GUJARAT TECHNOLOGICAL UNIVERSITY Diploma in Ceramic Technology Semester: 3

Transcription

1 GUJARAT TECHNOLOGICAL UNIVERSITY Diploma in Ceramic Technology Semester: 3 Subject Code Subject Name ADVANCED CHEMISTRY Sr. No. Course content 1. STATE OF MATTER : 1.1 Introduction. 1.2 Details of different state of matter such as solid state, liquid state and gaseous state. 1.3 Characteristics of different state of matter. 1.4 Crystal structures of silicate and clays. 2. COLLOIDS : 2.1 Introduction. 2.2 Know the crystalloids and the colloids, Classification of colloids 2.3 Comparison of the size of crystalloids and colloids. 2.4 Study dispersion media and dispersed phase. 2.5 Detail cause of stability of colloids. 2.6 Study of property of colloids such as optical property, kinetic property, coagulation of colloids, colour, heterogeneous nature, electro migration. 2.7 Details of preparing method of colloids by condensation method and by precipitation method. 2.8 Method of stabilization of colloids and need of electrolyte addition. 2.9 Details use of colloids in different fields, such as water treatment, sewage treatment Environmental engineering and in ceramic industries. 3. ABSORPTION AND ADSORPTION : 3.1 Introduction about physical and chemical adsorption, Difference between adsorption and absorption. 3.2 Details of adsorption isotherm and application of isotherm. 3.3 Study the application of adsorption and absorption in various fields such as scientific application, chemical reduction and during manufacture process of ceramic product. 4. PHASE RULE : 4.1 Introduction 4.2 Details of Gibb's phase rule, know the components, degree of freedom and desire phase rule. 4.3 Details understanding about phase rule, for any systems, the limitations of phase rule and calculation of degree of freedom for liquid water and vapors and especially of silicate systems. 4.4 Details of application of phase rule for one component system namely water system. Understanding of phase diagram for one component water system, nature of graph, triple point and area covered by phase & diagram. 4.5 Application of phase rule in different field of ceramic industries and method Diploma CERAMIC of study Sem-3 of phase rule diagram for two and three components systems. 1 of 12

2 5. CATALYST. 5.1 Introduction. 5.2 Different types of catalysts. 5.3 Discussion of criteria of catalyst on chemical reaction, mechanism of catalyst, adsorption theory and formation of activated complex. 6. CHEMICAL BONDING. 6.1 Details of different types of bond and Theory of valiancy. 6.2 Electronic configuration of atom like, SPdf, entry of electron. 6.3 Filling up of SPdf cells and stability of atom. 6.4 Discuss about inner gas configuration, exchange of valiancy, formation of ionic and electrovalent bond and ionization. 6.5 Discuss of conditions required for formation of ionic bond, mechanism of ionic bond, formation and characteristics of ionic compound. 6.6 Details regarding covalent bond, mechanism of formation of covalent bond, formation of co-ordinate covalent bond and the mechanism of formation of co-ordinate covalent bond. 6.7 Details of formulation of hydrogen bond and metallic bond. 6.8 Details about intermolecular and hydrogen bonding. 7. CHEMICAL ANALYSIS OF CERAMIC MATERIALS. 7.1 Introduction. 7.2 Details of preparing representative sample of minerals, soils and cements. Scope of variation in quality of different sources of samples and average quality required for batch preparation. 7.3 Details of apparatus required for chemical analysis of ceramic materials and products. 7.4 Methods of preparing solutions for examination such as water solution, acid solution and insoluble solutions. 7.5 Details about the different types of soluble such as water soluble, acid soluble and insoluble. Method of calculating the amount of water soluble, water soluble radicals, knowing the method of filtration, determination of total dissolve solid by different methods such as gravimetric method and conductivity method. LABORATORY EXPERIMENTS: 1. Study of ceramic chemistry s lab. 2. Adjustment of Analytical balance. 3. Preparation of stock solution. 4. Preparation of standard solution. 5. Preparation of representative samples. 6. Preparation of Acid solutions. 7. Understand and measure ph value. 8. Chemical analysis of Clay, Quartz, potash feldspar, soda feldspar, Soil, Cement, Lime, & Refractory. 9. Preparation of various batches for ceramic manufacturing stoneware body, Porcelain body, sanitary ware, Diploma CERAMIC Sem-3 LT and HT insulator. 2 of 12

3 Reference Books: 1. Physical chemistry by S.M. Glass stone 2. Physical chemistry by Khosala 3. Engineering chemistry by Jain & Jain 4. Elements of ceramic by F.H.Norton 5. Glass technology by R.Charan 6. Technical methods of analysis by R.C.Grifting Diploma CERAMIC Sem of 12

