Ceramic Industry October 2011

October 2011 | Volume 161 | Issue Number 10 www.ceramicindustry.com

NANOFIBER

Development ³ Rare Earths ³ Refractories

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Consistent design & quality assurance Anchor-Loc 3 module design features construction from a continuous fold of spun blanket, stainless steel alloy hardware and center mount attachment. The design allows for consistent furnace layout, ease of installation and dependable service life. All components meet or exceed established industry standards assuring the same high quality worldwide.

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Universal specifications

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Your kiln. Like no other. Your kiln needs are unique, and Harrop’s experienced staff will thoroughly analyze your process and objectives before recommending a final solution. This review often includes precise characterization of your ceramic materials and pilot testing at our in-house facility. After defining the most efficient thermal cycle for your product, Harrop then engineers an energy-efficient, properly sized kiln that is uniquely suited to your operation. Hundreds of customers will tell you that this expert application engineering is what separates Harrop from “cookie cutter” kiln suppliers. Learn more at www.harropusa.com, or call us at 614-231-3621 to discuss your special requirements.

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³ TABLEOFCONTENTS October 2011 | Volume 161 | Issue Number 10

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DEPARTMENTS

FEATURES

Inside CI . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 6

³ Self-Cleaning Anodes Researchers at Georgia Tech have developed nanoparticle technology that could facilitate cost-effective coal-powered fuel cells. . . . . . . . . . . . . . . . . . 14

International Calendar . . . . . . . . . . . . . . . . . 7 Ceramics in the News . . . . . . . . . . . . . . . . . . 8 People in the News . . . . . . . . . . . . . . . . . . . 11 IP in Depth . . . . . . . . . . . . . . . . . . . . . . . . . . 12 Ceramic Decorating. . . . . . . . . . . . . . . . . . . 24

³ Developing Ceramic Nanofibers Ceramic nanofibers can offer a number of technical advantages in a variety of applications . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 17 ³ Big Innovations from Small Science Problems long thought to be unsolvable begin to unravel with nanotechnology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 20

What’s New . . . . . . . . . . . . . . . . . . . . . . . 36 Buyers’ Connection . . . . . . . . . . . . . . . . . 36 Services Marketplace . . . . . . . . . . . . . . . 37 Classified Advertisements . . . . . . . . . . . 45

³ “Rare” Growth Opportunities Suppliers of rare earth materials are poised to expand resources in the U.S., Canada, Australia and many other countries . . . . . . . . . . . . . . . . . . . . 25

SPECIAL REPORT | REFRACTORIES

Advertiser Index . . . . . . . . . . . . . . . . . . . . 46 ³Assessing Monolithic Refractories Aluminum producers have developed a practical set of laboratory tests for furnace linings . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 29

ON THE COVER: Image taken with Agilent Technologies FESEM.

LIKE US ON FOLLOW US ON JOIN US ON

SPECIAL REPORT | RESOURCE MANAGEMENT ³Branding Your Workplace A strong workplace brand increases employee loyalty . . . . . . . 34

GET CONNECTED! Visit www.ceramicindustry.com/connect to join the CI community!

CERAMIC INDUSTRY (ISSN 0009-0220) is published 12 times annually, monthly, by BNP Media, 2401 W. Big Beaver Rd., Suite 700, Troy, MI 48084-3333. Telephone: (248) 362-3700, Fax: (248) 362-0317. No charge for subscriptions to qualified individuals. Annual rate for subscriptions to nonqualified individuals in the U.S.A.: $178.00 USD. Annual rate for subscriptions to nonqualified individuals in Canada: $216.00 USD (includes GST & postage); all other countries: $228.00 (Int’l mail) payable in U.S. funds. Printed in the U.S.A. Copyright 2011, by BNP Media. All rights reserved. The contents of this publication may not be reproduced in whole or in part without the consent of the publisher. The publisher is not responsible for product claims and representations. Periodicals Postage Paid at Troy, MI and at additional mailing offices. POSTMASTER: Send address changes to: CERAMIC INDUSTRY, P.O. Box 2145, Skokie, IL 60076. Canada Post: Publications Mail Agreement #40612608. GST account: 131263923. Send returns (Canada) to Pitney Bowes, P.O. Box 25542, London, ON, N6C 6B2. Change of address: Send old address label along with new address to CERAMIC INDUSTRY, P.O. Box 2145, Skokie, IL 60076. For single copies or back issues: contact Ann Kalb at (248) 244-6499 or [email protected].

CERAMIC INDUSTRY ³ October 2011

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³ INSIDECI by Susan Sutton | Editor-in-Chief, Integrated Media

®

www.ceramicindustry.com 6075 B Glick Road • Powell, OH 43065 281-550-5855 (p)

EDITORIAL / PRODUCTION STAFF

Fall Potpourri A lot of people I know don’t like autumn. They think this time of year is depressing because the leaves are dying and winter is on its way. I tend to take the opposite view; autumn is actually one of my favorite seasons. Mums of all shapes and sizes are blooming, the leaves are turning the most amazingly vibrant colors, and everyone’s digging out their cold-weather clothes. It seems like every day brings something new and interesting. The words “new” and “interesting” are certainly applicable to the myriad advances being made in our industry. For example, researchers at the Georgia Institute of Technology have developed technology that could enable solid oxide fuel cells to be powered by coal gas. “The technique could provide a cleaner and more efficient alternative to conventional power plants for generating electricity from the nation’s vast coal reserves,” writes Georgia Tech’s John Toon. Read about the team’s “Self-Cleaning Anodes” on pp. 14-16. As the use of ceramic materials continues to increase across multiple industries, the methods used to produce those materials have likewise continually evolved. Uniform ceramic nanofibers with diameters of 75-125 nm can now be created through an electrospinning process. According to John M. Finley II, chairman and CEO of MemPro Ceramics Corp., “The process begins with polymer chemistry, which is used to form ultrafine fibers that are treated and converted into ceramics.” Learn about “Developing Ceramic Nanofibers” on pp. 17-19. Rare earths are used in a number of applications ranging from dental ceramics and medical glassware to ceramic capacitors. Suppliers in areas such as the U.S., Canada and Australia are working to expand their resources to alleviate the problems caused by China’s reduced rare earth exports. Gradient’s David Mayfield discusses “‘Rare’ Growth Opportunities” on pp. 25-28. Be sure to take a look at the full Table of Contents on p. 5, or scan the mobile tag on the cover for direct access to all of our content online.

Amy Vallance, Publisher 281-550-5855 (p) • 248-283-6543 (f) • [email protected] Susan Sutton, Editor-in-Chief, Integrated Media 330-336-4098 (p) • 248-502-2033 (f) • [email protected] Teresa McPherson, Managing Editor 734-332-0541 (p) • 248-502-2102 (f) • [email protected] Kelsey Seidler, Associate Editor 614-789-1881 (p) • 248-502-2051 (f) • [email protected] Cory Emery, Art Director 248-391-2325 (p) • 248-502-2077 (f) • [email protected] Bryon T. Palmer, Production Manager 248-244-6435 (p) • 248-502-9113 (f) • [email protected] Ralph Ruark, Senior Technical Editor Charles Semler; Sandra Spence; Joe Cattaneo; George Muha, Contributing Editors

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EDITORIAL ADVISORY BOARD

INSIDE LOOK Take an Inside Look at upcoming industry events. This month, we feature the Fuel Cell Seminar & Exposition and Solar Power International.

E-NEWSLETTERS Sign up for free subscriptions to CI CyberNews, our weekly e-newsletter, and Advanced Ceramics & Glasses Digest, our quarterly e-newsletter dedicated to the advanced arena. Past issues are also archived for quick access.

DIGITAL EDITION CI’s digital editions are easy to read, search and download. This month’s digital edition is sponsored by Deltech Inc.

Surinder Maheshwary, Director, Quality Assurance/Process Improvement, Dal-Tile International; William Babik, Technical Sales Manager, Nabertherm Inc.; Charles Semler, Ph.D., Refractories Consultant, Semler Materials Services; Gary Childress, General Manager, Orton Ceramic Foundation; Matthew Centa, Technical Support Manager - Ceramics & Glass, Rio Tinto Minerals; James E. Houseman, Ph.D., President, Harrop Industries, Inc.

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October 2011 ³ WWW.CERAMICINDUSTRY.COM



³INTERNATIONALCALENDAR OCT 11-13 POWTECH 2011 ³ Nuremberg, Germany, www.powtech.de/en

Lower costs and improve your Ceramic Glaze and Body Formulations with

* OCT 16-20 Materials Science & Technology 2011 Conference and Exhibition (MS&T ’11), combined with the ACerS 113th Annual Meeting ³ Columbus, Ohio, www.ceramics.org OCT 18-19 Manufacturing with Composites ³ Fort Worth, Texas, www.sme.org/cgi-bin/get-event.pl?— 002084-000007-home—SMEOCT 20-22 17th Annual Manufacturing in Mexico Summit ³ San Carlos, Sonora, Mexico, www.manufacturinginmexicosummit.com OCT 25-27 The Battery Show ³ Novi, Mich., www.iccnexergy.com * OCT 30-11/2 13th Unified International Technical Conference on Refractories (UNITECR) ³ Kyoto, Japan, [email protected] OCT 31-11/4 2011 Fuel Cell Seminar & Exposition ³ Orlando, Fla., www.fuelcellmarkets.com NOV 9-10 The Composites Engineering Show ³ Birmingham, UK, www.compositesexhibition.com NOV 9-10 Mobile Power Technology Partnering Summit ³ Las Vegas, Nev., www.knowledgefoundation.com/viewevents.php?event_id=267&act=evt NOV 14-17 10th Annual LAV & Stryker Summit ³ Washington, D.C., www.LightArmoredVehiclesSummit.com JAN 23-26 36th Annual Conference on Composites, Materials and Structures ³ Cape Canaveral, Fla., http://advancedceramics.org * FEB 7-10 Cevisama 2012 ³ Valencia, Spain, http://cevisama.feriavalencia.com * FEB 21-23 Composites 2012 ³ Las Vegas, Nev., www.acmanet.org * MARCH 11-15 Pittcon ³ Orlando, Fla., www.pittcon.org * MARCH 26-28 St. Louis Section 47th Annual Symposium ³ St. Louis, Mo., www.ceramics.org MARCH 27-29 Westec ³ Los Angeles, Calif., www.westeconline.com * APRIL 17-20 Coverings ³ Orlando, Fla., www.coverings.com * MAY 8-10 Powder and Bulk Solids ³ Chicago, Ill., www.powderbulksolids.com * Look for Ceramic Industry magazine at these events! For a more detailed listing, visit our website at www.ceramicindustry.com.

In Natural and Frit Glaze Suspensions: • Acti-Gel®208 greatly improves adhesive strength by >80% which helps to reduce surface defects and glaze chipping from handling and shipping. • Acti-Gel®208 eliminates other mineral thickeners and reduces cellulose ethers in glaze formulations. • Acti-Gel®208 should be used without Phosphates Dispersants such as SHMP or STPP which chelate excess ions thereby de-activating Acti-Gel®208. • By using Acti-Gel®208 to reduce Cellulose Ethers and eliminate Phosphate Dispersants, the negative effects of Sodium are greatly

reduced, allowing for increased adhesion strengths and reduced surface defects. • Acti-Gel®208 allows the glaze to dry rapidly without cracking. • Acti-Gel®208 is added directly to the mill for ease of dispersion and for ease of glaze removal from ball mill. • Acti-Gel®208 based glazes are highly stable and can sit, without settling or hardpacking, for >30 days. • Acti-Gel®208 works efficiently in Suspensions from 25% to 80% solids. • Acti-Gel®208 contains no sulphates

In Ceramic Body Formulations: • Acti-Gel®208 is an excellent flow aid, binder and reinforcing agent in extrusion and dry press applications.

Acti-Gel®208 features and benefits: • Lowers Formulation Costs! • Increases adhesion strength! • Dewaters Rapidly! • Allows more efficient use and faster batch addition times. • Excellent Anti-Settling and Anti-Sag properties. • Low yield point of gel structures allows for quick, easy flow under shear conditions.

