A method of forming a ceramic product, the method comprising producing a ceramic forming mixture in the form of a slurry, causing the slurry to form, extruding the formed slurry to produce a plurality of lengths of extruding material each with a diameter of less than 10 mm, firing the extruded material so as to partially sinter the extruded material, forming the partially sintered extruded material into a required shape for a product, and subsequently firing the shaped partially sintered extruded material to form the ceramic product.

A method of forming a ceramic product, the method comprising producing a ceramic forming mixture in the form of a slurry, causing the slurry to form, extruding the formed slurry to produce a plurality of lengths of extruding material each with a diameter of less than 10 mm, firing the extruded material so as to partially sinter the extruded material, forming the partially sintered extruded material into a required shape for a product, and subsequently firing the shaped partially sintered extruded material to form the ceramic product.

Disclosed is a fire-proof thermal-insulation board of aerated concrete of B02-level lightweight autoclaved sand and its preparation method. Components of the thermal-insulation board are quartz sand, lime, cement, gypsum, aluminum powder, and foam stabilizer, weight percentages of the components are: 56%60% of the quartz sand, 8%11% of the lime, 20%30% of the cement, 2%4% of the gypsum, 0.24%0.26% of the aluminum powder, and 0.02%0.03% of the foam stabilizer. The fire-proof thermal-insulation board is made of an inorganic non-metallic material with lightweight, non-inflammable property and good thermal-insulation performance. The present disclosure well solves the thermal bridge problem of external wall of the building, and has A1-level fire-proof performance and good durability with the same service life as the building. The present disclosure overcomes low product strength, and inconvenience in transportation and construction in the prior art, reduces types of admixture used in the manufacturing process, and reduces the manufacturing cost.

Disclosed is a fire-proof thermal-insulation board of aerated concrete of B02-level lightweight autoclaved sand and its preparation method. Components of the thermal-insulation board are quartz sand, lime, cement, gypsum, aluminum powder, and foam stabilizer, weight percentages of the components are: 56%60% of the quartz sand, 8%11% of the lime, 20%30% of the cement, 2%4% of the gypsum, 0.24%0.26% of the aluminum powder, and 0.02%0.03% of the foam stabilizer. The fire-proof thermal-insulation board is made of an inorganic non-metallic material with lightweight, non-inflammable property and good thermal-insulation performance. The present disclosure well solves the thermal bridge problem of external wall of the building, and has A1-level fire-proof performance and good durability with the same service life as the building. The present disclosure overcomes low product strength, and inconvenience in transportation and construction in the prior art, reduces types of admixture used in the manufacturing process, and reduces the manufacturing cost.

An aerated composite material produced from carbonatable calcium silicate compositions (carbonation cured AAC) that has a compressive strength equivalent to autoclaved aerated concrete (ordinary AAC) at substantially the same density and a process of production of the same are provided. The composite material of the present invention comprises: a plurality of bonding elements, each including a core comprising calcium silicate, a first layer which partially or fully surrounds the core and is rich in SiO.sub.2, and a second layer which partially or fully surrounds the first layer and is rich in CaCO.sub.3; a plurality of filler particles having their particle sizes ranging from 0.1 m to 1000 m; and a plurality of voids; wherein the plurality of bonding elements and plurality of filler particles together form a bonding matrix and are substantially evenly dispersed in the matrix and bonded together, the plurality of voids are bubble-shaped and/or interconnected channels, a pore volume with a radius of 0.004 m to 10.0 m in the plurality of voids is 0.30 ml/composite material 1 g or less, and a estimated compressive strength expressed by the following formula (1): estimated compressive strength (absolute dry density=0.50)=compressive strength(0.50+absolute dry density).sup.2 is 2.0 N/mm.sup.2 or greater.

An aerated composite material produced from carbonatable calcium silicate compositions (carbonation cured AAC) that has a compressive strength equivalent to autoclaved aerated concrete (ordinary AAC) at substantially the same density and a process of production of the same are provided. The composite material of the present invention comprises: a plurality of bonding elements, each including a core comprising calcium silicate, a first layer which partially or fully surrounds the core and is rich in SiO.sub.2, and a second layer which partially or fully surrounds the first layer and is rich in CaCO.sub.3; a plurality of filler particles having their particle sizes ranging from 0.1 m to 1000 m; and a plurality of voids; wherein the plurality of bonding elements and plurality of filler particles together form a bonding matrix and are substantially evenly dispersed in the matrix and bonded together, the plurality of voids are bubble-shaped and/or interconnected channels, a pore volume with a radius of 0.004 m to 10.0 m in the plurality of voids is 0.30 ml/composite material 1 g or less, and a estimated compressive strength expressed by the following formula (1): estimated compressive strength (absolute dry density=0.50)=compressive strength(0.50+absolute dry density).sup.2 is 2.0 N/mm.sup.2 or greater.

Behavior of a flow of foam ejected to a gypsum slurry can be stabilized, and a relatively large amount of foam can be homogeneously or uniformly dispersed in the slurry. A mixer has a mixing area for preparing gypsum slurry, a slurry delivery section for delivering the slurry from the mixing area, and a feeding port for feeding foam to the slurry in the mixing area and/or the slurry delivery section under pressure. The slurry having the foam mixed therein is supplied to a production line for forming gypsum boards or gypsum-based boards. The feeding port is provided with a partition member dividing an ejecting region. The ejecting region is divided into a plurality of openings, which simultaneously eject the foam to the slurry.

Behavior of a flow of foam ejected to a gypsum slurry can be stabilized, and a relatively large amount of foam can be homogeneously or uniformly dispersed in the slurry. A mixer has a mixing area for preparing gypsum slurry, a slurry delivery section for delivering the slurry from the mixing area, and a feeding port for feeding foam to the slurry in the mixing area and/or the slurry delivery section under pressure. The slurry having the foam mixed therein is supplied to a production line for forming gypsum boards or gypsum-based boards. The feeding port is provided with a partition member dividing an ejecting region. The ejecting region is divided into a plurality of openings, which simultaneously eject the foam to the slurry.

Provided is a gypsum-based board producing apparatus including: a mixer configured to prepare a gypsum slurry; a foaming apparatus; and a pump configured to convey foam generated by the foaming apparatus to the mixer, wherein the pump is a positive displacement pump.

Provided is a gypsum-based board producing apparatus including: a mixer configured to prepare a gypsum slurry; a foaming apparatus; and a pump configured to convey foam generated by the foaming apparatus to the mixer, wherein the pump is a positive displacement pump.