Table Of ContentCeramic
Engineering
& Science
Proceedings
MAY-JUNE 1992
Proceedings of the
53rd Porcelain Enamel Institute
Technical Forum
Anthony R. Mazzuca
Conference Director
November 6-7, 1991
Ft. Mitchell, KY
Published for
The Porcelain Enamel Institute
bY
The American Ceramic Society
Westerville, OH 43081-6136
Copyright 0 1992
The American Ceramic Society
and The Porcelain Enamel Institute, Inc.
ISSN 01 966219
Ceramic
Engineering
& Science
Proceedings
MAY-JUNE 1992
Proceedings of the
53rd Porcelain Enamel Institute
Technical Forum
Anthony R. Mazzuca
Conference Director
November 6-7, 1991
Ft. Mitchell, KY
Published for
The Porcelain Enamel Institute
bY
The American Ceramic Society
Westerville, OH 43081-6136
Copyright 0 1992
The American Ceramic Society
and The Porcelain Enamel Institute, Inc.
ISSN 01 966219
Executive Director Editor
W. Paul Holbrook John Wachtrnan
B.
Director of Publications Production Assistant
Linda S. Lakemacher Lori A. Kozey
Committee on Publications: Delbert Day, chair; Richard Hommel; J.T. Adrian
Roberts; David W. Johnson, Jr., ex officio; John B. Wachtman, ex officio; David
Green, ex officio; W. Paul Holbrook, ex officio.
Editorial and Subscription Offices: 735 Ceramic Place, Westerville, Ohio,
43081-6136. Subscription $69 a year; single copies $15 (postage outside U.S. $5
additional). Published bimonthly. Printed in the United States of America. Allow
four weeks for address changes. Missing copies will be replaced only if valid
claims are received within four months from date of mailing. Replacements will not
be allowed if the subscriber fails to notify the Society of a change of address.
CESPDK Vol. 13, NO. 5-6, pp. 1-11 8, 1992
The American Ceramic Society assumes no responsibility for the statements and
opinions advanced by the contributors to its publications, or by the speakers at its
programs. The opinions expressed are not necessarily those of the Society, its
trustees and officers, its staff, or its general membership.
Copyright 0 1992, by the American Ceramic Society. Permission to photocopy for
personal or internal use beyond the limits of Sections 107 and 108 of the U.S.
Copyright Law is granted by the American Ceramic Society for libraries and other
users registered with the Copyright Clearance Center, provided that the fee of
$2.00 per copy of each article is paid directly to CCC, 21 Congress Street, Salem,
MA 01970. The fee for articles published before 1991 is also $2.00 per copy. This
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works. Requests for special permission and reprint requests should be addressed
to the Reprint Dept., The American Ceramic Society (019 6-621 9/91 $2.00).
Each issue of Ceramic Engineering and Science Proceedings includes a
collection of technical articles in a general area of interest. These articles are of
practical value for the ceramic industries and the general public. The issues are
based on the proceedings of a conference, Both American Ceramic Society and
non-Society conferences provide these technical articles. Each issue is organized
by an editor who selects and edits material from the conference proceedings. The
opinions expressed are entirely those of the presentors. There is no other review
prior to publication .
Comments by the Technical Forum Chairman
As I complete my two-year term as Chairman of PEI’s Technical Forum
Committee, I want to thank all those who have contributed so much
toward making these two events-the 1990 Technical Forum in Nashville
and the recent 1991 Technical Forum held in Fort Mitchell, Kentucky-
so successful. It has been an honor and a real pleasure for me to serve
as your Chairman.
I am grateful to many people, especially to my Vice Chairman Doug
Giese and to every member of the large committee that came up with
program format, selected the individual topics for papers, and then
lined up the authors who prepared and presented the excellent papers.
Our thanks also go out to all speakers and panelists for the time and
effort they put into preparing their papers and in presenting them at the
Technical Forum.
These Proceedings, the 53rd in the series that began in 1937, add to
the earlier volumes to make up what I believe to be the best record of
our industry’s progress and development over more than five decades.
I hope you agree that this year’s edition is a worthy addition to the
others.
As with every Technical Forum, this year’s program aimed to give
attention to those topics of greatest interest and practical value to those
responsible for assuring quality porcelain enamel products. The subject
of clean-only systems was featured as more and more of the industry
moves to this method of metal preparation.
Receiving much attention again this year was the subject of
porcelain enamel powder processing, certainly already established as the
industry’s most significant innovation during the last two decades. At
the same time, new slants on the enameling of cast iron-ur industry’s
oldest process-were reported in a special session.
...
111
Other subjects covered include energy savings, steels for porcelain
enameling, waste minimization, environmental affairs and plant safety,
industry technical programs, materials and processing advances,
marketing, and press room guidelines.
A special feature involved worldwide porcelain enameling with
reports by registrants from outside the United States on plant operations
and products being porcelain enameled in their countries.
I hope to see you at the 1992 Technical Forum, which will be held
in Nashville in September, with Doug Giese as your new Chairman.
Anthony R. Mazzuca, Mobay Corp.