• Ultra fine particle size gives excellent performance in spray and curtain coating applications. • Reduces extrusion pressures and improves forming and green strength. • Very low free crystalline silica (less than 1%), Grit Free. • Low free Moisture: Typical is 5%-8% FM.

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CERAMIC INDUSTRY ³ October 2011

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³ INTHENEWS Saint-Gobain to Build U.S. Ceramic Proppant Plant Saint-Gobain recently announced the construction of a ceramic proppant plant in Saline County, Ark. Representing a total investment of $100 million, the new facility will be built on a 28-hectare piece of land and will provide 140 jobs. The new plant will manufacture proppants—spherical beads about the size of a grain of sand that are used in the oil and gas industry. Proppants are inserted into underground fractures in oil and gas wells to “prop” open the fracture, increasing conductivity and enhancing well performance. “This investment is part of Saint-Gobain’s strategy to invest in new technologies for energy and the environment,” said John Crowe, Saint-Gobain general delegate in North America. “Growth in global energy demand is creating greater activity among oil and gas drilling companies, whose need for proppants will eventually exceed the production capacity of our Fort Smith (Ark.) facility. Saline County is the perfect location for the new plant because of its proximity to our major U.S. oil and gas customers.” Saint-Gobain reportedly plans to break ground for the new facility by the end of the year, with production expected to start in late 2012. For more information, visit www.saint-gobain.com.

NSG Group to Begin Producing Solar Energy Products in China The NSG Group recently announced it has reached an agreement with its local partner Shanghai Yaohua Pilkington Glass Co. Ltd. (SYP) to start production of the group’s NSG TEC™ solar energy products in China. According to the company, it is making this move in order to meet the rapidly increasing demands of the Chinese thin film solar energy industry. The NSG/SYP joint venture facility in Changshu (JSYP) already uses NSG proprietary online coating technology to manufacture Pilkington Energy Advantage™, which are energy-saving coated products for the Chinese market. This technology will now be upgraded for the manufacture of NSG TEC™ products, with shipments from Changshu expected to begin in January 2012. For more information, visit www.nsg.com.

Sacmi Supplies Machines to Ceramica Arpa Ceramica Arpa of Scandiano, Italy, has launched a plant modernization project and teamed up with Sacmi to ensure the provision of cutting-edge machines and systems. The project comprises two “pillars.” The first is the PH 3590 hightonnage press, which, due to a wide inter-column clearance of 1750 mm, 8

can press large sizes. It has reportedly allowed Arpa to maintain and increase its lead in the still-growing large-size tile sector, now an essential part of the product range for companies focused on the high end of the market. The second pillar of the project is a new system by Surface Inspection, a leader in automatic ceramic tile quality control systems and now a member company of the Sacmi Group via the recent acquisition of Nuova Fima. “The quest for upto-date solutions is essential if one is to remain market competitive,” the company’s manager said. “This is particularly true for large tiles and surfaces intended to provide the chromatic effects of natural stone in as realistic a way as possible.” Visit www.sacmi.com for more information.

Allied Mineral Products Begins Chinese Operations Allied Mineral Products Inc. recently announced the startup of its new Chinese operation, Allied Mineral Products (Foshan) Co. Ltd. (AMF). Located in Foshan, Guangdong province, this new facility will support Allied’s commitment to providing refractory products, service and technology to its customers in China and throughout Asia. Sales and customer service for China will continue to be handled through

October 2011 ³ WWW.CERAMICINDUSTRY.COM

Allied Mineral Products (Tianjin) Co. Ltd. (AMT). Sales and customer service for international customers will be provided through the company’s Asia sales and support team. Both AMT and AMF will produce Allied’s products for Chinese and Asian customers. Visit www.alliedmineral.com for more information.

PPG Tests Payout Applications for Thermoset Reinforcement Materials PPG Industries’ fiber glass business recently announced it is currently customer-testing outside payout applications of its direct draw reinforcement material. An outside-in payout application minimizes the twist of filaments and allows manufacturers to create thinner and denser, yet more lightweight layers of laminate, according to Greg Terchick, PPG sales director for fiber glass reinforcements in the Americas. “Products such as flexible pipe cannot be manufactured with any other type of material payout,” Terchick said. “Offering outside payout for PPG thermoset materials will enable our customers in the pipe and tank industries to create stronger products that achieve higher performance using the same amount of or less glass.” PPG is developing this direct draw packaging application in the U.S. with global launch and availability expected by the fourth quarter of 2011. The company also offers outside payout in thermoplastic material with TUFROV® long fiber thermoplastic (LFT) products. PPG also recently announced it has signed a letter of intent with Harsha Exito Engineering Private Ltd. to establish a 50-50 joint venture for the manufacture and sale of fiber glass reinforcement products. The transaction is subject to the completion of due diligence and the negotiation of definitive documentation. The projected expansion of the Indian economy will reportedly help drive demand for fiber glass in such end-use applications as infrastructure, transportation and wind energy. Additional details are available at www.ppg.com or www.ppgfiberglass.com.

Acme Brick’s Tayler Receives Ebright Award Garth Tayler, technical director at Acme Brick Co., received the Harry E. Ebright Award at the recent South West Section (SWACerS) meeting of the American Ceramic Society (ACerS). The Ebright Award was given in recognition of Tayler’s outstanding services to the South West Section. Tayler was born in the small town of Ogies (Afrikaans for “Little Eyes”) near Johannesburg, South Africa. As the son of a miner, he grew up in a family that moved to a number of different mining locations as his father climbed the management ladder and developed his career. Tayler was inspired early in his life by his father’s dedication, tenacity and determination. He immigrated with his wife to the U.S. to join Acme Brick in 1995. The company sponsored him through the naturalization process while he obtained his permanent residency. He became an American citizen in 2002. During his 16 years with Acme Brick, Tayler has been an active memberparticipant, speaker and promoter of SWACerS. As a recognized authority in his field, he has promoted the valuable and integral role that the SWACerS organization has had in the process of educating and motivating members as they develop their careers in the brick industry. Visit www.brick.com for additional information.

AGC Introduces Thin Glass Substrate for Semiconductors Asahi Glass Co. Ltd. (AGC) announced plans to begin selling a glass substrate used in back-grinding processes to reduce the thickness of a semiconductor chip. The new substrate is reportedly indispensable for producing thin, highperformance semiconductors, leading to slimmer mobile terminals, such as smartphones, with enhanced functionality. With production launched at AGC Electronics Co. Ltd., located in Fukushima Prefecture, Japan, AGC aims to capture a 50% share of a market that

is forecasted to grow to ¥10 billion (~ $130 million) by 2014. While stacking chips ver tically enhances the functionality of semiconductors used in mobile terminals, the thickness of individual chips must be reduced to enable the vertical structure. These thin semiconductor chips are produced by supporting silicon wafers on a glass substrate called a backgrinding substrate (BG substrate) and grinding them to reduce their thickness to about 50 μm. Meanwhile, it is essential to control the warpage of the silicon wafers, which is caused by differences in the coefficient of thermal expansion of the wafer and the BG substrate, and can occur during high-temperature treatment after the grinding process. For more information, visit www.agc.com.

Unifrax Acquires Bondlye Mat Business Unifrax I LLC recently announced that, through its Hong Kong subsidiary, Unifrax Asia-Pacific Holding Ltd., it has acquired the catalytic converter emission control mat business of Zhejiang Bondlye Motor Environmental Technology Co. Ltd. The Bondlye Mat Business produces support mat products used in automotive catalytic converters. It is reportedly the leading supplier of emission control mat products to domestic Chinese automotive manufacturers. The business is located in Linhai, China, in the Zhejiang Province. It employs approximately 25 people, who will be joining the Unifrax China team. Additional details are available at www.unifrax.com.

Owens Corning to Open China Composites Center Owens Corning recently announced it will open its China Composites Center in Shanghai, China, in early 2012. The center’s staff will use state-of-the-art facilities to focus on customer activities, including composite prototyping, materials testing, designing with composites and technical support. The staff will also work to develop new solutions, particularly in applications for renew-

Alfred University Researcher Tests Glasses for Major Particle Physics Experiment S.K. Sundaram, Ph.D., Inamori professor of Materials Science and Engineering in the Inamori School of Engineering at Alfred University, has been chosen to evaluate the glasses that will be used in a “huge particle physics experiment” being undertaken by the Brookhaven (BNL) and Fermi National Accelerator (FNAL) laboratories. Sundaram will evaluate the mechanical properties of glasses that could be critical to the success of the collaborative project being undertaken by the national laboratories. Two vendors have supplied glasses to the Brookhaven National Laboratory in Upton, N.Y., proposing the glasses be used to house neutrino detectors inside a device called a photomultiplier tube for the Long Baseline Neutrino Experiment (LBNE). Neutrinos are subatomic particles that are similar in size to electrons, but that have no charge. They travel over long distances close to the speed of light, and are very difficult to detect because they can pass through solid materials without affecting them. For more information, visit http://engineering.alfred.edu.

able energy, residential and commercial building, and vehicle components. For more information, visit www.owenscorning.com.

MIT Launches New Center for Graphene Devices and Systems The Massachusetts Institute of Technology (MIT) recently announced the creation of the MIT/MTL Center for Graphene Devices and Systems (MIT-CG). This interdepartmental center, part of the Microsystems Technology Laboratories (MTL), brings together MIT researchers and industrial partners to advance the science and engineering of graphene-based technologies. Graphene, a form of pure carbon arranged in a hexagonal lattice just one atom thick, has generated excitement CERAMIC INDUSTRY ³ October 2011

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IN THE NEWS

among researchers worldwide for its unique properties that stand to revolutionize materials science and electronics. Until recently, most studies have focused on the basic physical properties of graphene. Work at the new center will reportedly exceed this research, exploring advanced technologies and

strategies that will lead to graphenebased materials, devices and systems for a variety of applications, including graphene-enabled systems for energy generation, smart fabrics and materials, radio-frequency communications, and sensing. Additional details are available at www-mtl.mit.edu/wpmu/graphene.

ABM Equipment Named Exclusive Representative for Schenck AccuRate S c h e n c k Ac c u r a t e I n c . r e c e n t l y announced the appointment of ABM Equipment Co. Inc. as its exclusive representative in Washington, Oregon and Idaho. ABM will handle sales, application engineering, and after-sale support for Schenck AccuRate’s volumetric and gravimetric feeders, weighfeeders, mass flow meters, vibratory feeders, bulk bag discharging systems, belt scales, container loading systems, and related control packages. For more information, visit www.abmequipment.com or www.accuratefeeders.com.

Brazilian Composites Industry Earnings Drop 1.7% The Brazilian composite materials industry recently reported second quarter earnings of $440 million, a decrease of 1.7% compared to the first three months of the year. The consumption of raw materials fell 1400 tons, totaling 45,500 tons (-2.8%). These figures are part of the latest survey of Maxiquim, a consulting firm hired by the Brazilian Composite Materials Association (ABMACO). The second quarter performance reportedly led Maxiquim to revise its projections for 2011. The company now estimates that revenues will increase 7.9% in the composites sector, totaling $1.740 billion; the previous expectation had been an 8.2% increase. In terms of volume, Maxiquim estimates that Brazil will process 211,000 tons, 3.2% higher than in 2010 but lower than the initial estimate, which was 214,000 tons. Visit www.abmaco.org.br for additional details. 

