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Kiln
A kiln is a thermally insulated chamber, a type of oven, that produces temperatures sufficient to complete some process, such as hardening, drying, or chemical changes. Kilns have been used for millennia to turn objects made from clay into pottery, tiles and bricks. Various industries use rotary kilns for pyroprocessing—to calcinate ores, to calcinate limestone to lime for cement, and to transform many other materials. Pronunciation and etymology According to the Oxford English Dictionary, kiln was derived from the words cyline, cylene, cyln(e) in Old English, in turn derived from Latin ''culina'' ("kitchen"). In Middle English the word is attested as kulne, kyllne, kilne, kiln, kylle, kyll, kil, kill, keele, kiele. For over 600 years, the final "n" in kiln was silent. It wasn't until the late 20th century where the "n" began to be pronounced. This is due to a phenomenon known as spelling pronunciation, where the pronunciation of a word is surmised from its spelling ...
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Cement Kiln
Cement kilns are used for the pyroprocessing stage of manufacture of portland and other types of hydraulic cement, in which calcium carbonate reacts with silica-bearing minerals to form a mixture of calcium silicates. Over a billion tonnes of cement are made per year, and cement kilns are the heart of this production process: their capacity usually defines the capacity of the cement plant. As the main energy-consuming and greenhouse-gas–emitting stage of cement manufacture, improvement of kiln efficiency has been the central concern of cement manufacturing technology. Emissions from cement kilns are a major source of greenhouse gas emissions, accounting for around 2.5% of non-natural carbon emissions worldwide. The manufacture of cement clinker A typical process of manufacture consists of three stages: * grinding a mixture of limestone and clay or shale to make a fine "rawmix" (see Rawmill); * heating the rawmix to sintering temperature (up to 1450 °C) in a cement k ...
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Rotary Kiln
A rotary kiln is a pyroprocessing device used to raise materials to a high temperature (calcination) in a continuous process. Materials produced using rotary kilns include: * Cement * Lime * Refractories * Metakaolin * Titanium dioxide * Alumina * Vermiculite * Iron ore pellets They are also used for roasting a wide variety of sulfide ores prior to metal extraction. Principle of operation The kiln is a cylindrical vessel, inclined slightly from the horizontal, which is rotated slowly about its longitudinal axis. The process feedstock is fed into the upper end of the cylinder. As the kiln rotates, material gradually moves down toward the lower end, and may undergo a certain amount of stirring and mixing. Hot gases pass along the kiln, sometimes in the same direction as the process material (co-current), but usually in the opposite direction (counter-current). The hot gases may be generated in an external furnace, or may be generated by a flame inside the kiln. Su ...
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Hop Kiln
An oast, oast house or hop kiln is a building designed for kilning (drying) hops as part of the brewing process. They can be found in most hop-growing (and former hop-growing) areas and are often good examples of vernacular architecture. Many redundant oasts have been converted into houses. The names oast and oast house are used interchangeably in Kent and Sussex. In Surrey, Hampshire, Herefordshire and Worcestershire they are called hop kilns. They consist of a rectangular one- or two-storey building (the "stowage") and one or more kilns in which the hops were spread out to be dried by hot air rising from a wood or charcoal fire below. The drying floors were thin and perforated to permit the heat to pass through and escape through a cowl in the roof which turned with the wind. The freshly picked hops from the fields were raked in to dry and then raked out to cool before being bagged up and sent to the brewery. The Kentish dialect word ''kell'' was sometimes used for kilns ("Th ...
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Pottery
Pottery is the process and the products of forming vessels and other objects with clay and other ceramic materials, which are fired at high temperatures to give them a hard and durable form. Major types include earthenware, stoneware and porcelain. The place where such wares are made by a ''potter'' is also called a ''pottery'' (plural "potteries"). The definition of ''pottery'', used by the ASTM International, is "all fired ceramic wares that contain clay when formed, except technical, structural, and refractory products". In art history and archaeology, especially of ancient and prehistoric periods, "pottery" often means vessels only, and sculpted figurines of the same material are called "terracottas". Pottery is one of the oldest human inventions, originating before the Neolithic period, with ceramic objects like the Gravettian culture Venus of Dolní Věstonice figurine discovered in the Czech Republic dating back to 29,000–25,000 BC, and pottery vessels th ...
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Brick
A brick is a type of block used to build walls, pavements and other elements in masonry construction. Properly, the term ''brick'' denotes a block composed of dried clay, but is now also used informally to denote other chemically cured construction blocks. Bricks can be joined using mortar, adhesives or by interlocking them. Bricks are usually produced at brickworks in numerous classes, types, materials, and sizes which vary with region and time period, and are produced in bulk quantities. ''Block'' is a similar term referring to a rectangular building unit composed of similar materials, but is usually larger than a brick. Lightweight bricks (also called lightweight blocks) are made from expanded clay aggregate. Fired bricks are one of the longest-lasting and strongest building materials, sometimes referred to as artificial stone, and have been used since circa 4000 BC. Air-dried bricks, also known as mud-bricks, have a history older than fired bricks, and have an addit ...
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Oven
upA double oven A ceramic oven An oven is a tool which is used to expose materials to a hot environment. Ovens contain a hollow chamber and provide a means of heating the chamber in a controlled way. In use since antiquity, they have been used to accomplish a wide variety of tasks requiring controlled heating. Because they are used for a variety of purposes, there are many different types of ovens. These types differ depending on their intended purpose and based upon how they generate heat. Ovens are often used for cooking, where they can be used to heat food to a desired temperature. Ovens are also used in the manufacturing of ceramics and pottery; these ovens are sometimes referred to as kilns. Metallurgical furnaces are ovens used in the manufacturing of metals, while glass furnaces are ovens used to produce glass. There are many methods by which different types of ovens produce heat. Some ovens heat materials using the combustion of a fuel, such as wood, coal, or natu ...
