Clay Mixing Process and Stress Release Control in Brick Plants - FAQ

Q1: Is all internal stress eliminated after raw material crushing?
No. Crushing transforms large materials into finer particles, releasing some structural stress, but residual stress remains inside micro-particles, which requires further release during subsequent processes.

Q2: What is the essential function of water mixing in brick production?
1. It activates clay plasticity by forming flocculated structures;
2. Promotes particle breakdown, releasing internal residual stress;
3. Ensures uniform water-material combination, improving forming adaptability.

Q3: How to understand flocculation in clay mixing intuitively?
Flocculation is like childhood mud play: when cohesive soil mixes with water, particles entangle, creating a gel-like plastic mass. In contrast, pure sand lacks fine cohesive particles, so water cannot form plastic mud.

Q4: What are common mistakes in water mixing?
1. Using direct water streams instead of controlled spraying;
2. Poor positioning of water inlets, shortening effective mixing time;
3. Skipping secondary or final mixing, leading to incomplete mud structure.

Q5: What are the standards for proper water mixing?
1.  Use spraying systems to distribute water evenly;
2. Maximize the effective length of mixers for uniform blending;
3. Ensure primary mixing (water-material combination), secondary mixing (mud refinement), and final mixing (before forming) are all implemented.

Q6: Does clay plasticity depend on water temperature and mechanical force?
Yes:
1. Hot water or steam accelerates clay particle expansion and stress release;
2. Mechanical kneading, pressing, and cutting improve mud structure density and uniformity.

Q7: Why does water demand increase in winter compared to summer?
In winter, low temperatures increase mud hardness and reduce plasticity. Higher water content or warm water improves workability, similar to how dough becomes softer when mixed with warm water.

Q8: How to optimize mixing by using hot water or steam?
1. Hot water increases molecular activity, accelerating internal water diffusion and particle breakdown;
2. Steam pre-heats clay, reduces structural stress, enhancing formability;
3. Follows the same principle demonstrated in basic experiments showing faster diffusion in hot water than cold.

Q9: What insights do traditional clay preparation and ceramic processes offer to modern brick making?
1. Traditional clay kneading and ceramic refinement reflect the importance of stress release and plasticity enhancement;
2. Although red brick production appears simpler, water mixing remains critical to ensure clay quality and forming success.