Have News to Share with the Industry? E-mail news releases to Teresa McPherson at [email protected]

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October 2011 ³ WWW.CERAMICINDUSTRY.COM

³ PEOPLEINTHENEWS Rio Tinto recently announced that Chris Lynch has joined the boards of Rio Tinto plc and Rio Tinto Ltd. as a nonexecutive director. Lynch has reportedly had an extensive career in the mining and metals industry, including seven years at BHP Billiton, where he was CFO and then executive director and group president of Carbon Steel Materials. Prior to this, he spent 20 years with Alcoa Inc. He is currently CEO of Transurban Group and a commissioner of the Australian Football League. Ceradyne Inc. has named Siegfried Müssig, Ph.D., to its Board of Directors and the company’s Technology Committee. “The appointment of Dr. Siegfried Müssig as a member of the Ceradyne Board of Directors and a member of its Technology Committee represents Ceradyne’s continued focus on becoming a global corporation with a concentration on the development of advanced technical ceramic products for use in the exploration and recovery of oil and gas,” said Joel P. Moskowitz, chairman and CEO. Müssig fills the vacancy created from the recent resignation of Bill LaCourse, Ph.D., who stepped down for personal reasons. Stedman Machine recently announced several personnel changes within the company. Fernando Viera has been appointed sales manager for Latin America. He will be responsible for selling crushing equipment and systems throughout the region. Aaron Potter has been promoted to engineering manager for Innovative Processing Solutions. Potter has over 14 years’ experience as a systems and design engineer for Innovative Processing Solutions and Stedman. Dan Egbert has been appointed parts sales associate, responsible for customer support of all crusher parts and spares. Egbert has over 19 years’ experience at Stedman, starting in the Shipping and Receiving department. James Seymour has been named production scheduler assistant. His

n e w re s p o n s i b i l i t i e s w i l l i n c l u d e developing the manufacturing labor schedule, working closely with the par ts depar tment to fill orders in a timely manner, and routing job workflow to maximize material and labor efforts.

Goodfellow recently announced the appointment of Lee Wygant as a materials specialist. Wygant assumes various technical responsibilities both for the company’s customers and suppliers. He will also serve as technical liaison to Goodfellow’s suppliers. 

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CERAMIC INDUSTRY ³ October 2011

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³ IPINDEPTH by Michael Gzybowski | Counsel, Brinks Hofer Gilson & Lione

Patentability Standards

E

arly patented “widgets,” such as cigarette lighters, ball point pens or spring mouse traps, were probably far more challenging to design and develop than they were to patent. Fundamentally, patent protection is easier to obtain for a unique invention that is the first of its kind. Patentability has always required novelty and some amount of non-obviousness.

nation of previously known elements can be considered obvious if there is a suggestion or teaching in the prior art to combine elements shown in the prior art. Therefore, the critical inquiry is whether something in the prior art suggests the desirability— and thus the obvious nature—of the combination of previously known elements. This additional test is commonly referred to as the “teaching-suggestion-motivation” (TSM) test and was formulated to prevent hindsight bias by U.S. patent examiners.

Early Guidelines One of the earliest standards for patentability was the Flash of Genius Test (or Doctrine) in 1941. This test, which was used by the U.S. federal courts for more than a decade, held that the inventive act had to come into the mind of an inventor in a “flash of genius” and not as a result of tinkering. The simplicity of this test was that it could be applied by judges and unsophisticated jurors in any given patent dispute if the technology under consideration was beyond their scientific acumen. The Flash of Genius Test was rejected by the Patent Act of 1952, which held that “patentability shall not be negatived by the manner in which the invention was made.” The new test for obviousness was whether the invention’s subject matter and the prior art were such that the subject matter as a whole would have been obvious to a person with ordinary skill in the art at the time the invention was made. In 1966, the Supreme Court interpreted the Patent Act of 1952 in Graham v. John Deere, 383 U.S. 1 and set forth the manner in which obviousness could be determined. Basic factual inquiries into the scope and content of the prior art, the differences between the prior art and the claims at issue, and the level of skill possessed by a practitioner of the relevant art were deemed appropriate. The U.S. Patent and Trademark Office (USPTO) has since instructed patent examiners to apply these “Graham factors” by: • Determining the scope and content of the prior art; • Ascertaining the differences between the prior art and the claims at issue; • Resolving the level of ordinary skill in the pertinent art; and • Evaluating evidence of secondary considerations. The test for obviousness under Graham v. John Deere was modified by a federal circuit case (Winner Int’l Royalty Corp. v. Wang, 202 F.3d. 1340, 1348, Fed. Cir. 2000) that held the combi-

Updates and Amendments In 2007, the Supreme Court again addressed the test for nonobviousness in KSR International Co. v. Teleflex, Inc. (04-1350). In KSR, the court rejected the TSM test as too rigid. The court endorsed a more expansive and flexible approach under which “a court must ask whether the improvement is more than the predictable use of prior art elements according to their established functions.” On October 10, 2007, in light of KSR, the USPTO issued guidelines for examiners to follow when determining obviousness. In addition to the Graham factors, the guidelines generated seven rationales for determining obviousness of a claimed invention in light of the prior art, although other rationales may be used: • Combining prior art elements according to known methods to yield predictable results • Simple substitution of one known element for another to obtain predictable results • Use of a known technique to improve similar devices (methods or products) in the same way • Applying a known technique to a known device (method or product) ready for improvement to yield predictable results • “Obvious to try” (i.e., choosing from a finite number of identified, predictable solutions, with a reasonable expectation of success) • Known work in one field of endeavor prompts variations of it for use in either the same field or a different one based on design incentives or other market forces (if the variations would have been predictable to someone of ordinary skill in the art) • Some teaching, suggestion or motivation in the prior art that would have led one of ordinary skill to modify the prior art reference or to combine prior art teachings to arrive at the claimed invention (no longer the only rationale)

Michael Gzybowski is an intellectual property attorney with Brinks Hofer Gilson & Lione. He has over 25 years of experience, including serving as a patent examiner at the U.S. Patent and Trademark Office prior to entering private practice. He can be reached at [email protected].

Any views or opinions expressed in this column are those of the author and do not represent those of Ceramic Industry, its staff, Editorial Advisory Board or BNP Media.

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On September 1, 2010, the USPTO issued additional guidelines for examiners by providing examples of how obviousness was determined in 22 post-KSR federal circuit decisions. This is the present standard for patentability based on non-obviousness.

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Inventing vs. Patenting Has inventing become more difficult over the years? Some may say that today’s technologies that test and develop a concept into a practical design actually make inventing easier. In addition, numerous resources—including books like How to Invent Stuff by Andrew Auston, Internet websites, inventors’ clubs, youth inventor contests, employee incentives, etc.— promote the creative spirit and proliferation of inventions. Although inventing seems to have become easier, patenting an invention has, in some respects, become more challenging. In some “crowded” technologies, the barrier to patentability is the number of similar prior inventions. The first patented cigarette lighter, ball point pen, spring mouse trap, etc. enjoyed the advantage of a lack of comparable prior art. In these situations, the determination of obviousness could not have been very complicated. In 2010, on the other hand, the number of utility patent applications filed increased to 478,649—but the allowance rate was only 45.6%. When the determination of obviousness involves comparing an applicant’s proposed invention with the prior art and the amount of prior art increases dramatically, it can become challenging to find a basis for distinguishing an applicant’s proposed invention from each prior art reference and any combination of the prior art references an examiner may formulate based on the KSR rationales. In his Patently-O blog, Dennis Crouch recently reported that from 2005-2010, the average number of references cited in issued patents rose from 23 to 39. Crouch also reported that when KSR was cited in obviousness determinations before the Board of Patent Appeals and Interferences, examiners’ obviousness

Now it's easier than ever to stay connected to the BEST source of the latest news and information. Find us on Twitter, LinkedIn and Facebook. rejections were affirmed 67% of the time, as opposed to an affirmation of 47% when KSR was not cited. KSR has clearly changed the manner in which obviousness is treated at the USPTO.

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Future Rationales KSR was almost five years ago. Developing case law since KSR prevents the determination of obviousness from becoming static. Rather, case law development continues to frame and define how obviousness should be determined. In the post-KSR era, patent practitioners can learn how to draft patent applications to avoid or limit exposure to some of the KSR rationales. Moreover, practitioners can glean from successful appellants’ strategies to overcome examiners’ reliance on the KSR rationales. It is important to bear in mind that KSR did not change the concept of patentability; rather, it broadened the basis on which examiners and courts can determine a level of inventiveness that is above some threshold of what anyone can reach. If patentability was not defined by a standard somewhere beyond the capabilities of someone with ordinary skill in a given technology, patents would be meaningless—and anyone could own virtually anything without an inherent right of or entitlement to ownership. 

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³

Self-Cleaning Anodes

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sing barium oxide nanoparticles, researchers have developed a self-cleaning technique that could allow solid oxide fuel cells (SOFCs) to be powered directly by coal gas at operating temperatures as low as 750°C. The technique could provide a cleaner and more efficient alternative to conventional power plants for generating electricity from the nation’s vast coal reserves. SOFCs can operate on a variety of fuels, and use hydrocarbons gases directly—without a separate reformer. The fuel cells rely on anodes made from nickel (Ni) and yttria-stabilized zirconia (YSZ). Until now, however, carboncontaining fuels such as coal gas or propane could quickly deactivate these Ni-YSZ anodes, clogging them with carbon deposits in a process known as “coking”—especially at lower operating temperatures.

➤ Researchers at Georgia Tech have developed nanoparticle technology that could facilitate cost-effective coal-powered fuel cells. by John Toon, Georgia Institute of Technology To counter this researchers T hi problem, bl h have developed a technique for growing barium oxide nanostructures on the anodes. The structures adsorb moisture to initiate a water-based chemical reaction that oxidizes the carbon as it forms, keeping the nickel electrode surfaces clean even when carbon-containing fuels are used at low temperatures. “This could ultimately be the cleanest, most efficient and cost-effective way of converting coal into electricity,” said Meilin Liu, a Regents professor in the School of Materials Science and Engineering at the Georgia Institute of Technology. “And by providing an exhaust stream of pure carbon dioxide, this technique could also facilitate carbon sequestration without the

separation i and d purification ifi i steps now required for conventional coal-burning power plants.”

Carbon-Removal System Uses Water Vapor The water-mediated carbon removal technique was reported earlier this year in the journal Nature Communications. The research was supported by the U.S. Department of Energy’s Office of Basic Energy Sciences, through the HeteroFoaM Center, an Energy Frontier Research Center. The work also involved researchers from Brookhaven National Laboratory, the New Jersey Institute of Technology and Oak Ridge National Laboratory. Conventional coal-fired electric generating facilities capture just a third of

Above: Regents professor Meilin Liu (right) and postdoctoral researcher Mingfei Liu. (Georgia Tech Photo: Gary Meek)

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the energy available in the fuel they burn. Fuel cells can convert significantly more of the energy, approximately 50%. If gas turbines and fuel cells could be combined into hybrid systems, researchers believe they could capture as much as 80% of the energy, reducing the amount of coal needed to produce a given amount of energy and potentially cutting carbon emissions. But that would only be possible if the fuel cells could run for long periods of time on coal gas, which now deactivates conventional Ni-YSZ anodes after as little as 30 minutes of operation. The carbon removal system developed by the Georgia Techled team uses a vapor deposition process to apply barium oxide nanoparticles to the nickel-YSZ electrode. The particles, which range in size from 10 to 100 nanometers, form “islands” on the nickel that do not block the flow of electrons across the electrode surface. When water vapor introduced into the coal gas stream contacts the barium oxide, it is adsorbed and dissociates into protons and hydroxide (OH) ions. The hydroxide ions move to the nickel surface, where they combine with the carbon atoms being deposited there, forming the intermediate COH. The COH then dissociates into carbon monoxide and hydrogen, which are oxidized to power the fuel cell, ultimately producing carbon dioxide and water. About half of the carbon dioxide is then recirculated to gasify the coal to coal gas and continue the process.

“We can continuously operate the fuel cell without the problem of carbon deposition,” said Liu, who is also co-director of Georgia Tech’s Center for Innovative Fuel Cell and Battery Technologies. The researchers also evaluated the use of propane to power SOFCs using the new anode system. Because oxidation of the hydrogen in the propane produces water, no additional water vapor had to be added, and the system operated successfully for a period of time similar to the coal gas system.