4 GUJARAT TECHNOLOGICAL UNIVERSITY Diploma in Ceramic Technology Semester: 3 Subject Code Subject Name POTTERY I Sr. No. Course content 1. HISTORICAL DEVELOPMENT OF POTTERY INDUSTRY IN INDIA : 1.1 Historical development of pottery industry in India. 1.2 Present status of white were industry in India. 2. CLASSIFICATION OF WHITE WARES : 2.1 Brief details of tiles, crockery, sanitary wares art wares, pressed electrical porcelain and chemical porcelain 2.2 Classification of pottery products 3. RAW MATERIALS : 3.1 Clays :- China clay, ball clay and fire clay 3.2 Stony materials :- feldspar, quartz, sandstone, limestone 3.3 Other materials :- Naphthalene crenate, talc, wollastonite, magnetite, opacifiers, calcium carbonate, barium carbonate, borax, lead oxide and other coloring oxide. 4. BATCH FORMULATIONS AND CALCULATION : 4.1 Details regarding batch formulations different types of narrating batch composition of ceramic bodies and glazes. 4.2 Brief details regarding nuclear formula of various ceramic raw materials, oxide supplied to the ceramic bodies, glazes and colors. 4.3 Methods of various calculations of ceramic bodies and glazes i.e. batch recipe, chemical composition and molecular formula and vise-versa. 5. PROCESSING OF RAW MATERIALS : 5.1 Introduction. 5.2 Methods of grinding and crushing of raw materials. 5.3 Use of various machines such as raw crusher, roller crusher, edge runners, disintegrators, pulverizes. Study in details of their construction, functions. 5.4 Ball mill grinding and its theory, slip making, detail study of blungers, agitators, magnetic separators, vibrating sieves, diaphragm pumps, filter press and pug mills of both types ordinary and de-airing. 6. BODY MAKING : 6.1 Slip house, use of equipments such as filter press, pump, pug mill etc. brief description with regards to their function. Diploma CERAMIC Sem of 12

5 7. FORMING : 7.1 Forming methods, Throwing, jiggering, extrusion, casting, detailed working of forming machine such as potter's wheel, jigger and jolley's of various types, extrusion machines and process. Casting process with the use of plaster of Paris. 8. FINISHING & DRYING : 8.1 Methods of finishing the wares, trimming process, Sponging process. 8.2 Turning of green articles. 8.3 Method of drying of green articles. 8.4 Use of natural dryer and artificial dryer for drying various types ceramic articles. 8.5 Factors considerations during drying process. 9. GLAZES : 9.1 Preparation of glaze and Use of various materials for glaze making. 9.2 Glaze calculation and formulations glaze preparation. 9.3 Method of screening and storing of glaze. 9.4 Control of glaze properties. 9.5 Method of glaze application. 10. FIRING : 10.1 Stages of firing and Precautions during firing process Types of kilns & furnaces Uses of waste heat Pollution control Industrial visit to the ceramic industries. 11. SORTING OF VARIOUS DEFECTS : 11.1 Detection of various defects Reasons and remedies of defects Method of packing of finished. LABORATORY EXPERIMENTS: 1. Preparation of plaster of Paris moulds for cup & saucers. 2. To study of various methods of forming ceramic wares. 3. Preparation of earthenware body and shaping of articles by casting method. 4. Preparation of stoneware body and shaping of articles by casting process. 5. Preparation of porcelain ware body and shaping of articles by casting process. 6. Preparation of earthenware glaze. 7. Preparation of stoneware glaze. 8. Preparation of porcelain ware glaze. * Industrial visit of pottery industry. Diploma CERAMIC Sem of 12

6 Reference Books: 1. A hand book of modern pottery manufacture. H.N.Bose 2. Element of ceramics F.H.Norton 3. Ceramic glazes Kenneth shaw 4. Ceramic whitewares Sudhir sen 5. Ceramic whitewares Rexford new cemix 6. Ceramic calculation A.I.Audrews. 7. Fine ceramics F.H.Norton Diploma CERAMIC Sem of 12

