Method and apparatus for making continuous foam glass product

A continuous, moldless process for the manufacture of cellular ceramic product in which a foaming agent is added to a ceramic feed, said foaming agent requiring a temperature in excess of 500.degree. C. for activation, comprising:

• transporting a first amount of said ceramic feed through a first kiln section and heating said first feed amount in said first kiln section to a first temperature of at least 500.degree. C. but which is lower than said activation temperature;
• transporting said heated first feed amount into a second kiln section while transporting a second amount of said ceramic feed through said first kiln section and heating said second feed amount to said first temperature;
• adding foaming agent to said heated first feed amount after passage of said first feed amount through said first kiln section to form a mixture thereof;
• heating said mixture of foaming agent and said heated first feed amount to said activation temperature in said second kiln section for a time sufficient to form a first amount of foamed ceramic;
• transporting said first amount of foamed ceramic while it is at or above its softening point to a drawing kiln section while transporting said heated second feed amount into said second kiln section;
• adding foaming agent to said heated second feed amount after passage of said second feed amount through said first kiln section to form a mixture thereof;
• heating said mixture of foaming agent and said heated second feed amount to said activation temperature in said second kiln section for a time sufficient to form a second amount of foamed ceramic;
• and
• transporting said second amount of foamed ceramic while it is at or above its softening point to said drawing kiln section and forming said product from said first and second amounts of foamed ceramic.