Reduced Operating Temperatures Can Lower Cost SOFCs operate most efficiently at temperatures above 850º C, and much less carbon is deposited at higher temperatures. However, those operating temperatures require fabrication from special materials that are expensive and prevent SOFCs from being cost effective for many applications. Reducing the operating temperatures is a research goal, because dropping temperatures to 700 or 750ºC would allow the use of much less expensive components for interconnects and other important components. Until the development of the self-cleaning process, however, reducing the operating temperature meant worsening the coking problem. “Reducing the operating temperature significantly by eliminating the problem of carbon deposition could make these solid oxide fuel cells economically competitive,” Liu said.

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Fuel cells powered by coal gas still produce carbon dioxide, but in a much purer form than the stack gases leaving traditional coal-fired power plants. That would make capturing the carbon dioxide for sequestration less expensive by eliminating large-scale separation and purification steps, Liu said. The researchers have so far tested their process for 100 hours and saw no evidence of carbon buildup. A major challenge ahead is to test the long-term durability of the system for fuel cells that are designed to operate for as long as five years. Researchers must also study the potential impact of possible fuel contaminants on the new electrode. Forming the barium oxide structures can be done as part of conventional anode fabrication processes, and would not require additional steps. The anodes produced in the technique are compatible with standard SOFC systems that are already being developed for commercial electricity generation, home power generation and automotive applications. “We have started with state-of-the-art technology, and simply modified the surface of the electrode,” said Mingfei Liu, a postdoctoral researcher in the Center. “Because our electrode would be built on existing technology, there is a lower barrier for implementing it in conventional fuel cell systems.” In addition to those already mentioned, the research team included Lei Yang, Wentao Qin and Kevin Blinn from Georgia Tech; YongMan Choi and Ping Liu from Brookhaven National Laboratory; Haiyan Chen and Trevor Tyson from the New Jersey Institute of Technology, and Jianming Bai from Oak Ridge National Laboratory.  For additional details, visit www.gatech.edu.

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➤ Ceramic nanofibers can offer a number of technical advantages in a variety of applications.

Developing Ceramic Nanofibers

T

echnical ceramic products are traditionally made in a number of ways, including ncluding slip casting and injection molding. In these processes, tiny ceramic particles are mixed with water and other liquids as a critical step in the process. The ceramic industry ustry has made significant advances in these methods to attain better specifications. However, a very different method has been developed. The process begins with polymer chemistry, which is used to form ultrafine fibers that are treated and converted into ceramics. These ceramic materials feature characteristics that are useful in many industries and applications, including automotive, energy, pharmaceutical, and plastics and polymers. Uniform ceramic fibers feature fiber diameters in the range of 75-125 nm. Studies of the ceramic fibers using scanning electron microscope (SEM) images (such as the one shown in Figure 1) have been inconclusive regarding fiber length due to the narrow range of imagery using this analytical method. However, SEM analysis confirms the narrow range of diameters. Some of the ceramic materials that can be made into fibers are listed in the sidebar on p. 18.

Development Process

Figure 1. Uniform ceramic fibers feature fiber diameters in the range of 75-125 nm.

The University of Akron is globally respected for its polymer science and engineering programs, which have roots in the rubber and tire industry. Around 1990, Darrell Reneker, Ph.D., left a research position with The National Institute of Standards and Technology to join the faculty in the university’s Polymer Science department. Reneker’s interest focused on a 1930s process called electrospinning, which is used to make nano-scale polymeric fibers.

by John M. Finley II, Chairman and CEO, MemPro Ceramics Corp., Broomfield, Colo.

The concept behind electrospinning is that a liquid polymer, when charged positively, can be drawn to a negatively charged collection plate. The process requires very low power (measured in milli-amperes), but very high voltage (in the range of 20-75 kilovolts). Companies in the filtration industry have been makkilovolts) ing nano-scale fibers for decades to improve particle capture. Electrospinning is believed to be the most prevalent method for making nano-scale fibers. In 1989, George Chase, Ph.D., joined The University of Akron’s Chemical Engineering department. In the early 1990s, Chase’s interest in filter media with fine fibers led him to collaborate with Reneker in making polymeric nanofibers. Interests in fibers for high-temperature applications led the two researchers to fabricate ceramic nanofibers made by a polymer fiber template that is calcined to produce a pure ceramic material. Together, the two researchers discovered that electrospinning can be used to make ceramic fibers, beginning with a polymer mixture and finishing with a heat treating process. The results were significant because the ceramic fibers are well into the nano-scale range of diameters (100 nm ± 25 nm). The University of Akron Research Foundation has secured patents on Chase and Reneker’s inventions. Later research by Chase and his students showed that ceramic fibers can be “functionalized” by adding materials to the polymer mixture. An example of this is the inclusion of catalysts, which results in “catalyzed ceramic nanofibers.” Figure 2 (p. 19) illustrates a single ceramic fiber that “holds” tiny catalyst particles in its surface. The black spots on the fiber are palladium particles embedded in the surface of the ceramic fiber. (Validation of the process to make catalyzed fibers was funded by the National Science Foundation.)

Commercialization In 2008, MemPro Ceramics Corp. entered into an exclusive license with The University of Akron Research Foundation to use intelCERAMIC INDUSTRY ³ October 2011

17

CERAMIC NANOFIBERS

Potential Nanofiber Materials

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Aluminum oxide . . . . . . . . . . . . . . . . . . . . . . . . . . (Al2O3) Aluminum borate . . . . . . . . . . . . . . . . . . . (2Al2O3-B2O3) Alumina nitride . . . . . . . . . . . . . . . . . . . . . . . . . . . . (AlN) Aluminum titanate . . . . . . . . . . . . . . . . . . . . . . (Al2TiO5) Aluminum zirconate . . . . . . . . . . . . . . . . . . (Al2O3/ZrO2) Boron carbide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (B4C) Barium titanate . . . . . . . . . . . . . . . . . . . . . . . . . (BaTiO3) Boron trioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . (B2O3) Boron nitride . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(BN) Cerium (IV) oxide . . . . . . . . . . . . . . . . . . . . . . . . . . (CeO2) Ceria zirconia oxide . . . . . . . . . . . . . . . . . . . . (CexZr1-xO2) Cobalt (II,III) oxide. . . . . . . . . . . . . . . . . . . . . . . . (Co3O4) Chromic oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . .(Cr2O3) Indium oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (In2O3) Indium tin oxide. . . . . . . . . . . . . . (In2O3/SnO2 (90/10)) Lithium zirconate. . . . . . . . . . . . . . . . . . . . . . . . (Li2ZrO3) Cordierite . . . . . . . . . . . . . . . . . . . . . . . . . (Mg2Al4Si5O18) Magnesium boride . . . . . . . . . . . . . . . . . . . . . . . .(MgB2) Magnesium silicate . . . . . . . . . . . . . . . . . . . .(Mg3Si4O10) Magnesia oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . (MgO) Magnesium titanate . . . . . . . . . . . . . . . . . . . . . (MgTiO3) Manganese oxide . . . . . . . . . . . . . . . . . (Mn3O4-Mn2O3) Molybdenum disilicide . . . . . . . . . . . . . . . . . . . . (MoSi2) Mullite . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (Al6Si2O13) Nickel oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (NiO) Nickel ferrite . . . . . . . . . . . . . . . . . . . . . . . . . . .(NiFe2O4) Nickel titanate . . . . . . . . . . . . . . . . . . . . . . . . . . . (NiTiO3) Silicon carbide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(SiC) Silicon dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(SiO2) Tin oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .(SnO) Tin (IV) oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (SnO2) Tantalum nitride . . . . . . . . . . . . . . . . . . . . . . . . . . . (TaN) Titanium diboride . . . . . . . . . . . . . . . . . . . . . . . . . . (TiB2) Titanium carbide . . . . . . . . . . . . . . . . . . . . . . . . . . . .(TiC) Titanium carbonitride . . . . . . . . . . . . . . . . . . . . . . (TiCN) Titanium nitride . . . . . . . . . . . . . . . . . . . . . . . . . . . . (TiN) Titanium dioxide . . . . . . . . . . . . . . . . . . . . . . . . . . .(TiO2) Tungsten carbide . . . . . . . . . . . . . . . . . . . . . . . . . . . .(WC) Tungsten trioxide. . . . . . . . . . . . . . . . . . . . . . . . . . .(WO3) Zinc oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (ZnO) Zinc peroxide . . . . . . . . . . . . . . . . . . . . . . . . . . . . . (ZnO2) Zirconium oxide . . . . . . . . . . . . . . . . . . . . . . . . . . . (ZrO2) Zirconium-yttrium oxide . . . . . . . . . . . . . . . (ZrO2/Y2O3)

lectual property developed by Chase, Reneker and others at the university. This license is supported by international patents, as well as unpatented knowhow protecting the fibermaking process. In 2010, MemPro designed and built a pilot production system, called Figure 2. A single ceramic fiber “holds” PreciseFiber™, which tiny catalyst particles in its surface. increased the laboratoryscale production rates 100-fold and allowed MemPro to begin supplying samples to customers. A PreciseFiber production system is in development that will scale up 100-fold from pilot scale and allow the company to eventually make metric ton quantities.

• Small diameter (nano-scale) and long length (macro-scale) keep these materials from being classified as nanoparticles • Fibers can be made in various forms (e.g., polymer with the ceramic precursor in the polymer, crosslinked polymer, ceramic fibers with no polymer content, catalyzed ceramic fibers) • Catalyzed fibers have catalyst particles “embedded” in the surface of fibers In 2006, manufacturers in the automotive and chemical industries were invited to preview potential applications for ceramic nanofibers. Initial discussions focused on filtration, but they quickly moved on to additional possibilities. For example, the large surface area of nanofibers suggests that catalyzed fibers might require much less catalyst metal, such as the platinum, palladium and rhodium used in automotive catalytic converters, as well as other catalysts used in the production of chemicals and pharmaceuticals. Development is ongoing for applications such as automotive exhaust systems, energy production, pharmaceuticals, specialty chemicals and the enhancement of polymers. 

Applications Ceramic nanofibers offer a number of technical advantages, including: • Large surface area, leading to high efficiency

For more information, contact MemPro Ceramics Corp. at 585 Burbank St., Broomfield, CO 80020; call (888) 868-9222; email [email protected]; or visit www.mempro.com.

CERAMIC INDUSTRY ³ October 2011

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by Scott E. Rickert, Co-Founder and CEO, Nanofilm, Valley View, Ohio

Big Innovations from Small Science ➤ Problems long thought to be unsolvable begin to unravel with nanotechnology.

N

anotechnology is changing the rules in ceramics. It’s the key to new and enhanced properties that have application across the spectrum of the industry, from piezoelectrics and whitewares to refractories and fuel cells. Problems long thought to be unsolvable begin to unravel with nanotechnology. Performance that seemed unattainable looms on the horizon. The potential is vast, and the science is delivering results now. In some cases, the news is what nanoscale ceramics can bring to other fields. In other cases, the story is nanotechnology’s impact on the ceramic industry.

chemistry and environmental products, among others. Applications include structural ceramics; advanced coatings; catalysts and catalyst supports; and optical, electrical, and electronic components. One of the advantages that is drawing interest in nanoceramics is the ability to dramatically increase the capacity or effectiveness of materials, whether catalysis, strength or electrical exchange. When materials are taken down to the nanoscale, products can accomplish more with less. Why? Nanoscale materials provide greater surface area for chemical reactions or electrical activity, which increases efficiency. In catalytic converters, nanoscale mate-

Nanoceramics on the Rise A recent industry report by BCC Research captures the big picture on nanoceramics. The 2010 U.S. consumption of advanced and nanoscale powders was estimated at $3.1 billion, growing to $3.4 billion this year and $5.4 billion by 2016. Of that, nanoscale powders account for 17% of current use, growing to 24% by 2016, or around $1.2 billion. That represents about a 40% projected growth. Add to that the fact that more than 80 global companies are profiled in the report for their nanoceramics and advanced ceramics work, and the full scope of the expansion becomes evident. What’s the impetus? Let’s look at some of the fields referenced in the BCC report. The study suggests that nanoceramic powders play an important role in applications in the fields of microelectronics, optics, 20

October 2011 ³ WWW.CERAMICINDUSTRY.COM

rials have the capacity to absorb more pollutants faster than their micro-scale cousins. In batteries, nanoscale materials increase the available active surface of anodes and diodes, more efficiently enabling the flow of electrons.

