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home-made ceramic fiberboard? and what's the embodied energy?

 
pollinator
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Location: Massachusetts, 5a, flat 4 acres; 40" year-round fairly even
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I found the patent is abandoned for this.  Interesting.  (See below).

I was initially just trying to find out how guilty I shoudl feel for buying the materials for my rocket stove, as compared with how guilty I should feel for funding the gas company wiht a monthly donation.  Where's the tipping point where you get ahead?

...aaaand that led to the question of whether you could make this stuff at home.  Those chemical names SOUND simple enough...but ???




Process for producing ceramic fiber board
Abstract
In order to provide a ceramic fiber board which does not emit smoke and does not cause a problem of shedding of particles even when used in a high-temperature environment, the invention provides a method of producing a ceramic board which uses ceramic fibers containing Al2O3 and SiO2 as a raw material, in which a mixed liquid (Na2O×3SiO2) of SiO2 sol and water glass is used as an inorganic binder, in which weight ratio in terms of the solid contents of SiO2 and water glass is SiO2: 89 to 35% and water glass: 11 to 65%.
Images (4)
 
Classifications
C04B12/04 Alkali metal or ammonium silicate cements Alkyl silicate cements; Silica sol cements; Soluble silicate cements
View 5 more classifications
US20090321993A1
United States

Download PDF  Find Prior Art  Similar
InventorYohei FukinoCurrent Assignee ALMEDIO Inc
Worldwide applications
2006  JP 2007  WO US
Application US12/296,343 events
2006-05-08
Priority to JP2006128969A
2006-05-08
Priority to JP2006-128969
2007-05-07
Application filed by ALMEDIO Inc
2007-05-07
Priority to PCT/JP2007/059467
2008-10-07
Assigned to ALMEDIO, INC.
2009-12-31
Publication of US20090321993A1
Status
Abandoned
 
Joshua Myrvaagnes
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Source: https://patents.google.com/patent/US20090321993A1/en
 
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Adding Water Glass research here.

Water glass is a common name for sodium silicate, a chemical compound made from sodium oxide (\(Na_{2}O\)) and silica (silicon dioxide, \(SiO_{2}\)). The composition is more accurately represented as \((Na_{2}O)x\cdotp SiO_{2}\) or \(Na_{2}O\cdotp xSiO_{2}\), indicating a variable ratio of sodium oxide to silicon dioxide. The formula \(NaO\cdotp 3SiO_{2}\) mentioned in the query is a slightly incorrect representation of a particular ratio, typically written as \(Na_{2}O\cdotp 3SiO_{2}\). Key properties Composition: A colorless, crystalline solid or a clear, viscous liquid, often made by fusing sand and sodium carbonate (soda ash) at high temperatures.Solubility: Water glass is soluble in water, especially hot water, forming an alkaline solution. The solution becomes a hard, glass-like solid when it dries.Reactivity: In acidic solutions, the silicate ions react to form a hard, glassy silica gel. This property makes it useful as a bonding and sealing agent. Common uses Adhesive and cement: As a strong, high-temperature adhesive for paper, cardboard, ceramics, and more. It's also used in refractory cements for applications involving high heat.Concrete sealer and soil stabilizer: To reduce the porosity of concrete and masonry products, making them more durable and water-repellent. It is also used to stabilize soil during construction.Egg preservation: A traditional method for preserving fresh eggs by sealing the pores of the shell to prevent bacteria from entering.Detergents: Added as a builder in laundry and dish detergents, where its alkalinity helps in removing fats and oils.Engine repair: Used as a temporary fix for leaking head gaskets. The heat from the engine causes it to form a glass seal. The specific properties of water glass can be adjusted by altering the ratio of silica to sodium oxide, allowing it to be used for a wide range of industrial and consumer applications. 

You can convert sodium bicarbonate (baking soda) into sodium carbonate (washing soda) by heating it in an oven or on a stovetop. This process, called thermal decomposition, drives off carbon dioxide and water from the sodium bicarbonate, leaving behind the more alkaline sodium carbonate. A common method is to bake it at around 200°C (400°F) for an hour, spreading it evenly on a baking sheet.
Steps to Convert Sodium Bicarbonate to Sodium Carbonate
Preheat the oven: Set your oven to a temperature of about 200°C (400°F).
Spread the baking soda: Pour a layer of sodium bicarbonate onto a baking sheet.
Bake: Place the baking sheet in the preheated oven for approximately 30 minutes to 1 hour.
Stir (optional but recommended): Stir the baking soda once or twice during baking to ensure all of it reacts evenly.
Observe the reaction: You will see the baking soda puff up and hear bubbling as water and carbon dioxide are released.
Check for completion: The conversion is complete when the bubbling and gas release stops, indicating all the sodium bicarbonate has been converted to sodium carbonate.
Cool and use: Let the baked baking soda cool, and it will now be sodium carbonate.
Chemical Reaction
The chemical reaction that occurs during this process is:
2 NaHCO₃(s) → Na₂CO₃(s) + H₂O(g) + CO₂(g)

To make molten sodium carbonate, you must heat the anhydrous salt to at least its melting point, which is 851 °C (1,564 °F). Heating it above this temperature will result in molten sodium carbonate, though it can decompose at very high temperatures, so temperatures around 900-1000 °C are often used for processes like molten salt oxidation.
Key points
Melting Point
: The precise temperature for sodium carbonate to become a liquid (molten) is 851 °C.
Anhydrous Form
: This melting point applies to anhydrous (without water) sodium carbonate.
Decomposition
: Sodium carbonate will decompose at sufficiently high temperatures, so it does not have a boiling point.
Practical Uses
: In practical applications, such as molten salt oxidation, temperatures of 900-1000 °C are used to ensure the salt is fully molten and to facilitate the process.

Sodium silicate is made by reacting silica (silicon dioxide), often from sand, with a sodium source, such as sodium carbonate (soda ash) or sodium hydroxide (lye), at high temperatures. The most common method involves fusing silica and soda ash in a furnace to form a glass-like mass, which is then dissolved in water to create "water glass," an aqueous solution of sodium silicate. Alternatively, silica can be dissolved in a hot, concentrated solution of sodium hydroxide under pressure in an autoclave to produce the desired solution.  
Methods for Making Sodium Silicate
High-Temperature Fusion (Furnace Method)
Melting: Silicon dioxide (sand) and sodium carbonate (soda ash) are mixed and then heated to high temperatures, typically in a furnace.
Reaction: The silica melts and dissolves into the molten sodium carbonate, forming a glass-like solid.
Dissolving: This solid mass is then dissolved in water to create an aqueous solution of sodium silicate, known as water glass.
 
Skip LaCroix
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My previous statements were the results of googling and are not representative of personal knowledge or experience.
 
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Where I live, you can just buy sodium silicate by the gallon.
It often has trade names like rigidiser or water glass.
My local stove store also sells it mixed with fire clay to be used as a high temp glue.
 
I child proofed my house but they still get in. Distract them with this tiny ad:
List of Rocket Mass Heater Builders
https://permies.com/wiki/122347/List-Rocket-Mass-Heater-Builders
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