7 GUJARAT TECHNOLOGICAL UNIVERSITY Diploma in Ceramic Technology Semester: 3 Subject Code Subject Name REFRACTORY-I Sr. No. Course content 1. INTRODUCTION : 1.1 Brief history and scope of refractory industries in India. 1.2 Present status of refractory industries in India. 2. REFRACTORY RAW MATERIALS : 2.1 Types of refractory raw materials. 2.2 Detail study of clayey refractory raw materials, such as fire clay, china clay etc. 2.3 Study of properties and uses of silica, illuminate, and a Lucite, cyanide, mullet and bauxite. 2.4 Study of physical properties of magnetite, dolomite, for striate, chromites, graphite etc. 3. PROPERTIES AND OCCURRENCES OF REFRACTORY RAW MATERIALS : 3.1 Details of physical properties chemical composition, molecular formula of the refractory materials with their occurrences in Gujarat and Saurastra regions. 3.2 Study regarding grog and its use in refractory making. 3.3 Manufacturing methods of grog. 3.4 Grading of grog and their use in refractory making 4. CLASSIFICATION OF REFRACTORIES : 4.1 Introduction. 4.2 Study regarding natural and synthetic refractory. 4.3 Classification of refractory like acid, basic and neutral refractory on the basis of chemical and mineralogical characteristics of raw materials. 4.4 A preliminary idea of synthetic or super refractory such as silicon carbide, fused alumina, fused magnetite, mullets, magnesia alumina, spinal etc. 5. PROCESSING OF RAW MATERIALS : 5.1 Methods of crushing and grinding of refractory materials. 5.2 Brief details of machines used for crushing and grinding of refractory materials such as disintegrator, edge runner, pan roller, ordinary pug mill, de-airing pug mill elevators. etc. 5.3 Methods of mixing, aging and preparation of batch composition. 6. SHAPING METHODS OF REFRACTORIES : 6.1 Various methods of shaping of refractory. 6.2 Formulation of body mixture for making of different types of refractory. 6.3 Shaping process of bricks, saggers and crucibles such as hand molding, pressing, extrusion and casting. 6.4 Properties control of refractory during shaping. Diploma CERAMIC Sem of 12

8 7. DRYING : 7.1 General principles of drying. 7.2 Methods of drying refractory products. 7.3 Use of various types of dryers to dry the refractory products. 8. FIRING : 8.1 General principles of firing of refractory. 8.2 Stages of firing of refractory products. 8.3 Brief details regarding kilns used for firing refractory bricks. 8.4 Methods of loading of refractory bricks for firing. 8.5 Effects of heat on silica and fire clay. 9. PROPERTIES AND TESTS OF REFRACTORIES : 9.1 Study regarding physical properties of different types of refractory bricks. 9.2 Study in detail about other properties like porosity, permeability, specific gravity, bulk density etc. 9.3 Study in details about the size and tolerances. 9.4 Visit of refractory industries to obtain detail ideas regarding manufacturing of refractory. LABORATORY EXPERIMENTS: 1. To Prepare fire bricks & cut in to various shapes. 2. To Prepare I.S. 6 bricks containing 32% of alumina. 3. To Prepare I.S. 7 bricks with 28% Al2O3 content. 4. To Prepare I.S. 8 bricks containing 42% Al2O3. 5. To determine the moisture content of a given sample of refractory. 6. To determine porosity of given sample of refractory. 7. To determine the bulk density of given refractory brick. 8. To determine water absorption of a given refractory sample. 9. Project report of industrial visit of refractory industries. Reference Books: 1. Refractory M.L.Mishra 2. Refractory Rashid chesti 3. Refractory F.H.Norton 4. Refracty Materials A.B.Searle Diploma CERAMIC Sem of 12

9 GUJARAT TECHNOLOGICAL UNIVERSITY Diploma in Ceramic Technology Semester: 3 Subject Code Subject Name GLASS I Sr. No. Course content 1. INTRODUCTION : 1.1 Definition of glasses 1.2 General properties and uses of glass 1.3 Chemical composition of glass 1.4 Description in brief about different types of glass 2. RAW MATERIALS : 2.1 Details regarding various materials used in glass making 2.2 Classification of raw materials with their functions in glass making 2.3 Essential glass forming substances 2.4 Fluxes 2.5 Oxidizing agents 2.6 Reducing agents 2.7 Finishing agents 2.8 Coloring agents and cullets 2.9 Occurrences of various glass making raw materials in India 2.10 Properties of glass sands and other raw materials used in glass making 2.11 Grading and washing of sands used in glass making 3. BATCH MIXING AND CALCULATIONS : 3.1 Methods of batch preparation 3.2 Methods of batch mixing 3.3 Description of machines used for batch preparation and mixing 3.4 Processing of raw materials before batch making 3.5 Theory of glass making 3.6 Process of handling and mixing of raw materials 3.7 Methods of batch calculation detailed description of calculating batch recipe, chemical composition and molecular formula of glass 4. GLASS MELTING : 4.1 Introduction 4.2 Various types of furnaces used for glass melting 4.3 Construction and function of pot furnace 4.4 Construction and function of Tank furnace 4.5 Construction and function regenerative and recuperative type furnaces 4.6 Description regarding various parts of glass melting furnaces. 4.7 Details description regarding melting process of glass batches 5. MANUFACTURING OF GLASS ARTICLES : 5.1 Introduction 5.2 Description regarding manufacturing process of hollow wares by mouth blowing 5.3 Manufacturing of hollow ware articles by semi-automatic and automatic machines Diploma CERAMIC Sem of 12