Nanocomposites and Nanocoatings Nanotechnology can take two forms in ceramics. In some cases, components are formed of nanomaterial composites, while nanocoatings are used in other situations. The advantage of nanocomposites is that, as the ingredient particles get smaller, the resulting composite can be tighter and more uniform to a degree

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not achievable with micro elements. This enhances effectiveness. Nanocoatings offer even greater opportunity. New or enhanced performance characteristics that can’t be achieved in the compound can be added at the surface via nanocoatings, specifically at the points where they’re needed. Development is under way in many markets to offer self-cleaning, wear-resistant, corrosion-resistant, abrasion-resistant, UV-resistant and moisture-resistant nanocoatings. Other nanocoatings can improve hardness, thermal performance and flame retardancy. Conductive coatings will play a role in electronics, and antibacterial coatings will affect markets from medical devices to home products. Whether the need is for a coating that’s long-lasting or temporary, visible or optically clear, functional or protective, nanocoatings are likely already in the research commercialization pipeline.

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New and improved coating application methods, including vapor deposition, thermal spray, UV-activated and others, allow for the dependable application of nanocoatings to a growing array of ceramic and other surfaces.

October 2011 ³ WWW.CERAMICINDUSTRY.COM

Multiple Opportunities These factors combine to make nanocoatings of growing interest in the ceramic industry. In fact, a research report by Future Markets, Inc. suggests that the world market for nano-

Huge Potential

nanoceramic product—provides an opportunity to improve performance, reduce costs, and open new market possibilities. 

These current advances are just beginning to see widespread commercialization. Nanotechnology is poised to be the powerful change agent for ceramics in virtually every use. Each new innovation—whether it improves a product in ways major or incremental, or results in a completely new

For more information, contact Nanofilm at 10111 Sweet Valley Dr., Valley View, OH 44125; call (216) 447-1199; or visit www.nanofilmtechnology.com.

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structured coatings will rise from its current level of about $131 billion to over $351 billion by 2015. Of course, all that growth will not be in the ceramic industry. However, it’s a strong indicator of the potential for advancement. Several development areas are of particular note. In the refractories industry, nanocoatings could reduce the rate at which the liquid metals corrode through ceramic linings in metal refining furnaces. A thermal coating could fill the microscopic pores in the ceramic with a metal repelling barrier to prevent liquid metal from invading the refractory, protecting it from degradation. Another potential industrial use is in chemical separation processes. The ceramic materials used in the separation process can be enhanced by nanocoatings that increase absorption and residence time. In the automotive industry, a soilresistant coating could extend the life and efficiency of catalytic converters by blocking the buildup of soot and carbon on the ceramic honeycomb substrate and active platinum layer. The same thinking could benefit the nano-enabled batteries mentioned previously. In addition, the battery electrode coatings can dramatically expand the effective porosity of the substrate, making it much more efficient. A coating could also make the entire electrode more durable by providing protection from abrasion, corrosion and moisture. In electronics, nanocoatings may offer new avenues for conductivity and insulation. Ultra-thin thermal barriers and thermal conductors are already of immense value. Nanocoatings are even entering the world of household ceramics. A nanocoating on dishware can reduce friction and create a barrier that protects the surface from scratches, marring, and harsh detergents. Anti-bacterial nanocoatings now seen on medical products and even on household appliances may also find application in ceramic products from sinks to servingware.

Union Process offers fine grinding and dispersing systems capable of delivering narrow, uniform particle size distributions in the micron, sub-micron and nanometer ranges. Varying materials of construction are available for grinding tank linings, shafts, agitator arms and disks for material compatibility or metal-free milling systems. • Lab, pilot scale or full-sized production equipment available for either wet or dry milling. • Union Process is a full service solution provider offering grinding and dispersing equipment, grinding media, lab testing and process optimization services, toll milling, particle size analyses and particle characterization.

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Expanding the Possibilities For Size Reduction CERAMIC INDUSTRY ³ October 2011

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³ CERAMICDECORATING

by Sandra Spence, SGCDpro Legislative and Regulatory Liaison

SGCDpro Assists with Legislative Transitions

T

he Societ y of Glass and Ceramic Decorated Products (SGCDpro) has worked with the National Association of Manufacturers (NAM) and other organizations to effect changes in the Consumer Product Safety Improvement Act (CPSIA). This work resulted in amendments passed by the House and Senate in the middle of the controversial debates over debt reduction. The bill was signed by President Obama on August 12.

SGCDpro is working on a fact sheet to assist member companies in complying with testing mandates for the CPSIA and other regulations. Of particular interest to the decorating industry, one of the amendments means that a provision reducing the limit on lead content in children’s products from 300 parts per million to 100 ppm as of August 14 would apply only to products manufactured after that date. The tighter lim-

its would not affect inventory produced before that date. Another provision prohibits the CPSC from requiring third-party testing from “small batch manufacturers” until the CPSC has provided alternative testing requirements or an exemption for products of which 10,000 or fewer are made in a calendar year. A “small batch manufacturer” is defined as a manufacturer whose total gross sales in the previous calendar year was no more than $1 million. The bill also gives more flexibility to the Consumer Product Safety Commission in determining how individual products should be tested and regulated.

Getting the Word Out SGCDpro contributed to an advertising and promotion fund managed by NAM that led to passage of the bill amending the CPSIA. An advertisement appeared in the Congressional publication The Hill and an op-ed coordinated by NAM appeared in The Wall Street Journal. In addition, Nancy Nord, a member of the Consumer Product Safety Commission, wrote an op-ed for the Washington Times highlighting the unintended consequences of the regulation. Commissioner Nord was one of two who voted against lowering the lead threshold for the CPSIA to 100 ppm, effective August 14. The reduction was implemented by the three Democratic commissioners.

Fact Sheet Development SGCDpro is working on a fact sheet to assist member companies in complying

with testing mandates for the CPSIA and other regulations. SGCDpro has learned that some test labs are conducting inappropriate tests—often because they (or their customer) do not understand which test applies. When selecting a test method and protocol, one must consider the product, its intended use and its applicable limits and regulations. SGCDpro will email the fact sheet to members when it becomes available. The sheet will also be posted online at www.sgcd.org.

Deco 2012 Deco ’12 is scheduled for March 24-26 in Las Vegas. A golf outing will be held on Saturday to kick off the event; details of the outing are currently being finalized. The Ask the Experts regulatory update session will be held on Sunday, March 25, and will feature noted Proposition 65 attorney Carol Brophy, in addition to U.S. Food and Drug Administration retiree Richard Jacobs. Other panelists are being finalized. The society also expects that a representative from a test lab will speak about proper test protocol. In addition, several presentations will be offered on Monday to highlight new technologies.

SGCDpro Membership SGCDpro will conduct its annual membership renewal campaign beginning in October. SGCDpro will continue to work with CPSC, NAM, industry lobbyists and others to effect positive change in consumer law. The society’s fact sheets and regulatory updates are available to members only via email, newsletter, and the website at www.sgcd.org. 

Sandra Spence serves as legislative liaison for the Society of Glass and Ceramic Decorated Products (SGCDpro). As executive director of the SGCD from 1991 to 2001, she was instrumental in the development of voluntary guidelines still used in the industry today. For additional details, or for information on joining SGCDpro, call (740) 588-9882 or visit www.sgcd.org Any views or opinions expressed in this column are those of the author and do not represent those of Ceramic Industry, its staff, Editorial Advisory Board or BNP Media.

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October 2011 ³ WWW.CERAMICINDUSTRY.COM

“Rare” Growth Opportunities ➤ Suppliers of rare earth materials are poised to expand resources in the U.S., Canada, Australia and many other countries. by David B. Mayfield, M.S., DABT; and Neal C. Grasso, M.S., P.G.; Gradient, Cambridge, Mass.

T

he ceramic industry is projected to grow 8-16% from 2011-2016. As the ceramic industry expands, so will the demand for the raw materials it needs for production, including rare earth elements (REEs), a group of 17 metals that have unique chemical and physical properties that make them critical for a variety of commercial and technological uses. REEs are used in a variety of ceramic applications, from glass sculptures to high-tech hybrid vehicle components (see Table 1). The ceramic and glass industry consumes approximately 10-15% or more of the REEs in commerce each year. Cerium and yttrium are the most commonly used elements of this group, which are used for glass polishing and ceramic manufacturing. REE applications include glass polishing compounds, optical glass, ultraviolet (UV)-resistant glass, X-ray imaging, thermal control mirrors, color-

izers/decolorizers, capacitors, sensors, and scintillators. Rare earth elements are becoming an increasingly expensive commodity due to reduced exports from China, the leading global supplier of REEs. However, suppliers of rare earth materials are poised to expand resources in the U.S., Canada, Australia and many other countries. The costs of rare earth materials may not necessarily decrease with increasing supplies. Efforts to comply with environmental regulations in developed (and developing) nations may be a costcontrolling factor. Ceramic manufacturers can benefit from understanding the environmental lifecycle of their materials. A lifecycle analysis (LCA) can be employed to help implement more efficient processes so that vital resources are not wasted and to balance increased extraction rates while protecting the environment.

Mining LCA The development of new rare earth ore deposits (including initial investigation, site permitting, mining and refining) requires several years to complete, as well 1 as substantial capital investments. Historically, mining and processing activities have yielded a variety of environmental impacts, including soil, surface water, and groundwater contamination. These impacts are attributed to metals, acids, and other hazardous materials from mine tailings, wastewater impoundments, and ore processing facilities. They often require remedial actions to protect communities and/or the environment from exposure to hazardous materials. Acid mine drainage is of particular concern from mining operations. Mine tailings often contain the mineral pyrite (FeS2), which, when exposed to air and water, forms an acidic solution that can impact surface water bodies and groundwater. This

Table 1. Rare earth elements used in the ceramic industry. Rare Earth Uses Cerium Glass polishing, glass additives, ceramic additives

Example Products UV glass, medical glassware, television glass, dental ceramics, zirconium ceramics used in aircraft engines Neodymium Colorant (blue to lavender), ceramic composite materials Ceramic glazes, ceramic capacitors Erbium Colorant (pink) Ceramic glazes Praseodymium Colorant (yellow to green) Ceramic glazes Yttrium Ceramic composite materials, pigments Ceramic superconductors, metal-ceramic coatings, television glass tubes, ceramic sensors and nozzles CERAMIC INDUSTRY ³ October 2011

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“RARE” GROWTH OPPORTUNITIES

Figure 1. Environmental lifecycle of rare earth elements.

acidic solution often leaches arsenic and/or cyanide—both of which are hazardous to human health and the environment—out of surrounding rock formations. Rare earth mining and processing is unique in that it is a complex multi-step process that is resource-intensive and may lead to unintended environmental impacts if performed improperly. As a result, new REE mining projects are likely to face intense scrutiny during the permitting process. This has been the case at the Molycorp REE mine in Mountain Pass, Calif., the largest rare earth mine in the U.S., which had been closed since 2002 due to

environmental concerns and increased production from China. The mine ultimately reopened this year, in part due to increasing REE prices and reduced supplies from China; its lengthy closure was also because the state of California only recently approved its environmental permits. It took Molycorp nearly a decade to complete the permitting process and install new environmental controls. One way to understand how the increasing demand for REEs can impact the environment is to evaluate the sustainability of REE production using an LCA approach. Lifecycle analysis is an envi-

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October 2011 ³ WWW.CERAMICINDUSTRY.COM

ronmental management tool that takes a holistic approach to evaluating products and processes in an effort to avoid “problem shifting,” where a solution to one environmental problem impacts another part of a product’s lifecycle. In this way, the LCA process goes beyond environmental compliance in the traditional sense because it helps one industry (e.g., ceramic manufacturing) understand how activities along its entire supply chain (from resource extraction to disposal or reuse) impact the environment (see Figure 1). For example, a recent LCA study evaluated the environmental impacts of REE production at the Bayan Obo mine in China.2 This study found that the production of REEs resulted in increased greenhouse gas (GHG) emissions, resource depletion and waste production, including low level radioactive waste. Typical rare earth deposits contain small amounts of thorium and uranium, resulting in lowlevel radioactivity in the wastewater slurry and mine tailings. While this example used an LCA approach to understand the environmental impacts associated with REE production, other studies have documented environmental impacts at former mining operations and facilities that formally processed REEs. For example, the previously discussed Bayan Obo mine has had documented releases of thorium, uranium, and heavy metals that have been linked to a possible increased incidence of illnesses in Baotou, China (population 1.7 million). Releases of thorium, uranium, and heavy metals, as well as chlorinated solvents (e.g., volatile organic compounds or VOCs), have also been documented at REE mining and processing facilities in the U.S. and Malaysia. However, many of these releases occurred in the 1970s, ‘80s, and ‘90s. In the case of China, the releases

occurred more recently (within the last decade), and environmental concerns are part of what fueled China’s decision to curb exports in 2010. As a result of the current state of knowledge regarding the environmental risks associated with REE mining and the advent of new treatment technologies, many of these concerns can be easily addressed at new and proposed REE mining and processing operations.

