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The Ceramext® Process
The Ceramext® Process is a patent-pending, energy efficient technology capable of converting a wide variety of materials including coal, lignite, and biomass fly ash, bottom ash, slag, clays, volcanic ash and mine tailings into high-strength, low-porosity, industrial ceramics such as floor and roof tiles, brick, and other marketable construction products.
The Ceramext® process is a proprietary method generally based on vacuum extrusion at elevated temperatures. While conventional ceramic extrusion processes are based on plasticity developed from the use of wet clay at ambient temperatures, the Ceramext® extrusion process derives plasticity by the formation of a liquid phase in the material at high temperature. The raw material is fed into the extruder, heated within it to a plastic state, and extruded through a shaped die. It can therefore utilize a very wide variety of raw materials, including those that are considered waste materials, such as coal fly ash, incinerated garbage ash, and mine tailings which are currently disposed of in expensive landfills.
Golden Bear Ceramics has constructed a pilot plant in Grass Valley, California to demonstrate the technology. Preliminary engineering studies completed to date indicate low capital and operating costs in comparison to conventional industrial ceramic operations.