Chairman, 1991 Technical Forum Committee
iv
Table of Contents
53rd Porcelain Enamel Institute Technical Forum
...............................
Errata and Retraction 1
..............
Effect of Neutralizers on Clean-Only Systems 3
Robert L. Hyde
A Checklist for Your Clean-Only System: Equipment,
........................
Controls, and Processing Cycles 7
Hank Arnold
...............
Plant Experiences with Clean-Only Systems 11
David F. Thomas
............
Pumping Dry Porcelain Enamel-A Case History 15
Gerald W. Crum
....................
Powder Porcelain in a World Market 22
William L. Rauch
.............
Update on Electrostatic Dry Porcelain Powder 27
James M. Enright
................
Black Cover Coat Powder Enamel Systems 30
Cynthia J. Labant
...........
Wet to Powder Porcelain Ground Coat Conversion 33
Walt Skovron
Using Natural Gas Futures to Manage Your Natural
.....................................
Gas Supplies
36
Brian McLaughlin
Observations on Transportation of Wellhead
..................
Gas-The Local Utility Company’s Role
37
Tom Hollis
.........
Reducing Utility Costs with Open Market Electricity 38
Kevin S. Songer
Steelmaking-A Videotape Produced by the American
.............................
Iron and Steel Institute 39
Larry L. Steele
V
Observations on Steelmaking and Steels for Porcelain
..........................
Enameling-A Panel Session 41
Otto Ehrsam, Rusty Rarey, Dick Rogich, and Larry L. Steele
.......
Observations on the Cookware Industry in the Far East 47
Floyd J. Williams
....................
Overview of PEI Technical Programs 53
Jeffrey F. Wright
..........
Report of the PEI Furnace Atmosphere Committee 57
John K. Cook
.....
Reports on Current Technical Programs-A Panel Session 60
Larry L. Steele, Timothy R. Rugh, and Joel Stein
.....
Equipment for Handling and Recycling Enamel Materials 63
Lester N. Smith
........
Total Quality Environmental and Safety Management 65
James J. Carleton
.........................
Current Environmental Issues 71
Jack E. Waggener
...........................
PEI’s Marketing Programs 76
Cullen Hackler
.......................
What Happens When You Cook? 80
William D. Faust
..............
Techniques for Solving Press Room Problems 86
Victor P. Smith
.............
Ready-to-Use Wet Cover Coat Enamel System 90
Ann M. Lynch
A Study of Glass Compositions Suitable for Cast
............................
Iron Enamel Applications 94
Amy M. Grimes
...................
High-Quality Cast Iron Enamel Ware 99
Robert J. Long
.......
Wet Process Porcelain Enameling of Cast Iron Grates 103
Gregory R. Prinzbach
..............
1991 PEI Technical Forum Attendance List 114
vi
Ceram. Eng. Sci. Proc.
13[5-6] pp. 1-2 (1992)
Errata and Retraction
Bentone as a Clay Substitute
Robert L. Hyde
Ceram. Eng. Sci. Proc., 12 [5-6] 759-767 (1991)
and
Proceedings of the 1990 Porcelain Enamel Institute Technical Forum
Several errors appear in the above article which merit its retraction.
In the article, the name Bentone was incorrectly stated to be a trade
name for the mineral hectorite. Bentone is a registered trademark of
Rheox Corporation (Hightstown, New Jersey) for a family of rheologi-
cal additives, many of which do not contain hectorite. For the purpose
of the above paper, only Bentone EW was used. This material is the
mineral hectorite containing a certain amount of polymeric additive.
The compositions of bentonite and hectorite as listed in the article are
incorrect. The composition for bentonite, for example, is SiO,, 65.47%;
A1,0,, 23.15%; MgO, 3.66%; Na20, 2.81%; and H20, 4.91% on a weight
basis. Bentonite is principally an aluminum silicate with some
substitution of magnesium for aluminum, whereas hectorite is princi-
pally a magnesium silicate with some substitution of lithium for
magnesium.
Figure 7 in the paper represents the effect of aging on the viscosity
of slips formulated with Bentone EW additive. When aged at a
temperature of 120"F, this change in apparent viscosity as a function of
time may be due to the presence of the polymeric additive or other
unexplained factors and is not a true indication of how untreated
hectorite might behave. No further effort was made to determine the
reason for this change in viscosity. This was not explained in the paper
and would allow the reader to incorrectly conclude that hectorite was
unstable at elevated temperatures.
Figure 8 in the paper is a plot of viscosity as a function of time at
a constant shear rate and is not a true measure of thixotropy, as was
stated in the article. In order to show true thixotropy, a hysteresis
curve of viscosity as a function of increasing and decreasing shear rate
should have been plotted as is indicated by several authoritative articles
on the rheology of suspensions.
In conclusion, the statement "Bentone has questionable value as a
suspension agent" is not correct and is retracted. Bentone rheological
additives are known and sold worldwide and they are well suited for
1
many applications, including as suspension agents. Bentone EW has
been successfully used in many formulations, especially in combination
with clay, with good results.
A. Stroucken
Vice President
Miles Inc.*
8
As of January 1, 1992, all Mobay business began operation under Miles Inc.
2