Commercial Considerations Following extraction and processing, users of REEs must contend with a number of rules governing products in commerce. Environmental compliance does not stop once the pure rare earth oxide powders are shipped off to ceramic manufacturers. As REEs proliferate in the marketplace and in consumer products, the risk of human and environmental exposures is also more likely. Unfortunately, little health hazard information exists for most rare earth metals.

Regulators in Europe, the U.S., and other countries are requiring the disclosure of toxicity and hazard information for these materials. For example, the European Union’s Registration, Evaluation, Authorization, and Restriction of Chemical substances (REACH) regulation requires companies to provide comprehensive environmental characterizations based on import tonnage. Thus, requirements for reporting and examining environmental impacts for many chemical substances are expected to increase in the future. Purified REEs typically come in powdered forms and, therefore, working with these materials can lead to the inhalation of metal dusts. Ceramic and glass manufacturers working with metal powders during product development typically implement occupational monitoring programs to ensure a safe working environment. Unfortunately, occupational standards for most rare earth compounds are

lacking,3 and manufacturers have limited guidance to aid them. The only available REE occupational standard is for yttrium compounds (1 mg/m3 in air). Limited information suggests that exposure to

Users of REEs must contend with a number of rules governing products in commerce. high levels of REEs (particularly cerium) can affect the respiratory system. Therefore, ceramic manufacturers should critically evaluate their safety programs and limit exposure to metal dusts. Finally, ceramic manufacturers must also ensure the safety of their products. Stricter

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“RARE” GROWTH OPPORTUNITIES

public health laws are being developed in many U.S. states, and these laws will eventually apply to products incorporating REEs. For example, California’s Proposition 65 requires businesses to notify Californians about significant amounts of chemicals in the products they purchase, that may be present in their homes or workplaces, or that are released into the environment. The U.S. Environmental Protection Agency (EPA) has a Green Chemistry Initiative whereby businesses are encouraged to evaluate chemical products and processes, and develop technologies or substitutes that reduce or eliminate the use or generation of hazardous substances. Lastly, the EPA and many state agencies are implementing electronic waste recycling programs to recover valuable metals and reduce the amount of wastes sent to landfills. These laws can often be difficult to navigate and require manufacturers to reevaluate their environmental strategies. In addition, some states and foreign gov-

ernments are requiring facilities to have ISO 9000-certified environmental management systems in place.

For additional information, email the authors at [email protected] or [email protected], or visit www.gradientcorp.com.

Multiple Opportunities REEs are key components for emerging “green” technologies. Components of hybrid and electric vehicles, solar panels, and wind turbines contain many ceramic components strengthened by these unique metals. The development of new rare earth resources in the U.S. and abroad is expected to alleviate current supply chain shortages. The increased REE supply will hopefully contribute to the growing ceramic market sector. However, glass and ceramic manufacturers should continue to evaluate viable chemical substitutes, proper waste disposal techniques, and recycling programs to balance short-term supply shortages. The emerging green economy will have a bright future if ceramic manufacturers consider the environmental lifecycle of REEs. 

References 1. Long, K.R., Van Gosen, B.S., Foley, N.K., Cordier, D., “The Principal Rare Earth Elements Deposits of the United States—A Summary of Domestic Deposits and a Global Perspective,” U.S. Geological Survey Scientific Investigations Report 2010-5220, 2010, http://pubs. usgs.gov/sir/2010/5220/. 2. Tharumarajah, A., Koltun, P., “Cradle to Gate Assessment of Environmental Impact of Rare Earth Metals,” presented at 7th Australian Conference on Life Cycle Assessment, Life Cycle Assessment: Revealing the Secrets of a Green Market, Melbourne, Australia, March 9, 2011. 3. American Conference of Governmental Industrial Hygienists (ACGIH), “2011 Guide to Occupational Exposure Values,” ACGIH Publication No. 0389, 2011.

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special report | refractories

Assessing Monolithic Refractories by Andy Wynn, Ph.D., Global Technical Director—IFB and Monolithics, Morgan Thermal Ceramics

➤ Aluminum producers have developed a practical set of laboratory tests for furnace linings.

M

onolithic refractories are well established as linings for a range of holding and melting applications during aluminum processing, as they provide optimum productivity and cost effectiveness. A wide range of products is available and, since aluminum furnaces have their own unique set of operating conditions compared to other refractory applications, suppliers offer specifically tailored material solutions.

need to maintain a complex and lengthy testing scheme for furnace linings. The purpose is to subject potential materials to the full range of conditions that they are likely to experience in service. Since a broad range of conditions exists, it is not practical or cost effective to test materials for all types of conditions. Instead, alumi-

num producers have developed a practical set of laboratory tests. The two main failure mechanisms that limit service life are chemical attack (e.g., corundum growth or corrosion from flux addition) and mechanical damage (e.g., ingot loading, cleaning practices or thermal shock). Producers have developed

Background Monolithics are used to line the metal and non-metal contact regions in typical melt-hold gas-fired reverberatory furnaces. Each region is divided into sub-regions (see Figure 1), all of which experience a different set of operating conditions—and hence environment—for the furnace lining. A variety of refractories is therefore required for a complete furnace lining. End users melt and hold a variety of fluxing materials, so the monolithic products need to cope with the specific chemistry present in the furnace. In addition, different operating practices with respect to furnace management (e.g., methods and frequency of cleaning) mean that diverse physical conditions can influence different parts of the furnace. The diverse nature of the furnace environment means aluminum producers

Figure 1. Furnace zones in an aluminum melt-hold reverb furnace.

Figure 2. Mold for sample preparation, Method 1.

Figure 3. Mold for sample preparation, Method 2. CERAMIC INDUSTRY ³ October 2011

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ASSESSING MONOLITHIC REFRACTORIES

Dried

Pre-Fired to 2192ºF

Pre-Fired to 1472ºF

Pre-Fired to 2195ºF

Figure 5. Materials A, B and C tested by Method 3.

Figure 4. Materials A, B and C tested by Method 1.

tests to simulate these effects as part of their approval program. The investigation of tests in this article focuses on the metal contact region, as this produces the most aggressive set of conditions and represents the most demanding part of the furnace in terms of lining performance. Corundum growth is the most significant threat in this area and therefore receives the most attention when designing and testing furnace lining materials. Corundum forms when liquid aluminum reacts with free silica in refractories, as shown in the formula: 4Al (l) + 3SiO2 (s) A 2Al2O3 (s) + 3Si This transformation leads to a very large expansion in volume, causing severe distortion and cracking of the lining. The most prevalent laboratory test for corundum growth resistance is the aluminum “cup” test. The objective of this investigation is to understand how different test conditions affect the behavior of the lining materials by evaluating how existing furnace lining materials behave when subjected to aluminum producers’ contact “cup” test methods.

Test Details The standard metal contact “cup” tests of three large aluminum producers are outlined below. These procedures are routinely used to assess the suitability of monolithic refractories for use in melt-hold furnace linings. 30

October 2011 ³ WWW.CERAMICINDUSTRY.COM

Method 1 To prepare the sample, a series of 100 mm cubes are cast from compositions mixed at standard water addition. The mold is shown in Figure 2 (p. 29). Each cube has a 50 mm deep, slightly tapered hole (55 mm diameter at top, 53 mm at base). Samples are set overnight, then de-molded, cured and dried at 230°F for 18 hours. Half of the dried sample cups are then pre-fired to 2192°F for five hours. Lids of the same material (25 mm thick) are also made to minimize loss of volatiles. Typically, 7075 alloy is used for testing, supplied as 52 mm bar and cut to 50 mm lengths. The cut alloy sample is inserted into the hole in the sample cup, and the lid is placed on top (unsealed). Both as-dried and pre-fired samples are tested at the same time for comparison. The assembled cups are placed in a kiln, heated to 1832°F at a rate of 302°F/hour and held at temperature for 100 hours. The kiln is then allowed to cool naturally. After cooling, the samples are sectioned vertically; dried; visually assessed for the degree of metal penetration, corundum growth, or ease of removal of the aluminum; and photographed. Method 2 Following the supplier’s mixing recommendation, a standard brick size (e.g., 230 mm high x 114 mm wide x 76 mm deep) of the test material is cast into a mold that incorporates a curved face to form a cup shape with a maximum depth of 32 mm for holding the alloy. The mold is shown in Figure 3 (p. 29). After the recommended curing time, the sample is fired according to the supplier’s recommendation to 1499°F, with a 10-hour hold, and left to cool naturally in the kiln. The curved cup section is then roughened using a diamond saw to expose the refractory grain.

Table 1. Characteristics of metal contact materials studied. Material A Material type Phosphate-bonded castable Furnace zone Belly band Bond type Chemical Material type Bauxite Maximum use temperature (°C) 1450 Material required cast (kg/m3) 2650 Wt% water addition 10:1 solid to liquid

The cup sample is raised to 1499°F in a furnace at a rate not exceeding 302°F/hour. Meanwhile, 7075 alloy is melted in a silicon carbide crucible, heated to 1499°F and sampled for analysis. The molten alloy is then ladled into the brick cavity at 1499°F to about 3 mm below the top of the brick, and held at temperature for 72 hours. The alloy is raked every half-hour for the first three hours to remove the oxide film barrier at the metal/refractory interface. After 72 hours, the oxide formed on the top of the molten alloy is cleaned and a sample of alloy from the cup is taken for analysis.

B LCC + non-wetting additive 1 Lower walls/ramp Hydraulic Bauxite 1400 2800 5.5-6.5

C LCC + non-wetting additive 2 Hearth Hydraulic Bauxite 1300 2900 5-5.8

Any remaining metal is poured off and the cup surface is cleaned with a Superwool blanket pad. The cup is air cooled and sectioned through the center (along the short axis) to assess the degree of metal attack. The initial and final chemical analyses of the alloy are compared to determine silicon and iron pickup. Method 3 Samples are prepared according to the supplier’s recommendations and cast into the same molds as those used in the first

Figure 6. Sub-hearth gunning material tested by Method 2.

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ASSESSING MONOLITHIC REFRACTORIES

method. Following the same setting, curing and drying process, half of the dried sample cups are pre-fired to 1472°F for five hours and half to 248°F. Four test pieces are heated simultaneously in an electric furnace alongside a quantity of the test alloy in a crucible at 50°F/ min to 1472°F ± 41°F. Pure aluminum (160 g, > 99.8%) is ladled into the sample hole and the cups are held at 1472°F for 72 hours. The melt is stirred daily to break the oxide film. After the melt is left to cool naturally in the furnace, it is cut diagonally and the cut face inspected for penetration and reaction with metal. It is also photographed.

