Equipment

The equipment consists of machines in an extensive pilot plant, laboratories with devices for all ceramic analyzes and last but not least mobile analyzing instruments to help you on the spot.

Pilot Plant

The Keramikinstitut´s pilot plant consists of machines and facilities to simulate the most important details of any ceramics production facility – from raw materials preparation to firing. Combining production tests with meticulous scientific analytics enables us to answer questions on real production systems in a truly unique way.


Preparation

2 Spray-dryers (spray tower, spray granulator) Water evaporation capacity: approx. 60+120l/h
Minimum preparation: 100 kg solids
Ystral mixer (jetstream mixer) ceramic construction
Filter press (chamber filter press) Pressed quantity per cycle: 50 - 60 kg; Press pressure: 12 bar
2 Annular gap bead CoBall-Mills (Co. FrymaKoruma) MS12 and MS18 Middle grinding-chamber volume 0.5 l
Ball mill (rotary drum mill) Drum capacities: 40 l, 100 l, 250 l
Cylinder mill 4 - 6 mills with mill capacities from 5 - 10 l
Slip transport pump (diaphragm pump) Pumping capacity: 60 l/h
Agitator mill (Co. Netzsch) LMK4 Payload volume: ca. 3.6 l
Vacuum agitator Payload volume: ca. 30 l
Roller mill (roll grinder) Roller diameter 180 mm, width 190 mm Smallest possible gap width: ca. 0.8 mm
Granulating plate Plate diameter: 400 mm; Infinitely variable speed up to 400 rpm; Adjustable plate angle
Vibration disk mill Wet and dry micro-grinding of small quantities, tungsten carbide lining
Jaw crusher Grain size achievable: 1 mm
Disc mill (Co. Fritsch) Maximum charge particle size: 20 mm Grinding gap adjustment (product-dependent): 1.0 – 0.1 mm
Pin mill (pin beater mill, pin disintegrator) Throughput: 20 kg/h; exchangeable sieve trays
Turbo pulper Charge quantity: 50 l

Contact

Tom Scholz
+49 (0)3521/463-527

Mixing / Screening

Double shaft mixer (Twin-shaft mixer) Mixing chamber volumes: 20 l, 30 l with vacuum, Mixing chamber volume: 100 l
3 Eirich intensive mixer (Co. Eirich) Trough volume: 5 kg / 8 l; stainless steel construction;
Trough volume: 65 kg / 40 l; stainless steel construction;
Trough volume: 400 kg; stainless steel construction
Sieve drum mill Payload volume: ca. 30 l
Vibrating screen Variable sieve mounting

Contact

Dipl. Ing. Gero Stolle
+49 (0)3521/463-530

Forming

Die-casting plant (die casting machine, high-pressure die casting unit) Medium pressure range 40 bar; max. tool size 600 x 700 mm² (clamping area); Slip pre-warming possible
Vacuum extrusion press (extruder) PVPS20: max. mouthpiece diameter 200 mm; throughput ca. 2.5 t/h

PZVQRG-8a: screw diameter 80 mm; max. moulding pressure 80 bar; extruded profile with external dimensions of ca. 0.3 cm² to 50 cm²

V5: max. log diameter 33 mm; throughput 30 - 80 kg/h

V10HD: max. log diameter 60 mm; throughput 300 - 500 kg/h
Piston extruder KP 200A (piston press) horizontal or vertical use, pressure up to 280 bar, pressure head up to 155 mm, vacuum possible
Uniaxial press Pressing force: 160 t; press table size: 800 x 800 mm, top and bottom ram press

Contact

Dipl. Ing. Thomas Haake
+49 (0)3521/463-542

Drying

Climatic test chamber Temperature range -40 to 180°C, Variable humidity from 5 to 98 %, Capacity ca. 200l
Drying cabinet (convection dryer) Temperature range 20 to 250°C, Capacity 0.75 m³

