The present disclosure relates to the manufacture of ceramic products by aqueous gelcasting. Exemplary ceramic products include sanitary ware, such as toilets and sinks. The process includes a slurrying step, a mixing step, a molding step involving aqueous gelcasting, a drying step, a glazing step, and a firing step.

The present invention relates to fabricating lightweight ceramic sand as a building and construction material. More specifically it relates to a novel process of manufacturing sintered synthetic lightweight ceramic sand particulates directly from pond ash and fly ash as a secondary raw material. The said synthetic lightweight ceramic sand can be used as a building material. The novel feature of the invention is to manufacture low cost lightweight sand at high throughput to compete against the fast depleting natural sand and crushed stones.

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.

The present disclosure relates to the manufacture of ceramic products by aqueous gelcasting. Exemplary ceramic products include sanitary ware, such as toilets and sinks. The process includes a slurrying step, a mixing step, a molding step involving aqueous gelcasting, a drying step, a glazing step, and a firing step.

Material, use thereof and method to manufacture said material; wherein the material is porous and has: a total porosity ranging from 50% to 80%, in particular from 60% to 70%; interconnected pores; at least a part made of a hydrophilic material, in particular at least a part of the inner surfaces of the pores is made of a hydrophilic material; a permeability coefficient greater than 10.sup.6 m/sec; and wherein, in a given volume of the material, the total volume of pores with a diameter ranging from 0.1 m to approximately 0.3 nm is at least greater than 15% of the total volume of the pores, preferably it ranges from 15 to 36%.

Material, use thereof and method to manufacture said material; wherein the material is porous and has: a total porosity ranging from 50% to 80%, in particular from 60% to 70%; interconnected pores; at least a part made of a hydrophilic material, in particular at least a part of the inner surfaces of the pores is made of a hydrophilic material; a permeability coefficient greater than 10.sup.6 m/sec; and wherein, in a given volume of the material, the total volume of pores with a diameter ranging from 0.1 m to approximately 0.3 nm is at least greater than 15% of the total volume of the pores, preferably it ranges from 15 to 36%.

A method for producing a honeycomb structure including producing an unfired pillar shaped honeycomb body; placing the unfired pillar shaped honeycomb body on a receiving table such that the unfired pillar shaped honeycomb body stands thereon; conveying the unfired pillar shaped honeycomb body placed on the receiving table; drying the unfired pillar shaped honeycomb body after the conveying step, or drying the unfired pillar shaped honeycomb body during the conveying to obtain a honeycomb dried body; and firing the honeycomb dried body to obtain a honeycomb structure. The receiving table includes at least one protrusion. In the honeycomb formed body conveying step, the unfired pillar shaped honeycomb body is conveyed while supporting it by inserting the at least one protrusion of the receiving table into a bottom surface of the unfired pillar shaped honeycomb body placed on the receiving table.

A method for manufacturing a naturally cooling ceramic receptacle comprising preparing a clay body by adding ball clay and/or quartz, water and deflocculant, forming the clay body into a desired shape of the ceramic receptacle with molds by at least one of roller making, pressure casting and slip casting, demolding the formed clay body and drying at a temperature higher than a room temperature, performing a first firing of the clay body in a kiln at a temperature higher than 1050 C. to obtain a biscuit receptacle, mixing a slip casting clay with desired color pigments to produce plastic colored slip casting clay, dipping the biscuit receptacle into the colored slip casting clay and drying, and performing a second firing of the biscuit receptacle with the dried color slip casting clay in a kiln at a temperature higher than 1000 C. but lower than the temperature of the first firing.

A method for manufacturing a naturally cooling ceramic receptacle comprising preparing a clay body by adding ball clay and/or quartz, water and deflocculant, forming the clay body into a desired shape of the ceramic receptacle with molds by at least one of roller making, pressure casting and slip casting, demolding the formed clay body and drying at a temperature higher than a room temperature, performing a first firing of the clay body in a kiln at a temperature higher than 1050 C. to obtain a biscuit receptacle, mixing a slip casting clay with desired color pigments to produce plastic colored slip casting clay, dipping the biscuit receptacle into the colored slip casting clay and drying, and performing a second firing of the biscuit receptacle with the dried color slip casting clay in a kiln at a temperature higher than 1000 C. but lower than the temperature of the first firing.