Chemical process industries

1. 1
Presented to: Mr Waqas
Presented by: M. Usama Haroon

2. Introduction
 A ceramic is an inorganic, nonmetallic solid prepared by the action
of heat and subsequent cooling.
 Ceramic materials may have a crystalline or partly crystalline
structure or may be amorphous.
 The majority of ceramics are compounds of metals or metalloids and
nonmetals. Most frequently they are oxides, nitrides, and carbides.

3. Crystalline Ceramics
Non-Crystalline Ceramics

4. Crystalline Ceramics:
 The structural ceramics tend to be crystalline and show greater strength
as well as stability at high temperature
Examples:
 BaTiO3
 SrZrO3
 MgAl2O4
 FeAl2O4

5. Defects in Crystalline Ceramics
• Vacancy
• Interstitial
• Dislocation
Cation Interstitial
Anion Vacancy
Cation Vacancy

7. Non-Crystalline Ceramics:
 The viscosity of the material at ambient temperature is
relatively high but as the temperature increases there is a
continuous decrease in viscosity.
 When the viscosity has decreased to the point that the
ceramic is a fluid, it is considered to have melted.
 At ambient temperature while it is still solid, it is said to be
in the “glassy” condition.

8. Mechanical & Chemical Properties:
Ceramic is:
 Solid
 Inert
 Brittle
 Hard
 Strong in compression
 Weak in shearing and tension
 Chemically resistant in an acidic or caustic environment
 Able to withstand very high temperatures from 1,000 °C to 1,600 °C (1,800
°F to 3,000 °F).
Inert Compounds:
In chemistry, the term inert is used to describe a
substance that is not chemically reactive. The noble gases were
previously known as inert gases because of their perceived lack of
participation in any chemical reactions.

9. 9
• Clay
• Shale , mudstone
• Feldspar
• Silica

10. Ingredients:
Traditional ceramic raw materials:
 Silica and Clay
 Kaolinite
 Aluminium oxide (alumina)
Applications: Traditional ceramics include high-
volume items such bricks and tiles and pottery.
Modern (Advanced) ceramic raw materials:
 Silicon carbide
 Tungsten carbide

11.  Depend on the properties of required product.
 Plastic and Moldable ----- soft state
 Rigid ----- dry state
11

12.  Potash Feldspar(K2O. Al2O3. SiO2)
 Soda Feldspar(Na2O.Al2O3.6SiO2)
 Lime Feldspar(CaO.Al2O3.6SiO2)
May be present in clay as Mined or Added.
Important Fluxing Agent
12

13. Equipments
13

14.  It stores the liquid.
More importantly, it
provides pressure by having
the liquid compress a
volume
of air as the
tank fills.
48

15.  Purpose: To transport the
material.
Belt Conveyer
Bucket Elevator
15

16. To reduce the
size of particle
by squeezing
action.
Variable size
product
obtained.
16

17. 17
To grind the material
with the help of
some grinding media
i.e balls in case of
ball mill.

18.  Seperation of particle on the basis of
 size.
18
200 Mesh
0.60 Mesh

19.  To separate out the
particle on the basis of
their size.
 Two mesh size use
1. 0.60 mesh
2. 4 mesh
19

20.  Froth floatation is a process used for separating.
hydrophobic (having little or no affinity for water)
material from hydrophilic(having strong affinity for
water).
20

21. 21
The tray dryer is the device used the drying of the wet
products of the crude drugs, chemicals, powders or the
granules etc.

22. Porecelain Industry
22
Porecelain Industry

23. Contents
What is porcelain
Manufacturing process
Equipment's
Advantages
Disadvantages
23

24. Definition
 It is a vitrified translucent ware with a hard glaze which
resist abrasion to the maximum degree.
24

25. Kinds of porcelain
Hard paste
Soft paste
Bone china
25

26. Raw materials for making porcelain
Clay
Feldspar
Flint
Silica
To create different types of porcelain, people combine
these raw materials in varying proportions until they
obtain the desired green (unfired) and fired
properties.
26

27. Manufacturing process
There are three manufacturing process.
1. Wet process
2. Dry process
3. Cast process
27

28. Wet process porcelain
Wet process porcelain used for the production of highly
glazed insulators for high voltage service.
28

29. Dry process porcelain
Dry process porcelain , employed for rapid production of
more open-textured , low voltage pieces .
29

30. Cast process porcelain
This process is necessary for making of pieces too large
or too intricate for other two methods.
30

31. Manufacturing steps
Crushing raw materials
Cleaning and mixing
Forming the body
Bisque firing
31

32. Cont…………
Glazing
Firing
32

33. Wet process
Raw materials of proper proportions and properties
are weighted from overhead hoppers into the weighing
car
Feldspar ,clay and flint is mixed with water in blunger
Then this material passed over magnetic separator
Most of water is removed in filter press
All the air is taken out in pug mill assisted by vacuum.
This result in denser more uniform and stronger
porcelain
33

34. Cont…
The prepared clay is formed into blanks in a hydraulic
press or by hot pressing in suitable moulds
The blanks preliminary dried ,trimmed and finally
completely dried all under carefully and controlled
conditions
A high surface luster is secured by glazing with selected
materials
A vitrification of the body and glaze is carried out in kiln
with exact controlled of temperature
The porcelain pieces are rigidly tested and inspected
34

35. Pug Mill

36. Equipments
Magnetic separator
Magnetic ores like pyrolusite
(MnO2) and chromite
(FeO.Cr2O3) are enriched by
this method by making use of
the difference in the magnetic
properties of the ore and
gangue particles.
36

37. Crusher
Working
A crusher is a machine
designed to reduce large
rocks into smaller rocks,
gravel, or rock dust.
 Crusher may be used to
reduce the size.
37

38. Hopper bins
Working
Steel Hopper Bins and Plastic
Hopper Bins can be designed
to handle a wide variety of
powders and dry granular
materials.
38

39. DryerWorking
It used for continuous
drying and cooling of pellets,
pastes,moulded compounds
and panels using air, inert gas
or flue gas .
39

40. Blunger
Working
A blunger is a machine
commonly used in the
pottery industry for mixing
clay and water. A
blunger usually consists of a
round or octagonal tank with
a mixer.
40

41. Vacuum pug mill
Working
It is a machine in which
materials are simultaneously
grind and mixed with a
liquid. Industrial applications
are found in pottery ,bricks
and cement.
41

42. Filter
Working
A device (usually a membrane
or layer) that is designed to
physically block certain
objects or substances while
letting others through.
42

43. Kiln
Working
A kiln is a thermally insulated
chamber, or oven in which a
controlled temperature is
produced.Kilns are also used
for the firing of materials,
such as clay and other raw
materials, to form ceramics .
43

44. Advantages of porcelain tiles
Porcelain tiles are non-porous
Porcelain tiles are very dense and strong
Porcelain tiles are extremely resistant to abrasion
Porcelain tiles are highly resistant to chemicals
Porcelain tiles are extremely low maintenance
Porcelain tiles are environmentally friendly
44

45. Disadvantages of porcelain
Porcelain tiles are more expensive compared to non-
porcelain ceramic tile
Porcelain tile pieces are not uniform in size
Installing a porcelain tile floor is not an ideal do-it-
yourself project
45