Contact

Dipl. Ing. Gero Stolle
+49 (0)3521/463-530

Firing

Bottom-loading kiln (Lift-bottom furnace) Tmax: 1800°C
usable volume 250 x 200 x 200 mm (LxWxH)

Tmax: 1400°C
Tile fast firing – firing chamber for 2 tiles 250 x 200 mm
Gradient kiln Tmax: 1320°C
usable volume approx. 1000 x 150 x 75 mm (LxWxH) divided into 6 segments
Muffle kiln (Electric chamber kiln, laboratory sintering kiln, electric kiln) Tmax: 1400°C
usable volume approx. 400 x 400 x 400 mm (LxWxH)

Tmax: 1400°C
usable volume approx. 320 x 320 x 320 mm (LxWxH)

Tmax: 1750°C
usable volume approx. 300 x 170 x 220 mm (LxWxH)

Tmax: 1380°C
usable volume approx. 440 x 350 x 350 mm (LxWxH)
CTB-kiln
natural gas
Tmax: 1600°C
usable volume approx. 1000 x 450 x 600 mm (LxWxH)
Grün-kiln
(gas-fired chamber kiln, natural gas and liquefied gas)
Tmax: 1440°C
usable volume approx. 900 x 500 x 550 mm (LxWxH)

Contact

Dipl. Ing. Michael Bormann
+49 (0)3521/463-531

Pilot Plant: Sample Preparation / Testing Devices

Autoclave Pressure vessel volume: 2.75 l; max. operating pressure 60 bar

Pressure vessel volume: 110 l; max. operating pressure: 40 bar
Muffle kiln (Electric chamber kiln, Laboratory sintering kiln) Tmax: 1400°C
usable volume approx. 400 x 400 x 400 mm (LxWxH)

Tmax: 1400°C
usable volume approx. 320 x 320 x 320 mm (LxWxH)

Tmax: 1750°C
usable volume approx. 300 x 170 x 220 mm (LxWxH)

Tmax: 1750°C
usable volume approx. 190 x 300 x 250 mm (LxWxH)
Rapid moisture analyser Infra-red
Testing press (High-pressure testing press) max. pressure: 3000 kN
pressure-plate size 320 x 520 mm;
testing space height 320 mm
Vacuum test container Volume: 70 l
Weighing scales Weighing range up to 200 kg
Pallet truck with integrated weighing scales Weighing range up to 400 kg
Freezers Volume: 550 l / 870 l; automated program control
Cube grinding machine Surface grinding of areas up 250 mm in diameter
Clipper saw (diamond saw)  
Diamond-wire saw  

Contact

Tom Scholz
+49 (0)3521/463-527

Laboratories

Our laboratory equipment and our scientists’ skills enable us to carry out nearly all testing and investigation of ceramic raw materials, ceramic materials, ceramic products, and consumables. Only testing methods approved by relevant regulatory bodies are applied.


Laboratories: Preparation / Sample Preparation

Magnetic stirrer with or without heating
Mortar grinder agate lining
Rapid moisture analyser Infra-red
Vibratory sieve shaker 10 mm to 63 µm throw-action sieving
Planetary ball mill agate and SiN jar mill
Overhead shaker  
Pressure Filtration unit max. 8 bar
Centrifuge  
Vibrations mills agate, stainless special steel and tungsten carbide lining
Disc mill stainless special steel and zirconium disks, min. 0.5 mm
Planetary mono mill agate lining
Hydraulic press max. pressure 50 t
Laboratory stirrers  
Ultrasonic cleanser Various sizes

Contact

Tom Scholz
+49 (0)3521/463-527

Laboratories: Drying / Firing

Drying cabinets Tmax: 250°C max. capacity 115 l
Vacuum drying cabinet Tmax: 260°C max. capacity:50 l
Muffle kiln Tmax: 1400°C
usable volume approx. 400 x 400 x 400 mm (LxWxH)

Tmax: 1400°C
usable volume approx. 320 x 320 x 320 mm (LxWxH)

