aggregate, which does not show a transformation of crystal structures substantially up to 500.degree. C., and 20.about.40 wt % of clay to obtain a mixture, adding phosphate as a hardening agent to the mixture in such a manner that more than 2.0 wt % of phosphoric acid exists therein with respect to 100 wt % of the mixture, adding a forming agent and a water to the mixture to obtain a formable batch, extruding the batch into a honeycomb structure to obtain a honeycomb structural formed body, drying the honeycomb structural formed body, and subjecting the honeycomb structural formed body to a heat treatment in 300.degree..about.500.degree. C. The thus obtained honeycomb structural body has excellent catalyst carrying property and fireproof property, which are used as a catalyst carrier for ozone dissolving, deodorizing and so on in an inexpensive manner.

Abstract: A whiteware ceramic composition is provided comprising a filler, 4 to 10% by weight of a flux having a median particle size of below 6 microns, a prefired ceramic material milled separately from the other components, and raw clay constituting from 5 to 20% by weight of the composition. Fired whiteware made by firing the composition of the invention is also disclosed.

Abstract: A corundum porcelain composition containing from 60 to 94% by weight of a component A and from 6 to 40% by weight of a component B, wherein component A contains from 0 to 70% by weight of alumina, from 20 to 70% by weight of clay material, from 10 to 50% by weight of glass formers and from 0 to 30% by weight of quartz, and component B comprises comminuted broken porcelain, the chemical composition of the mixture of the components A and B comprises from 20 to 75% by weight of SiO.sub.2, from 15 to 80% by weight of Al.sub.2 O.sub.3 and from 2 to 10% by weight of flux selected from the group consisting of K.sub.2 O, Na.sub.2 O, FeO, MgO, CaO, Li.sub.2 O; BaO, SrO, ZnO and fluoride, and the comminuted broken porcelain has a mean particle size between 25 and 800 .mu.m, useful, for example, in sintered bodies, such as insulators.

Abstract: The invention relates to a porcelain with a transparency and strength properties of a hard porcelain, characterized by a phosphate-containing glass phase as well as the predominance of unreacted quartz bodies [sic; grains] in the matrix. The invention relates to a porcelain batch composition as well as to a method for the manufacture of the porcelain.

Abstract: An object of the present invention is to shorten the working time for high pressure slip casting. There is provided a composition for high pressure casting slip including a first starting powder forming a frame of a mold body and second starting powder forming the frame of the mold body and acting as a plastic agent, wherein the first and second starting powders are uniformly mixed in a dry condition. "Slip" of a minimum water content is easily prepared by the composition to effect optimal fluidity of the slip so that the water is removed from the slip in a short time during a casting process.

Abstract: The present invention has disclosed raw materials for producing color ceramic products, which is prepared by using V-bearing titanomagnetite tails obtained after ore dressing as base material with a given proportion of additives and with or without coloring agents. The total content of Fe, Ti, Co, and Ni in said base material is in a range of about 3-45% by weight. The raw materials of the present invention have the advantages of no free iron and soluble vanadium compounds contained therein, thus when they are used to produce ceramic products, they can be sintered in a wide temperature range within shorter time. The products produced therefrom have the advantages of higher strength and hardness, lower water absorption, higher corrosion resistance, and stable tints. Products with a variety of sorts and various colors can be produced by using the raw materials of the present invention.

Abstract: A slurry composition is described, which comprises 100 parts by weight of a raw mineral material for white ware and/or a raw mineral material for advanced ceramics, from 0.5 to 20 parts by weight of a re-dispersible resin powder, and water. A shaping using the slurry composition and a fired body are also described.

Abstract: A method for making a high strength porcelain for use as an insulator or a structural ceramic, comprising:A) forming a mixture comprising alumina, clay and a fluxing material;B) forming the mixture into a shaped article; andC) firing the shaped article.