Mechanical Evaluation and Minerals Phases Identification of Fine and Coarse Okelele Block Clay Composites for Furnace Lining Application

Abstract

The suitability of fine and coarse Okelele clays as refractory raw materials for furnace lining application was investigated. The clay samples were crushed and pounded with a mortar and pestle to a particle size of 20 microns. 230 g each of fine clay was mixed with 50 mls of water inside a bowl and stirred thoroughly to form homogenous plastic paste. 10 g, 15 g, 25 g, 35 g and 45 g of coarse clay were added respectively to the 230 g of homogenous fine clay paste in different container. The fine and coarse clays composites weighing 240 g, 245 g, 255 g, 265 g and 275 g were respectively put in a mold of dimension 3 x 5 x 6 cm and air dried for 7 days. The samples were fired at temperature of 1200 oC for five hours using Carbolite Furnace. After cooling, the fine and coarse clay composites of 240 g and 245g were broken by the heat and composites blocks 255 g, 265g and 275g were hardened and remove for compressive test analysis. The fine and coarse clays were characterized using X-ray Diffractometer PW1830forminerals phases’ identification. The result of XRD shows that the clay was majorly composed of Quartz and Kaolinite with the traces of other minerals such as Smectile, Illite/Mica, Albite, Jarosite, Gypsum and Pyrite. The Kaolinite contains aluminum silicate (Al2O3·2SiO2) and Quartz has the silicon and oxygen atoms. The compressive strength test result judged the 275 g fire block of clays composite the best with the maximum force breaks of 7652 N with deflection of 3.734 mm and Young Modulus of 212 N/mm2 for the time to failure of 22 seconds. The results proved that Okelele clays are suitable as refractory material for furnace lining application.