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Brickworks
A brickworks, also known as a brick factory, is a factory for the manufacturing of bricks, from clay or shale. Usually a brickworks is located on a clay bedrock (the most common material from which bricks are made), often with a quarry for clay on site. In earlier times bricks were made at brickfields, which would be returned to agricultural use after the clay layer was exhausted. Equipment Most brickworks have some or all of the following: *A kiln, for firing, or 'burning' the bricks. *Drying yard or shed, for drying bricks before firing. *A building or buildings for manufacturing the bricks. *A quarry for clay. *A pugmill or clay preparation plant (see below). Brick making Bricks were originally made by hand, and that practice continues in developing countries and with a few specialty suppliers. Large industrial brickworks supply clay from a quarry, moving it by conveyor belt or truck/ lorry to the main factory, although it may be stockpiled outside before enter ...
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Charcoal Kilns, California
Charcoal is a lightweight black carbon residue produced by strongly heating wood (or other animal and plant materials) in minimal oxygen to remove all water and volatile constituents. In the traditional version of this pyrolysis process, called charcoal burning, often by forming a charcoal kiln, the heat is supplied by burning part of the starting material itself, with a limited supply of oxygen. The material can also be heated in a closed retort. Modern "charcoal" briquettes used for outdoor cooking may contain many other additives, e.g. coal. This process happens naturally when combustion is incomplete, and is sometimes used in radiocarbon dating. It also happens inadvertently while burning wood, as in a fireplace or wood stove. The visible flame in these is due to combustion of the volatile gases exuded as the wood turns into charcoal. The soot and smoke commonly given off by wood fires result from incomplete combustion of those volatiles. Charcoal burns at a higher temper ...
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Spelling Pronunciation
A spelling pronunciation is the pronunciation of a word according to its spelling when this differs from a longstanding standard or traditional pronunciation. Words that are spelled with letters that were never pronounced or that were not pronounced for many generations or even hundreds of years have increasingly been pronounced as written, especially since the arrival of mandatory schooling and universal literacy. Examples of words with silent letters that have begun to be often or sometimes pronounced include ''often'', ''Wednesday'', ''island'', and ''knife''. In addition, words traditionally pronounced with reduced vowels or omitted consonants (e.g. ''cupboard'', ''Worcester''), may be subject to a spelling pronunciation. If a word's spelling was standardized prior to sound changes that produced its traditional pronunciation, a spelling pronunciation may reflect an even older pronunciation. This is often the case with compound words (e.g., ''waistcoat'', ''cupboard'', ''for ...
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Lime (material)
Lime is a calcium-containing inorganic material composed primarily of oxides and hydroxide, usually calcium oxide and/or calcium hydroxide. It is also the name for calcium oxide which occurs as a product of coal-seam fires and in altered limestone xenoliths in volcanic ejecta. The International Mineralogical Association recognizes lime as a mineral with the chemical formula of CaO. The word ''lime'' originates with its earliest use as building mortar and has the sense of ''sticking or adhering''. These materials are still used in large quantities as building and engineering materials (including limestone products, cement, concrete, and mortar), as chemical feedstocks, and for sugar refining, among other uses. Lime industries and the use of many of the resulting products date from prehistoric times in both the Old World and the New World. Lime is used extensively for wastewater treatment with ferrous sulfate. The rocks and minerals from which these materials are derived, ty ...
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Calcination
Calcination refers to thermal treatment of a solid chemical compound (e.g. mixed carbonate ores) whereby the compound is raised to high temperature without melting under restricted supply of ambient oxygen (i.e. gaseous O2 fraction of air), generally for the purpose of removing impurities or volatile substances and/or to incur thermal decomposition. The root of the word calcination refers to its most prominent use, which is to remove carbon from limestone (calcium carbonate) through combustion to yield calcium oxide (quicklime). This calcination reaction is CaCO3(s) → CaO(s) + CO2(g). Calcium oxide is a crucial ingredient in modern cement, and is also used as a chemical flux in smelting. Industrial calcination generally emits carbon dioxide (), making it a major contributor to climate change. A calciner is a steel cylinder that rotates inside a heated furnace and performs indirect high-temperature processing (550–1150 °C, or 1000–2100 °F) within a contr ...
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Pyroprocessing
Pyroprocessing (from Greek Πυρος = ''fire'') is a process in which materials are subjected to high temperatures (typically over 800 °C) in order to bring about a chemical or physical change. Pyroprocessing includes such terms as ore-roasting, calcination and sintering. Equipment for pyroprocessing includes kilns, electric arc furnaces and reverberatory furnaces. Cement manufacturing is a very common example of pyroprocessing. The raw material mix ( raw meal) is fed to a kiln where pyroprocessing takes place. As with most industries, pyroprocessing is the most energy-intensive part of the industrial process. Recycling used nuclear fuel through pyroprocessing Argonne National Laboratory pioneered the development of pyrochemical processing, or pyroprocessing, a high-temperature method of recycling reactor waste into fuel, demonstrating it paired with the EBR-II and then proposed commercializing it in the Integral Fast Reactor. The latter was cancelled by the Clinton Adm ...
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