Tmax: 1750°C
usable volume approx. 300 x 170 x 220 mm (LxWxH)

various sizes and maximum temperatures available, programmable

Contact

Dipl. Ing. Gero Stolle
+49 (0)3521/463-530

Laboratories: Analysis / Test Equipment

Weighing scales Weighing range up to 12000 g
Testing machine for flexural and compressive strenth Force messuring: 1 kN, 10 kN
Testing machine for particle density  
Specific surface area (Areameter) Measurement range: 0,1 - 1000 m²/g
Testing machine for surface abrasion Abrasimeter: variable rotation max. 12000 (DIN EN 10545)
Grinding wheel (Böhme)  
Mercury Intrusion Porosimeter Pore size: 4 nm - 116 µm pressure: max. 4000 bar
Reflectoneter (Measuring unit for determining the gloss) Standard angle: 20°, 60°, 80° and combinations, Test area: 90 x 35 mm
Rheometer (Gallenkamp) wire: 24, 26, 30, 32, 34, 36 SWG
Viscosity cup nozzles according to Lehmann: 1,13; 1,6; 2,26; 3,2; 4,51; 6,38 mm
according to Keyl: 2; 3; 4; 5; 6; 8 mm
X-ray spectrometer (RFA, RFS) chemical composition of solids and powders, elements F to Pb, 10 ppm to 100%
X-ray diffractometer
(RDA, XRD; RFS)
phase composition of solids and powders, special anlysis of clay minerals, more than 100 preparation of standards of all regions from oxidic materials, quality analysis with ICCD Powder Diffraction File
carbon analyser
(TOC, TIC, TC)
infrared spectroscopy, determination of total carbon, organic und inorganic carbon of solids and powders, tube furnace to 1500°C
measuring range: 0,01 bis 100 %C
Thermogravimetry (TG) / differential thermal analysis (DTA) Temperature range: room temperature to 1600°C;
heating rate: 0,001 bis 50 K/min;
atmosphere: static, dynamic, inert, oxidizing or reducing
Dilatometer Temperature range: room temperature to 1600°C;
heating range: 0,01 bis 50 K/min;
atmosphere: static, dynamic, inert, oxidizing or reducing
Low Temperature Dilatometer Temperature range: -170 to 1000°C;
heating range: 0,01 bis 50 K/min;
atmosphere: static, dynamic, inert, oxidizing or reducing
Hot Stage Microscope Temperature range: room temperature to 1500°C;
heating range: 1 bis 50 K/min;
video evaluation
SediGraph measuring range: 0,1 - 250 µm
2 Laser Granulometer measuring range: 0,2 bis 2000 µm
Color meters Spectrophotometer with gloss trap
Scanning electron microscope with EDX-spectrometer; all elements from atomic number 6 to 92
Stereo microscope with digital image aquisition; 100x magnification
Digital microscope VHX 5000 high depth of focus; 2D- and 3D-view; images with up to 200x magnification + additional digital magnification; panoramic view (stitching); measuring options (up to 30 different options for 2D- and 3D-measurements); cross-section measurements on any surface
Test dishwasher According to DIN 12875-1

Contact

Dipl. Ing. Gero Stolle
+49 (0)3521/463-530

Mobile Devices

For the first-time operation and the optimization of production facilities the Keramikinstitut has all mobile devices available that are necessary for a successful help on the spot.


Mobile Devices for On-site Application

Datapaq Data logger Temperature logging up to 1600°C for thermal element type K or type B
Datapaq 21 Data logger with radiot- elemetry Online temperature logging up to 1200°C for thermal element type K
CeriDRY Data logger for simultaneous measurement of humidity from 5-99% Temperature 0-140°C Shrinkage 0-20mm and %
Ultramat 20 and 23 Atmospheric measurement O2, CO, CO2
Testo atmospheric measurement Atmospheric measurement O2, CO, CO2 with simultaneous temperature measurement up to 1200°C
Testo flow measurement 0-40 m/s
Thermal element calibration SE1200 Calibration temperature 300°C-1205°C

Contact

Michael Bormann
+49 (0)3521/463-531