Low density ceramics produced from paper recycling residuals

A method for making a lightweight aggregate comprising the steps of:

• providing a paper residual comprising
• from about 0.5 to about 99 percent, by weight, of at least one filler,
• from about 0 to about 20 percent, by weight, of a dye,
• from about 0 to about 10 percent, by weight, of an ink,
• from about 0.5 to about 99.5 percent, by weight, of paper fiber, and
• from about 0 to about 30 percent, by weight, of other components, based on a dry weight of the residual;
• forming the paper residual into a temporary shape;
• and
• firing the shaped paper residual to a temperature ranging from about 1850° F. to about 2900° F.

A method for making a ceramic material comprising the steps of:

• providing a paper residual comprising
• from about 0.5 to about 99 percent, by weight, of at least one filler,
• from about 0 to about 20 percent, by weight, of a dye,
• from about 0 to about 10 percent, by weight, of an ink,
• from about 0.5 to about 99.5 percent, by weight, of paper fiber, and
• from about 0 to about 30 percent, by weight, of other components, based on a dry weight of the residual;
• forming the paper residual into a temporary shape;
• firing the shaped paper residual to a temperature ranging from about 1850° F. to about 2900° F. and pulverizing the fired mass to form a lightweight aggregate;
• admixing a ceramic substance with the lightweight aggregate, the ceramic substance comprising up to about 90 percent, by weight, of the admixture, based on a dry weight of the admixture;
• forming the admixture into a desired shape;
• and
• firing the admixture to a temperature range from about 1850° F. to about 2900° F.;
• whereby sulfur-containing compounds are not substantially released during either of the two firing steps.