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 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 consent does not extend to other kinds of copying, such as copying for general distribution, for advertising or promotional purposes, or for creating new collective 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