PREPARATION AND SOME PROPERTIES OF SINTERED
ALUMINOSILICATE CERAMIC BASED ON HCBS. PART I
Yu. E. Pivinskii,
P. V. Dyakin,
D. V. Gorbachev,
and S. A. Strel’tsov
Translated from Novye Ogneupory, No. 2, pp. 30 – 41, February, 2013.
Original article submitted November 16, 2012.
Wet grinding in a disk mill is used to prepare highly-concentrated ceramic binder suspensions (HCBS) based
on broken porcelain electric insulator and pearlite with a volume concentration of solid phase of 70% and with
specified rheotechnological properties. A semifinished product, obtained by slip casting and centrifugal mold
ing, has original porosity of 20 – 22% and shrinkage during drying of less than 0.05%.
Keywords: HCBS, pearlite, wet grinding, rheotechnological properties, fineness, slip casting, centrifugal
molding, shrinkage during drying.
Recently technology connected with preparation and use
of HCBS has been developed quite rapidly and improved
predominantly in the area of molded and unmolded
refractories [1 – 5]. In addition, they are effective or may be
no less effective in the area of preparing various ceramic ma-
terials. Currently the overwhelming majority of objects of
quartz ceramic are prepared with use of quartz glass or fuzed
quartz HCBS [6, 7]. Previously the efficiency of HCBS has
been demonstrated as applied to preparing corundum ceram-
ics [2, p. 480], ceramics based on mullite, and corundum-zir
con [3, p. 141]. HCBS are very effective applied to technol
ogy for high-alumina ceramics (89 – 91% Al
). Based on
bauxite HCBS its zero open porosity has been achieved with
a firing temperature of 1400 – 1450°C [4, p. 224], which is
considerably lower than in traditional technology.
URGENCY OF THE PROBLEM
According to our assumptions, in the area of ceramic
production there is very extensive volume of production of a
class of objects during whose preparation by means of using
technology based on HCBS it is possible to achieve signifi
cant technical and economic effects. We are talking about
production not only of normal or medium, but also large por
celain insulators, formed predominantly from a plastic mix
[8 – 11] and having significant weight (up to 100 kg), height
up to 3 and diameter up to 2 m. Taking account of the signifi-
cant shrinkage of these objects during drying (5 – 6%) and
firing (up to 15%) their manufacture is connected with pro-
duction problems and significant losses due to scrap. As a re-
sult of this cost of even significantly smaller electrical insu-
lators reaches 250 – 200 thousand rubles per ton [12, 13],
which is higher by a factor of 40 – 50 than the cost of similar
traditional chamotte refractories with respect to chemical
composition, fired at the same temperatures as electrical en
gineering porcelain . In order to form these porcelain ob
jects with a complex shape there is also use of slip casting,
and this is connected with similar problems.
It is proposed that HCBS of appropriate chemical com
position may be prepared on the basis of previously manu
factured sinter, or what is more effective from a technical and
economic viewpoint, based on broken material and scrap of
objects similar in chemical and mineral composition. It
should be noted that there are many years of factory practice
for using fired porcelain broken material in traditional tech
nology for manufacturing this product. For example, it is
well known that within the composition of porcelain mixes
for high-voltage insulators the content of broken porcelain is
within the limits 5 – 20% [8, p. 63], and in glazed material it
is 19 – 29% [8, p. 72]. From the data provided there is evi
dently a significant yield of scrap in insulator production.
It is not excluded that in a number of cases technology
based on HCBS may be effective in quite a wide range of ob
ject production made of porcelain and hard faience [10, 11].
Taking account of the reduced requirement for water absorp
tion (3 – 5% for semiporcelain and 10 – 12% for hard fa
Refractories and Industrial Ceramics Vol. 54, No. 1, May, 2013
1083-4877/13/05401-0054 © 2013 Springer Science+Business Media New York
OOO NVF Kerambet-Ogneupor, St. Petersburg, Russia.
GOU VPO St Petersburg State Technological Institute (Technical
University), St. Petersburg, Russia.
OOO VKVS-Tekhnologii, Lipetsk, Russia.