“The Effects of Variable Extrusion Moisture on Extrusion,

Drying, and Fired Physical Properties of a Shale Body and

How Extrusions Aids Can Effect the Properties”Harold B. Newman

Pine Hall Brick

Topics to be Discussed

• Variable Moisture Content-Factors• Green Strength Properties• Drying Shrinkage Properties• Cold Water Absorption Properties• Body Additives

Soda Ash Lignosulfonate

OUT OF CONTROL

COVERED STORAGE-Material Blending

Ground Material Moisture Content 2008-2011

56789

10111213141516171819202122232425

1 5 9 13 17 21 25 29 33 37 41 45 49 53 57 61 65 69 73 77 81 85 89 93 97 101

105

109

113

117

121

125

129

133

Perc

ent M

oist

ure

10 %

19 %19 %

10 %

Research Project

• Proportion Batches of Shale Variable Moisture Contents

• Mix for Constant Time Period• Extrude Lab Test Bars-Good Vacuum• Test Bars For Green Strength• Test Bars for Drying Properties• Fire Bars and Test for Shrinkage and

Absorption Properties

Add to Mixer

Add Controlled Amounts of Water

Constant Mixing Time 5 Min

Discharge Mixed Material

Check Consistency

Maintain Good Vacuum

Extrude Bars with Good Vacuum

Extruded Column

Cut Sample Bars for Testing

Test Bars

• Green weight• Dry weight• Column hardness• Green strength

Testing Green Strength

Record the Data

Recording the Sample WeightDetermine Moisture Content

Shale Body Green Strength Vs Extrusion Moisture

101520253035404550556065

18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26Moisture Content

Gre

en S

treng

th

ShaleSoda Ash

Lignosulfonate

Shale Mix Body Additions Green Strength Vs Extrusion Moisture Sensitivity

21 -24 % Linear Regression Lines

y = -11x + 290R2 = 0.9934

y = -12.2x + 305.5R2 = 0.9976

y = -4.4x + 128R2 = 0.9132

0

10

20

30

40

50

60

70

18 19 20 21 22 23 24 25Moisture Content

Gre

en S

tren

gth

Shale Mix - 11

Lignosulfonate Mix -4.4

Soda Ash Mix - 12.2

SHALE MIX BODY ADDITIONS GREEN STRENGTH

21 % AND 24 % EXTRUSION MOISTURE

0

10

20

30

40

50

60

70

GR

EEN

STR

ENG

TH

21% Moisture 60 34 5024% Moisture 27 21 13

SHALE .25 % AA .2% S ASH

Shale Body Dry Shrinkage Vs Moisture Content

00.5

11.5

22.5

33.5

44.5

55.5

6

18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26Moisture Content

Perc

ent S

hrin

kage

Shale

Ligno

Soda Ash

SHALE MIX BODY ADDITIONS PERCENT DRY SHRINKAGE

21% AND 24 % EXTRUSION MOISTURE

0

1

2

3

4

5

6

PER

CEN

T SH

RIN

KA

GE

21% Moisture 2.9 3.46 3.8524% Moisture 4.4 4.8 4.7

SHALE .25 % AA .2% S ASH

Shale Body Dry Strength Vs Extrusion Moisture

0

50

100

150

200

250

300

350

400

18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26Moisture Content

Dry

Str

engt

h Shale

Soda Ash

Lignosulfonate

SHALE MIX BODY ADDITIONS DRY STRENGTH

21 % AND 24 % EXTRUSION MOISTURE

050

100150200250300350400

STR

ENG

TH P

OU

ND

S

21 % Moisture 230 275 33524 % Moisture 180 280 280

SHALE .25 % Lig .2% S ASH

Shale Body Cold Water Absorption Vs Extrusion Moisture

44.5

55.5

66.5

77.5

88.5

99.510

18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26Moisture Content

Perc

ent

Shale

Lignosulfonate

Soda Ash

SHALE MIX BODY ADDITIONS 24 HR COLD WATER ABSORPTION

21 % AND 24 % EXTRUSION MOISTURE

0123456789

PER

CEN

T A

BSO

RPT

ION

21 % Moisture 6 5.7 624 % Moisture 7.75 7.25 6.9

SHALE .25 % Lig .2 %S ASH

Shale Body Total Shrinkage Vs Extrusion Moisture

55.5

66.5

77.5

88.5

99.510

18 18.5 19 19.5 20 20.5 21 21.5 22 22.5 23 23.5 24 24.5 25 25.5 26Moisture Content