Results As characterized in Table 1 (p. 31), three monolithic materials were tested using the three “cup” test methods to assess how the different test conditions used by the aluminum producers affect the outcome of the test results. As shown in Figure 4 (p. 30), none of the materials tested using Method 1 show any significant corundum growth, as would be expected since all three materials are routinely used in aluminum furnaces. Material C, which has been pre-fired to 2192°F, does show a thin layer of corundum formed at the interface with the metal; this suggests that corundum resistance begins to degrade as firing temperature increases. This behavior would have performance implications in service when furnaces are operated more aggressively.

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The results of Method 2 show no corundum growth on any sample at lower temperatures of 1499°F, despite roughening of the contact surface to try to promote reaction (see Figure 5, p. 30). However, the alloy analysis reveals that silicon pickup increases going from material A to B to C. “Cup” test failures are normally accompanied by increased concentration of silicon and iron in the alloy after testing (see Figure 6, p. 31).

Resistance to corundum growth can alter considerably in the presence of salts. Table 2 reveals that the trend in increasing silicon pickup matches the reduction in alumina/silica ratio in the material. In addition, as silica content increases, more Si is detected in the alloy. Despite the low testing temperature of Method 2, material C is close to the failure threshold for the maximum allowable silicon pickup of 0.5%. As with Method 2, the results of Method 3 show no visible signs of corundum growth on any sample. The results indicate that testing at 1832°F accelerates the corundum reaction and that pre-firing the sample at higher temperatures can cause the non-wetting additive to react with other material constituents and to lose its effectiveness. As all the materials studied are already in use in many furnaces, it was expected that all the materials tested would pass these cup tests; for most of the studied test conditions, that has been observed. However, as the severity of the test conditions increases, more metal/refractory interaction has been observed, specifically in material C. This matches general operational observations, where it has been noted that material C starts to suffer from corundum growth in more aggressively run furnaces. According to these laboratory tests, metal contact performance appears to start deteriorating as the temperature increases to 1832°F. In the past, such high test temperatures were considered unrealistic, since holding temperatures tended to be well below this level. However, in more recent times, as aluminum furnaces continue to be pushed harder, chamber temperatures have risen and conditions have become more aggressive for the refractory lining. Therefore, test conditions that accelerate the reactions involved by increasing temperature above tradi-

tional aluminum holding temperatures are now more valid. In particular, corundum growth is often seen to start at hot spots in the furnace, where temperatures can be measured in excess of 1832°F. This situation is exacerbated by exothermic reactions from salt and dross build-up on the lining. As industry needs have changed, so too has the furnace environment. Material test methods must therefore evolve to reflect this. In light of modern aluminum test practices, the testing temperatures of Methods 2 and 3 appear too low, as they do not accelerate corundum growth reactions adequately. In addition, the high melt surface area in Method 2 promotes excessive dross formation and volatilization. Methods 1 and 3 use relatively small alloy samples, which also suffer from volatilization, but this can be controlled to improve test repeatability by covering the sample “cup” with a refractory lid of test material. “Cup” test results are further complicated when salts are introduced into the metal contact “cup” tests. These studies have shown that resistance to corundum growth can alter considerably in the presence of salts. Further investigation on this subject is under way.

Table 2. Method 2, 7075 alloy analysis. As Supplied After Testing with Material Alloy A B % Si 0.036 0.16 0.35 % Fe 0.098 0.16 10.25 % Cu 0.9 0.9 0.9 % Mn 0.07 0.08 0.077 % Mg 2.69 0.53 1.43 % Cr 0.48 0.52 0.52 % Zn 5.66 5.74 5.8 % Ti 0.006 0.012 0.005

Given the increasingly challenging environment that the refractory lining has to work in, aluminum producers must ensure that their material assessment tests also reflect these changes in conditions. Otherwise, the tests will produce unrealistic results and material selection may be compromised. The results of this investigation suggest that those “cup” tests using lower temperatures are not aggressive enough

C 0.43 0.17 0.93 0.079 1.86 0.52 5.92 0.007

for assessing lining materials in today’s furnace environment. In the past, such test conditions were adequate, but the test methods have not evolved in line with the furnace conditions that they are trying to simulate.  For more information, contact Morgan Thermal Ceramics at (706) 796-4200, email [email protected] or visit www.morganthermalceramics.com.

Thermo. Dynamic.

Updates Needed The metal contact “cup” test methods used by three aluminum producers for furnace lining selection have been investigated using monolithic materials currently in use in several melt-hold furnaces around the world. Aluminum producers have worked to increase productivity to remain competitive. This is normally achieved by increasing heat input to the furnace with more powerful burners to melt the metal faster. However, this practice leads to increased metal losses as a result of surface oxidation, as well as larger heat gradients across the metal that result in the segregation of alloying elements and a reduction in metal quality. These effects are countered by increased use of fluxes to suppress surface oxidization and increased stirring of the metal to achieve homogenization.

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g n i d n bra

Your Workplace

W

hen we think of brands, we think of products and companies like Coca-Cola, McDonald’s, Apple, Google, and Mercedes-Benz. Brands are an ever-present part of our lives—from the clothes we wear to the food we eat, the toys our children play with to the drinks we consume, and from our mobile phones to our expensive cars. Brands are everywhere. The most successful brands are ones that build trust. They cultivate an image, persona, or personality that appeals to a specific target audience and gives its members comfort that they are making the right decision.

Brand Importance Why are brands so powerful? First, brands nurture increased customer loyalty. Consumers develop a strong affiliation to particular brands. Therefore, they feel a commitment toward or even an obligation to purchase or use a particular brand. Brand loyalty is impacted by the experience and sense of satisfaction felt by customers. Whether customers will have a positive or negative experience depends on the company’s ability to keep its promise—to successfully execute its operating model. Once customers experience a brand, they view their experience as a promise that they will have that same experience in the future. Each experience builds on the previous one. Customers become attached to the company’s implied promise and, at times, are willing to pay more or go out of their way to experience that promised feeling. In the same way, a strong workplace brand increases employee loyalty. With a strong workplace brand, employees develop a meaningful affiliation with the company and the work culture. When the company makes (and keeps) a valid promise that this company is a great place to work, positive things occur. Once employee loyalty increases, the company’s employee retention rate goes up, saving thousands of dollars in hiring and training costs. Second, brands offer a means of differentiating products and services in competitive markets. When the marketplace under34

October 2011 ³ WWW.CERAMICINDUSTRY.COM

➤ A strong workplace brand increases employee loyalty. by Martin O’Neill stands how your product or service offering is different from that of your competition, it’s easier to generate new prospects, develop relationships with them, and lead them into a buying situation. If you are unable to differentiate your offerings, you’ll spend time and money “selling” your prospective customers on why they should buy from you. In most cases, it is money poorly spent because you’ve never developed the relationships or trust needed to get their ear in the first place. Similarly, your company must stand out as a truly remarkable place to work in order to attract the employees you need for the company to succeed and grow. Employees should be drawn to your company not only because of salary and perks, but also because of the intangibles involved with working for your company. Prospective employees need to be able to envision themselves working for your company. They need to be able to read or listen to employee testimonials on your website and see themselves in those positions. For example, one company sends a customized video clip via email to each candidate after the initial interview, thanking that person for their time and effort to come in for an interview. That sets the stage immediately that this could be a very good place to work. Third, brand loyalty influences pricing. Because of the reassurance of quality often associated with a brand, the manufacturer can often charge a premium price. Even more important to our application of brands, a strong brand can often undercut its rivals simply because its name is better known or associated with certain characteristics, like quality, style, or even sex appeal. Likewise, a strong workplace brand will help manufacturers break out of the cycle of price competition. In other words,

special report | resource management

employees will look at more than the pay scale when considering joining the organization. A strong workplace brand does not mean that companies can underpay or take advantage of the workforce. Instead, it means that they can offer a fair compensation package and be far ahead of the competition by using their workplace brand as a way to close the deal.

Capitalizing on the Brand Manufacturers can take several steps to realize the benefits of branding their workplace. Claims about the workplace environment must be built on a solid foundation of truth. A claim without substance won’t stand. Saying that the company is a truly unique place to work is not enough—it must truly be a unique place to work. Companies should identify three to five unique truths about the workplace environment that can easily be proven to prospective employees. For example, are workers empowered? Prospective employees should be shown examples where current employees have been given authority to make decisions. Does the company respect its workers? Prospective employees should be able to talk with current employees to verify claims. Has the company won awards for culture, safety, or greatest places to work? If so, those awards should be posted in a prominent place. Manufacturers can be bold in their proclamations, as long as they are true. Companies should customize their brand according to the type of employees they are trying to attract. The following exercise will help manufacturers determine their target

employees. Gather the company’s managers and leaders and divide them into two teams. Ask the first team, “What attributes would you use to describe one of your most valued employees?” Ask the second team, “What attributes would you use to describe a successful entrepreneur?” Have each team answer its question in isolation. Then compare the results together. Most likely the two lists of attributes will be nearly identical. This indicates that the most valuable employees exhibit the attributes of an entrepreneur. If a company wants entrepreneurial employees, the workplace environment must attract such employees. Manufacturers must be able to express how their workplace environment addresses the needs of this type of employee. This is the key to workplace brand building. The workplace environment must also be inclusive. It should empower employees at every level to feel that they are part of a greater team and that their opinions matter. For example, ad agencies often attract talented and creative designers by offering them the opportunity to build world-class portfolios and work as equal members in a design team where everyone’s creative input is considered on projects. This builds equity in the workplace environment. At times, leaders will have to take the time to explain why things are happening as they are. In such cases, leaders become teachers. When students (employees) begin to understand the consequences of their actions and the nature of the markets, they can begin to make decisions that benefit both themselves and the company. Inclusiveness means that consequences—positive and negative— will be felt by everyone. For a workplace brand to be inclusive, people must rate the environment or culture as a major factor in why they came to work for the company. The CEOs and managers of King Arthur Flour, for example, communicate nearly everything to all of the people in the organization, which, in turn, empowers the employees as partners in the business endeavor. One of the reasons for the high employee retention rate at King Arthur Flour is that people are attracted to this inclusiveness and can’t find it in other workplaces.

Loyalty is Key When their workplace environment is credible, customized and inclusive, manufacturers will have created a workplace brand, a valuable tool that increases employee loyalty. Very few people in leadership positions consider the workplace as something that can be branded, but those who do reap tremendous benefits. 

About the Author Martin O’Neill is a frequent speaker and consultant on leadership, corporate culture, strategic planning, and building enterprise value. He is the author of The Power of an Internal Franchise (Third Bridge Press, 2011) and Building Business Value, and the coauthor of Act Like an Owner. Visit www.corsum.com for more information. CERAMIC INDUSTRY ³ October 2011

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³ WHAT’SNEW

³ BUYERS’ CONNECTION NETZSCH introduces the new LFA 457 MicroFlash® system to measure thermal diffusivity, thermal conductivity and specific heat of advanced materials, including advanced ceramics, metals, polymers, liquids and more. Using the laser flash principle, the instrument operates from -125 to +1100°C, in pure gas atmospheres or in vacuum, and includes an automatic sample changer for unattended overnight operation. For details please visit: http://netzsch-thermal-analysis.com Netzsch Instruments Burlington, MA 01803 Ph: 781-272-5353 • Fax: 781-272-5225 E-mail: [email protected]

Microwave Firing Successfully Commercialized

One System - PM, SO2, HCl, Hg, & NOx

UltraCat Catalyst Filter • One system for PM, NOx , SO2 , HCl, dioxins, mercury, or any combination • Low temp NOx control by catalyst-embedded filters eliminates costly SCR • Project sizes up to 200,000 cfm

Harrop, in collaboration with Ceralink Inc Inc. and Thermex Thermatron LP, has commercialized a microwave-assisted electric elevator kiln. This first production kiln has a setting volume of 30 cu .ft. and operates to 1600ºC. Significant processing cost savings have been achieved by firing the structural carbon foam shapes successfully in a fraction of the time required with conventional electric kiln designs.

For further information, contact Harrop at [email protected].