10 5.4 Manufacturing process of articles by pressing process 5.5 Manual and automatic machines pressing process 5.6 Manufacturing process of flat glass by manual pressing process & automachine process 5.7 Manufacturing process of sheet glass 6. GLASS COMPOSITION AND DEVITRIFICATION : 6.1 Detail of melting phenomenon of glass 6.2 The composition of molten glass 6.3 Method of solidification of molten glass 6.4 Devitrification in glass 6.5 Danger period in glass melting 6.6 Working temperature and working zone of glass 7. VISCOSITY OF GLASS AND ANNEALING : 7.1 Introduction 7.2 Importance of Viscosity in glass manufacturing 7.3 Effect of heat on glass viscosity 7.4 Reasons of annealing of glass 7.5 Methods of annealing of glass 7.6 Precaution required during annealing of glass 7.7 Relation between annealing and viscosity of glass LABORATORY EXPERIMENTS: 1. Dry sieve analysis of sand 2. Wet sieve analysis of sand 3. Preparation of soda-lime glass batch recipe 4. Preparation of opal glass batch recipe 5. Preparation of glass batch of blue colour glass 6. Preparation of glass batch of green colour glass 7. Preparation of glass batch transparent glass 8. Preparation of glass batch of black colour glass 9. Industrial visit of glass industries Reference Books: 1. A hand book of glass Manufacture R.Charan 2. Modern glass practice S.R.Scholes 3. A hand book of glass engineering E.B.Shand 4. Elements of ceramics F.H.Norton 5. Glass manufacture Vol. I & Vol. II F.V.Tooley 6. History of glass making W.Douglass Diploma CERAMIC Sem of 12

11 GUJARAT TECHNOLOGICAL UNIVERSITY Diploma in Ceramic Technology Semester: 3 Subject Code Subject Name DRYING AND FIRING Sr. No. Course content 1. THEORY OF DRYING : 1.1 Introduction. 1.2 Study of factors governing drying. 1.3 Details of various stages of drying. 1.4 Information regarding drying system. 1.5 Drying shrinkage. 1.6 Drying efficiency. 1.7 Rate of drying. 1.8 Process of drying such as evaporation, aeration, heating ventilations and absorption. 2. CLASSIFICATION OF DRYERS : 2.1 Introduction. 2.2 Intermittent dryers. 2.3 Semi continuous dryers. 2.4 Construction and functions of tunnel dryers. 2.5 Construction and functions of mangle dryers, rotary dryers and spray dryers. 2.6 Detail study regarding infrared drying and high frequency drying. 2.7 Detail study various defects arising during drying and their rectification. 3. EFFECT OF HEAT ON CERAMIC WARES : 3.1 Effect of heat on physical properties of ceramic wares drying. 3.2 Effect heat on properties of ceramics ware during drying. 3.3 Effect of heat on properties of ceramic bodies. 3.4 Effect of heat on properties of ceramic glazes during firing. 4. GENERAL REMARKS ON FIRING : 4.1 General remarks on modification in the constitution of bodies. 4.2 Details study regarding part played by different materials used for constitution of bodies with regards to their fusibility. 4.3 Modification remarks in the volume and density. 4.4 General remarks in modification in coloring. 4.5 General remarks in size control due to variation in shrinkage. 5. STAGES OF FIRING : 5.1 Detail study regarding various stages of firing. 5.2 Detail study regarding thermo-chemical reactions in bodies and glaze during firing. 5.3 Defectors occurs in bodies and glazes after firing. Diploma CERAMIC Sem of 12

12 6. KILNS & FURNACES : 6.1 Introduction. 6.2 General remarks on kilns. 6.3 Study regarding various aspects of kilns, such as fire places, draughts, chimney, ducts, flues, dome and holes. 6.4 Kilns their classification detailed description of various kilns, modern operation of various types of kiln such as up draught kiln, down draught kiln, continuous kiln, intermit tent kiln, and chamber kilns with their construction and functions. 7. SETTING OF CERAMIC WARES : 7.1 Introduction. 7.2 Various methods of setting of wares. 7.3 Setting of crockery s wares. 7.4 Setting of refractory wares. 7.5 Precautions required during setting of wares. 7.6 Detail study of setters and saggers used in biscuit & glost firing of commercial wares. 7.7 Study regarding loading and unloading of wares. 8. BURNERS : 8.1 Know the fuel efficient burners used in ceramic industries. 8.2 Selection of burners and their operation. 8.3 Method of controlling temperature by adjustment of burners. 8.4 Handling of fuels. Reference Books: 1. A hand book of modern pottery manufacture H.N.Bose 2. Ceramic white wares Rexford, New Cambe 3. Industrial ceramics Singer & Singer 4. Treatise on clay 5. Elements of ceramics F.H.Norton 6. Refractory F.H.Norton Diploma CERAMIC Sem of 12