FOAMED CLAY-WATER SYSTEMS FOR LEIGHTWEIGHT AGGREGATE PRODUCTION

A METHOD OF PRODUCING A LIGHTWEIGHT AGGREGATE BY THE FOAMING OF A CLAY SLIP AND STABILIZING IT IN THE FORM OF PELLETS IS DESCRIBED. THE CLAY-WATER SLIP WAS PREPARED USING A VARIABLE SPEED MIXER. SMALL ADDITIONS OF BALL CLAY WERE DESIRABLE TO IMPROVE THE DRY STRENGTH OF THE PELLETS PRODUCED. THE PELLETS WERE DRIED OVERNIGHT IN A CIRCULATING AIR DRIVER. THE FIRED PELLETS HAVE BULK DENSITIES OF 35-47 LB/FT. SATISFACTORY LIGHTWEIGHT AGGREGATE WAS OBTAINED FROM NONBLOATING MATERIALS BY THE FOAMED SLURRY PROCESS. THE ELIMINATION OF ADDITIVES, PRIOR PARTICLE SIZING, SPECIAL KILN EQUIPMENT WITH CAREFULLY CONTROLLED TEMPERATURE ZONES AS WELL AS KILN ATMOSPHERE CONTROL MAY BE POSSIBLE ADVANTAGES. THE METHOD OFFERS A MEANS OF PRODUCING LIGHTWEIGHT AGGREGATE FROM CLAYS, SHALES OR OTHER OXIDES WHICH ARE NOT NATURAL BLOATING MATERIALS.