Call or email today... Ph: 801.294.5422 [email protected] ®

Since 1960

Tri-Mer

Ceramic Fiber Filter, New 10 ft. Length

Controls NOx at 350°F to 700°F Particulate to less than 2.0 mg/Nm3

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CI’s November 2011 EQUIPMENT DIGEST Position your company for success and put the power of Ceramic Industry to work for you!

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Call TODAY! Amy: 281-550-5855 [email protected]

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October 2011 ³ WWW.CERAMICINDUSTRY.COM

Rapid Cooling System

Post-sinter hot isostatic pressing (HIPing) has been shown to minimize grain growth and improve the density, tensile strength, hardness, and corrosion resistance of PIM parts designed for severe service. Many of this company’s HIP models can be equipped with a uniform rapid cooling (URC) furnace that cools the load in a fraction of the time needed by conventional HIP furnaces. This feature can reportedly reduce total cycle time by up to 70%, allowing up to three complete cycles in an eighthour shift and reducing per-unit process HIPing costs by up to 70%. Visit www.avure.com/pim.

BYK-GARDNER

Factory Headquarters: Owosso, Michigan

Contact Amy Vallance 281-550-5855 • [email protected]

AVURE TECHNOLOGIES

Temperature Recorder The new temp-gard temperature recorder system for measuring and saving object and air temperature during the curing process is now available. The data logger comes in two configurations: 12 temperature probe connections or six probe connections. The instrument features a large color graphics display and a USB memory stick connection for easy data transfer. Visit www.byk.com.

COORSTEK Online Store A new online store offers direct sales of this company’s ceramic labware products. The site provides 24/7 ordering, enables factory-direct orders from the manufacturing plant in Golden, Colo., and reportedly saves customers 10% off list price for porcelain labware. Visit http://labware. coorstek.com. 

³ SERVICESMARKETPLACE ³CONSULTING & ENGINEERING SERVICES Brinks Hofer Gilson & Lione . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

³MAINTENANCE/SERVICES

Ceralink, Inc . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Ceramic Maintenance Services, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

Ceramics Consulting Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Jonathan Kaplan Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

³PROCESSING SERVICES

Ragan Technologies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

AVEKA . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Richard E. Mistler, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

CCE Technologies, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Ruark Engineering, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

Powder Processing and Technology, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

Semler Materials Services . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 37

Powder Technology, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44 Union Process . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43

³CONTRACT MANUFACTURING SERVICES C-Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

³RECYCLING SERVICES

Coalition Technology Co., Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

A-Ten-C, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 44

CoorsTek . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38 Superior Technical Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 38

³REFRACTORY SERVICES Fuse Tech/Hot Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

³FINISHING & MACHINING SERVICES Advanced Ceramic Technology . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39

³SPRAY DRYING

Bullen . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

General Spray Drying Service, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

EBL Products, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Ferro-Ceramic Grinding, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

³CONSULTING & ENGINEERING SERVICES

Machined Ceramics, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 O’Keefe Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 PremaTech Advanced Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 39 Sonic-Mill . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

³FIRING & DRYING SERVICES Allied Kiln Service Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 American Isostatic Presses. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Centorr/Vacuum Industries . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Harrop Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 Ipsen Ceramics . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40 I Squared R Element Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 40

Experts in Ceramic Engineering & Materials Science • Microwave & RF Process Development • Scale-up • Equipment Design

• Materials Engineering Ceramics, Glass, Composites

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SBL Kiln Services, Inc.. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 TevTech, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

³GLASS SERVICES Ceradyne VIOX, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Phone: 480-895-9830 FAX: 480-895-9831 e-Mail: [email protected]

Fuse Tech/Hot Tech . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Glass Inc. International . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

Dr. Charles E. Semler

SEM-COM Co., Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41 Specialty Glass, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 41

³INDEPENDENT AGENTS Tape Casting Warehouse . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

President/Consultant SEMLER MATERIALS SERVICES 10153 E. Elmwood Dr. Chandler, AZ 85248

Taylor Tunnicliff Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

³LABORATORY & TESTING SERVICES Activation Laboratories Ltd. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Geller Microanalytical Laboratory . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Harrop Industries, Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 JTF Microscopy Services, LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 43 Micron Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Netzsch Instruments NA LLC . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 NSL Analytical Services Inc. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 Quantachrome . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42 West Penn, Spectrochemical Labs. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 42

CERAMIC INDUSTRY ³ October 2011

37

³CONSULTING & ENGINEERING SERVICES / CONTRACT MANUFACTURING SERVICES ³CONTRACT MANUFACTURING SERVICES

High Shear Compaction— Superior Tape Forming Process • Full thickness single layer tapes: • HSC efficient high-volume 0.1 mm to greater than 13 mm process compatible with any powder: ceramic, glass, metal • Aqueous binder systems— extreme thickness control or plastic Ragan Technologies Inc. • Tape Development > Toll • Improvement over roll compac978-297-9805 Manufacturing > Turnkey tion —Isotropic tapes are [email protected] Installations never brittle & fire flat www.ragantech.com

INNOVATIVE SOLUTIONS FROM CONCEPT TO PRODUCTION • • • •

Delivering solutions for diverse applications & industries Extrude, dry press, iso press, precision machine AS9100 & ISO9001:2008 Certified Plantwide Customer-Focused Culture

802-527-7726 • [email protected] • www.ceramics.net

Alumina • Zirconia • ZTA • Steatite • Cordierite • BN • Macor

Jeff Zamek Ceramics Consulting Services

6 Glendale Woods Drive Southampton, MA 01073

Precision Ceramic Components fj^X`"ijgc egdidine^c\

Telephone 413 527 7337 Fax 413 529 2674 [email protected] www.fixpots.com ]^\]"kdajbZ bVcj[VXijgZg

Ceramic Product Design and Development Whitewares and Tabletop Custom Molds and Models Veea^XVi^dc Zc\^cZZg^c\

3520 Brighton Blvd., Denver CO 80216 (303) 909-5488 www.plinthgallery.com [email protected]

Michael S. Gzybowski Intellectual Property Attorney 734.302.6046 [email protected]

Suite 200 | 524 South Main Street | Ann Arbor, MI 48104 usebrinks.com

Ruark Engineering, Inc. Customer Oriented Expert Kiln Assistance • • • •

CONTINUOUS IMPROVEMENT OF KILN OPERATIONS KILN UPGRADE AND MODIFICATIONS NEW KILN PROCUREMENT SPECIALIZED TRAINING ON SITE

Ralph Ruark, PE 10506 Cypress Point Drive Bradenton, FL 34202

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P: 941-730-2253 F: 941-360-3211 [email protected] http://www.ruarkengineering.com

October 2011 ³ WWW.CERAMICINDUSTRY.COM

CoorsTek is the largest US-owned technical ceramics manufacturer in the world. Call 303-271-7006 or email [email protected] for expert assistance on your next project. Visit us on the web www.coorstek.com

³CONTRACT MANUFACTURING SERVICES / FINISHING & MACHINING SERVICES

WORLD LEADER IN PRECISION CERAMICS

Over a Quarter Century of Precision Ceramic Machining Process Development, has resulted in hundreds of satisfied customers. Put our experience and knowledge to work for you and become one of our satisfied customers.

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in d n

g

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t ics & Advanced Ma

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EBL PRODUCTS, INC.

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CERAMIC INDUSTRY ³ October 2011

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³FINISHING & MACHINING SERVICES / FIRING & DRYING SERVICES ³FIRING & DRYING SERVICES

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Contract Machining Company and Ceramic Component Supplier • ISO 9001:2000 & AS9100B • CAD/CAM CNC Machining • Extensive Material Inventory • Material/Technical Support • Over 40 Years of Service Specializing in BN, SiC, Macor, Si N , Al O , ZrO , Quartz, Ferrites and other related materials 3

4

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I SQUARED R ELEMENT CO., INC. AKRON, NY USA

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October 2011 ³ WWW.CERAMICINDUSTRY.COM

ISOSTATIC PRESSING Specializing in

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American Isostatic Presses 1205 S. Columbus Airport Rd. Columbus, Ohio 43207 Phone (614) 497-3148 Fax (614) 497-3407

TEVTECH, LLC MATERIALS PROCESSING SOLUTIONS Custom Vacuum Furnaces & Hot Zone Refurbishment for Sintering • CVD • Purification • Brazing 100 Billerica Ave., N. Billerica MA 01862 Tel. (978) 667-4557 • Fax. (978) 667-4554 www.tevtechllc.com

BUS.: (608) 783-4455 ALLIED FAX: (608) 783-4420 KILN EMAIL: [email protected] SERVICE INC. TIMOTHY J. TOBIN

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Refractory Repair Specialists • Ceramic Welding & Periscope Surveys • Port & Checker Cleaning • Hot Refractory Sawing & Drilling • Furnace Overcoating • Hot & Cold Refractory Repair

Electronic and Specialty Glass Frits & Powders • • • • • • • • • •

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³GLASS SERVICES

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GLASS TECHNOLOGY Design • Development • Manufacturing

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CERAMIC INDUSTRY ³ October 2011

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³INDEPENDENT AGENTS / LABORATORY & TESTING SERVICES

USA McCuen & Associates Ph: 330 482-1074 Fax: 330 482-4560 Email: [email protected] www.davemccuen.com

BULLERS RINGS • Improve Kiln Yields • Reduce Loss • Improve Production Profits • Guarantee Consistent Firings

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LOWER COST MILLING SOLUTIONS Holding off on capital purchases? Union Process still has several low cost options for you to get the job done economically and efficiently using the finest size reduction equipment on the market.

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Ohio Company needs a materials engineer or technician. Responsibilities include product development, marketing and sales. Products sold to diverse industries. Experience in ceramic coatings, glazes, inorganic materials and metals a plus. Excellent benefits and opportunity for advancement. Please reply to General Manager, P.O. Box 18243, Cincinnati, Ohio 45218 or [email protected]

CERAMIC INDUSTRY ³ October 2011

45

³ ADVERTISERINDEX ADVERTISER

PAGE NO.

ADVERTISER

PAGE NO.

* Active Minerals International, LLC www.activeminerals.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 7

SACMI www.sacmi.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IFC

* American Chemet Corp. www.chemet.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 10

* Saint-Gobain Ceramics Systems www.refractories.saint-gobain.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 11

* Applied Test Systems, Inc. www.atspa.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

* Thermaltek www.thermaltek.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 28

* Carbolite Inc. www.carbolite.us . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 27

Thermcraft Inc. www.thermcraftinc.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 22

* FLSmidth Inc www.flsmidth.com. . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 26

* Tokuyama America Inc [email protected] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 15

* Harper International Corp. www.harperintl.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 33

* Uk Abrasives www.ukabrasives.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 32

* Harrop Industries [email protected] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 4

* Unifrax Corp. www.unifrax.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 3

Lucifer Furnaces www.luciferfurnaces.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

* Unimin Corp [email protected] . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . .BC

* Mohr Corp. www.mohrcorp.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 45

Union Process Inc www.unionprocess.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 23

* Netzsch Premier Technologies www.netzsch-grinding.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 19

* U.S. Electrofused Minerals Inc. www.elfusa.com.br . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 31

O’Keefe Ceramics www.okeefeceramics.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 16

* Wesbond Corp. www.wesbond.com . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . 18

Pittsburgh Conference www.pittcon.org . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . . IBC * See our ad in the 2011-2012 Ceramic Industry Data Book & Buyers’ Guide. This index is a feature maintained for the convenience of the advertiser. It is not part of the advertiser’s contract, and Ceramic Industry assumes no responsibility for its accuracy.

Spend less time searching for information

and more time using it

www.ceramicindustry.com/databook

Online Data Book & Buyers’ Guide s4HEBUYERSREFERENCEFORCERAMIC GLASSANDRELATEDINDUSTRIES s3EARCHBYPRODUCTCATEGORYORCOMPANYNAME s$OWNLOADABLEPRODUCTSPECSHEETS s!LPHACOMPANYLISTINGS s,IVEWEBEMAILLINKS

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GET Connected

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