CLAY PRODUCTS Bricks, Tiles, Refractory bricks, earthen wares and stone wares : From CLAY CLAY o Naturally

occurring material as soil cover o Clay is Secondary material, by disintegration of rocks. o One or more minerals : Kaolinite, Montmorillonite, Illite, Vermiculite etc. o Potash feldspar, orthoclase or microcline is mainly responsible for yielding clay minerals. o These minerals decomposes to yield kaolinite (silicate of alumina) which on hydration gives a clay deposit Al2O3 2H2O known as KAOLINE. CLASSIFICATION OF CLAY Based on Genesis Characteristics Residual clay China Clay (Purest, high kaolinite) Transported clay Fire clay (Kaolinite+Silica+Alumina) Glacial Vitrifying clays (rich in fluxing compound) Marine The Brick Clays (low grade clay) Alluvial Lacustarine

MANUFACTURING OF BRICKS
Selection of Clay Preparation Of mud Moulding

Firing

Loading To Kiln

Drying

Cooling

Unloading

Selection of Good / suitable Brick earth Chemical composition (IS:2117-1995) Clay : 20 to 30 % , Silt : 20-35 % , Sand : 35-50 % by weight. Clay & silt > 50 % , 15% < CaO , MgO > 1 % , Functions Silica: (50-60%)prevents shrinkage, warping, cracking, if more then brittle. Alumina : (20-30%)makes earth plastic , should be mixed with sand Lime and oxide of iron (4-6 % each) acts as flux (Red color of bricks by Iron oxide) Iron oxide excess makes brick Blue, more Magnesia makes brick Yellow Harmful ingredients Pebbles of Stone and Gravels Alkaline-Salts (common salts presents is sulphate of Ca, Na, K) efflorescence Lime stone or Kankar Vegetation and Organic matter. Field Test (1) Consistency test (2) Moulding properties (3) Deformation & Shrinkage (4) Strength Test So.. Requirement of Good brick earth? Stage :Preparation of Mud Winning Tempering (convert brick earth to mud) Manual Pug mill tempering 2 3 mt. height 30 m 3 / da y

Stage : Moulding of Bricks Hand Moulding and Machine Moulding Hand Moulding Most common method in India Soft Mud Process (25 to 30 % water)

Tools required: The Mould Stock Board Pallets and Strike (1) Ground Moulding For making ordinary bricks (slop moulding and sand moulding) Moulding bricks with frog (also called pallet moulding)

(2) Table Moulding Machine Moulding Cheaper in longer run, Uniform quality Stiff mud process. Small quantity of water : 12 to 18 % Worm Gear type 1000-2000 No/hr Vacuum Press Mix clay from pug mill Pushed in to vacuum chamber with help of body screw through perforation Mass is de-aired and crushed in operating chamber Made to pass through the die by operating the crushing screw Comes out from die in form of continuous ribbon. Brick length is cut Dry Press Process Mechanized plant Small quantity of water to finely crushed and clean clay. Resulting mix is dry or best dump Mix fed through hopper in special brick moulds. Mould placed under plunger and pressure : 50-150 Kg/cm2 Such bricks are called PRESSED BRICKS , Perfect shape, size, corners, edges Stage : Drying of Bricks Reasons for drying: For rough handling, loss of moisture, Save fuel during burning stage. Drying by Natural methods or Artificial methods.

Natural methods Pre stacking stage Stacking stage : Layer by layer, 100 cm wide and 10 brick layers. Air drying takes 4-10 days and 2-4 % moisture remains. The Artificial drying Chamber drying Specially designed, temperature and humidity controlled Tunnel drying Bricks stacked on mobile cars, made to pass on rail through drying tunnels Stage : Burning of Bricks. Essential for developing desired building properties. Chemical changes that takes place are : Dehydration Removal of water from pores (425 7650C) Lose all water and also some water from crystallization from its component. Oxidation Takes place above 9000C All organic matter gets oxidized. C & S eliminated as oxides. The fluxes becomes reactive. Acquire red color due to oxidation of iron Vitrification Last reaction , between 9000C to 11000C Alumina and silica starts softening in presence of fluxing compound. Grains get bound firmly.

Methods of Burning Clamp burning or Kiln burning. 1) CLAMPS OR PAZWAS No permanent Structure Alternate layers with space Covered with mud plaster Allowed to burn for a month Cooling for month

Advantage :Easy to erect, type of fuel , Supervision, economical Disadvantage: Burning not uniform, cant regulate heat , time,

Brick Kilns Permanent structure for burning Bricks Types : Intermittent and Continuous The Allahabad Kiln. o Loading : Dried bricks on rouse, 3 bricks on edge ,8 to 10 layer, top layer flat, upper few layer projected to form arch shape, top cover with earth /ash o Firing: Low fire for 2-3 days, dampers are closed and heat raised for 2-3 days o Cooling : 7-10 days o Unloading The Bull's trench kiln o British engineer, W. Bull, designed in 1887 o Circular or elliptical in shape. o On dry land, by digging a trench, 6 - 9 m wide, 2 - 2.5 m deep, and 100 - 150 m long. o An alternative method is to build up the sides of the kiln with bricks. o Gaps are left in the outer wall for easy assess to the trench during setting and drawing of bricks. Dampers provided for temp. control Working Loading The green bricks to be fired are set in rows, two to three bricks wide. Holes in between that allow feeding of coal and a sufficient flow of air. Fuel galleries made in lower region that are continuous, with flues in outside wall. On top of the bricks, two layers of bricks, covered with ash or brick dust. The trench contains 200 - 300,000 bricks at a time. Preheating Hot and waste gases from preceding burning chamber by raising dampers. Burning Required volume of air supplied by controlling dampers. Additional quantity of fuel provided from top. 24-30 hours for perfect burning. the chimneys are moved forward 5 to 7 m Cooling Outer gates are closed by lowering dampers Internal gates are opened to lead hot gases to preheating section. 3-4 days to cool down. Unloading

The Hoffman Continuous kiln Continuous kilns for the firing Hoffmann kilns are probably the best known and most widely used, began around 1849 . Hoffmanns technology is two thirds fuel saving over the intermittent and semicontinuous kiln. Great circular ring chamber, with massive walls and a large chimney at the centre. Underground radial flues converged from the inside walls of each of the 12 chambers. Each chamber is provided with separate gate in outer wall for loading, unloading and firing. Central chimney, over-ground construction and permanent roof: main Working : Principle of continues kiln. Burning, preheating, cooling, unloading done simultaneously Imp.condition is establishment of upward draft Scheme of cyclic operation , many variation Burning Preheating Loading Cleaning Unloading Cooling

The Tunnel Kiln o Continuous type of kiln, highly efficient o Channel or tunnel 60-150 mt. long and 3-5 m wide. o Provided with rail tracks for cars. o Working: Preheating, burning and cooling. o Temperature and humidity in strict control.

Sr. No. 1 2

Factor Initial cost

Clamp Burning Low

Kiln Burning High High Skilled Invariably used Discontinuous Good

Operating cost Low Fuel Labour Unskilled Use of waste hot Not possible gas Continuity of operation Quality of bricks Suitability Continuous Ordinary

3 4 5

Small scale, Large scale ordinary type bricks Bulls trench kiln Low Hoffmans kiln High Lower Continuous Ratio : Best/total high Suitable for mechanized/ semi

Sr. No. 1 2 3 4 5

Factor Initial cost

Operating cost Higher Continuity Quality of bricks Suitability Semi-Continuous Ratio : Best/total less Low investment production