Perc

ent

Shale

Lignosulfonate

Soda Ash

PLANT STUDY

Old PlantHand Hack

Tumbled Line16 Wide Kiln

Monitor Plant Conditions

• Moisture of Ground Dirt• Moisture of Dirt Fed to Pug Mill• Manual Water Addition Rate-Die Oil Pressure• Production Rate• Vacuum Level• Green Brick Moisture• Green Strength-Penetrometer• Additive Feed Rate

PLANT DATA DIRT FEED MOISTURE 3-4-09 TO 5-7-09

89

10111213141516171819202122

1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97 103

109

115

121

127

133

139

145

SAMPLES

PER

CEN

T M

OIS

TUR

E

11 %

19 %19 %

11 %

PLANT DATA MANUAL WATER ADDITION RATE GALLONS / MIN 3-4-09 TO 3-13-09

0123456789

10111213141516

33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33 33

3/4/09 3/5/09 3/6/09 3/9/09 3/10/09 3/12/09 3/13/09

GA

LLIN

S / M

IN

15 Gallons15 Gal

4 Gal

PLANT DATA EXTRUDED BRICK MOISTURE

3-4-09 TO 5-7-09

14.014.515.015.516.016.517.017.518.018.519.019.520.020.521.021.522.0

1 6 11 16 21 26 31 36 41 46 51 56 61 66 71 76 81 86 91 96 101

106

111

116

121

126

131

136

141

146

SAMPLES

PER

CEN

T M

OIS

TUR

E

20.5

16.5

PLANT DATA BRICK GREEN STRENGTH

3-4-09 TO 5-7-09

100110120130140150160170180190200210

1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97 103

109

115

121

127

133

139

145

SETS OF SAMPLES

POU

ND

S

195

110

PLANT DATAPENETROMETER READINGS

3-4-09 TO 5-7-09

0.00.51.01.52.02.53.03.54.04.55.05.56.0

1 7 13 19 25 31 37 43 49 55 61 67 73 79 85 91 97 103

109

115

121

127

133

139

145

SAMPLE SETS

CO

LUM

N H

AR

DN

ESS

5.5

2.0

5.5

2.0

THINGS OUT OF CONTROL

PLANT TEST CONTROLLED MOISTURE CONTENT TEST

GREEN STRENGTH VS MOISTURE CONTENT

100110120130140150160170180190

15 15.5 16 16.5 17 17.5 18 18.5 19 19.5 20 20.5 21

PERCENT MOISTURE CONTENT

GR

EEN

STR

ENG

TH

PLANT DATAVARIED MOISTURE CONTENT

GREEN STRENGTH VS PENETROMETER

100110120130140150160170180190200

2 2.5 3 3.5 4 4.5 5 5.5 6PENETROMETER

GR

EEN

STR

ENG

TH

PLANT TESTS CONTROLLED EXTRUSION MOISTURE

GREEN STRENGTH VS EXTRUDER AMPS

5060708090

100110120130140150160170180190200210

300 350 400 450 500 550 600AMPS

POU

ND

S

Action Taken

• Installed a Moisture Control System-In House • Monitor Incoming Dirt Feed Rate and Moisture

Content• Control Water Addition and Additive Feed Rate

Based on Incoming Dirt Feed Rate• Eliminated Manual Water Feed Adjustments• Control Moisture Feed Rate Based on

Automatic Continuous Penetrometer Readings

RESULTS

• Got Control of Extrusion Process Moisture Addition Rate Additive Feed Rate Production Rate

• Set Target Penetrometer Reading at 3.9• Improved Green Brick Quality• Improved Brick Hack Quality• Allowed Control of Drying Process

• Increased Recovery Rate by 5-7 %

Potential Value 6 % Increase in Recovery

• 40 Million Brick Production

• 2.4 Million Extra Brick to Sell

• Market Value $225 / M

• Increased Revenue $540,000

• 75 Million Brick Production

• 4.5 Million Extra Brick to Sell

• Market Value $225 / M

• Increased Revenue $1,012,500

Message to Sales

“We Got Extra Brick” “You Need to Sell Them”