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Properties of Ugandan minerals and fireclay refractories
KTH, School of Industrial Engineering and Management (ITM), Materials Science and Engineering.
2005 (English)Doctoral thesis, comprehensive summary (Other scientific)
Abstract [en]

Development of products which can be produced from a country’s natural resources is very important as far as the industrialization of a nation and saving foreign exchange is concerned. Presently, industries in Uganda and the other states in the Lake Victoria region import all refractory-related-consumables, as the demand cannot be met locally. Based on the abundance of ceramic raw materials for high temperature applications in the region and the demand for refractories by industries it is pertinent to develop and manufacture firebricks by exploiting the locally available raw materials.

This thesis thus, concerns the characterisation of ceramic raw mineral powders from the Lake Victoria region, more particularly, Uganda, with the aim of developing firebrick refractories from the minerals. Two main deposits of kaolin and a ball clay deposit were investigated to assess their potential in the manufacture of refractory bricks. Raw- and processed sample powders were investigated by means of X-ray diffraction (XRD), thermal analysis (DTA-TG) and Scanning Electron Microscopy (SEM). In addition, the chemical composition, particle size distribution, density, and surface area of the powders were determined.

A comprehensive study on beneficiation of Mutaka kaolin was carried out using mechanical segregation of particles. The aim of the study was to explore other potential applications like in paper filling and coating. The beneficiation process improves the chemical composition of kaolin to almost pure, the major impurity being iron oxide.

A general production process scheme for manufacturing fireclay bricks starting with raw powder minerals (Mutaka kaolin and Mukono ball clay) was used to make six groups of sample fireclay brick. Experimental results from the characterization of formulated sample bricks indeed revealed the viability of manufacturing fireclay bricks from the raw minerals. Based on these results, industrial samples were formulated and manufactured at Höganäs Bjuf AB, Sweden. Kaolin from the Mutaka deposit was used as the main source of alumina while ball clay from Mukono was the main plasticizer and binder material. The formulated green body was consolidated by wet pressing and fired at 1350°C in a tunnel kiln. Characterization of the sintered articles was done by X-ray diffraction, scanning electron microscopy, and chemical composition (ICP-AES). In addition, technological properties related to thermal conductivity, thermal shock, alkali resistance, water absorption, porosity, shrinkage, permanent linear change (PLC), linear thermal expansion, refractoriness under load (RUL), and cold crushing strength were determined. The properties of the articles manufactured from the selected naturally occurring raw minerals reveal that the produced articles compare favourably with those of parallel types. Thus, the raw materials can be exploited for industrial production.

Place, publisher, year, edition, pages
Stockholm,: KTH , 2005. , viii, 42 p.
Keyword [en]
Materials science, kaolin; clay; Ugandan minerals; fireclay; refractory, powders characterization, beneficiation, ceramics, mullite
Keyword [sv]
Materialvetenskap
National Category
Materials Engineering
Identifiers
URN: urn:nbn:se:kth:diva-225ISBN: 91-7178-083-1 (print)OAI: oai:DiVA.org:kth-225DiVA: diva2:7958
Public defence
2005-06-03, Sal B2, Briellvägen 23, Stockholm, 10:00
Opponent
Supervisors
Note
QC 20101029Available from: 2005-05-27 Created: 2005-05-27 Last updated: 2010-11-01Bibliographically approved
List of papers
1. State of the art paper on development and manufacture of firebrick refractories from locally available alumnia-rich clays in Uganda.
Open this publication in new window or tab >>State of the art paper on development and manufacture of firebrick refractories from locally available alumnia-rich clays in Uganda.
2003 (English)Report (Other academic)
Publisher
61 p.
National Category
Materials Engineering
Identifiers
urn:nbn:se:kth:diva-25742 (URN)KTH/MSE-03/71-SE+MEK/TR (ISRN)
Note
QC 20101029Available from: 2010-10-29 Created: 2010-10-29 Last updated: 2010-10-29Bibliographically approved
2. Powder characterization of high temperature ceramic raw materials in the Lake Victoria Region.
Open this publication in new window or tab >>Powder characterization of high temperature ceramic raw materials in the Lake Victoria Region.
2005 (English)In: Silicates industriels, ISSN 0037-5225, Vol. 70, no 10-sep, 127-134 p.Article in journal (Refereed) Published
Abstract [en]

Two main deposits of kaolin and one of fireclay, located in the Lake Victoria Region, Uganda, were investigated to assess their potential in the manufacture of refractory bricks. Raw- and processed sample powders were investigated by means of x-ray diffraction (XRD), thermal analysis (DTA-TG) and Scanning Electron Microscopy (SEM). In addition, the chemical composition, particle size distribution, density, and surface area of the powders were determined.

Keyword
X-ray methods, electron microscopy, clays, refractories, kaolin deposit, central uganda, clay, mineralogy, behavior, origin
National Category
Materials Engineering
Identifiers
urn:nbn:se:kth:diva-14999 (URN)000231522200001 ()2-s2.0-33745130697 (Scopus ID)
Note
QC 20100525Available from: 2010-08-05 Created: 2010-08-05 Last updated: 2017-12-12Bibliographically approved
3. Production of Fireclay Refractories from Kaolinitic Clays of the Lake Victoria Region.
Open this publication in new window or tab >>Production of Fireclay Refractories from Kaolinitic Clays of the Lake Victoria Region.
2004 (English)In: Journal of the Australian Ceramic Society, ISSN 2510-1560, Vol. 40, 12-19 p.Article in journal (Other academic) Published
National Category
Materials Engineering
Identifiers
urn:nbn:se:kth:diva-25747 (URN)
Note

QC 20101029

Available from: 2010-10-29 Created: 2010-10-29 Last updated: 2017-04-12Bibliographically approved
4. Laboratory Benefication And Evaluation of Mutaka Kaolin from the Lake Victoria Region, Uganda
Open this publication in new window or tab >>Laboratory Benefication And Evaluation of Mutaka Kaolin from the Lake Victoria Region, Uganda
(English)In: Applied Clay Science, ISSN 0169-1317, E-ISSN 1872-9053Article in journal (Other academic) Submitted
National Category
Materials Engineering
Identifiers
urn:nbn:se:kth:diva-25751 (URN)
Note
QS 20120327Available from: 2010-10-29 Created: 2010-10-29 Last updated: 2017-12-12Bibliographically approved
5. Fireclay refractories from Ugandan kaolinitic minerals
Open this publication in new window or tab >>Fireclay refractories from Ugandan kaolinitic minerals
2006 (English)In: Steel Research International, ISSN 1611-3683, E-ISSN 1869-344X, ISSN 1611-3683, Vol. 77, no 8, 531-536 p.Article in journal (Refereed) Published
Abstract [en]

In the present work, two deposits, one of kaolin and the other of ball clay, located in Uganda were investigated for the possibility of manufacturing fireclay refractories. Kaolin from the Mutaka deposit was used as the main source of alumina while ball clay from Mukono was the main plasticizer and binder material. The formulated green body was consolidated by wet pressing and fired at 1350 degrees C in a tunnel kiln. Characterization of the sintered articles was done by X-ray diffraction, scanning electron microscopy, and chemical composition (ICP-AES). In addition, technological properties related to thermal conductivity, thermal shock, alkali resistance, water absorption, porosity, shrinkage, permanent linear change, linear thermal expansion, refractoriness under load, and cold crushing strength were determined. The properties of the articles manufactured from these naturally occurring raw minerals reveal that they compare favorably with those of parallel types. Thus, the raw materials can be exploited for industrial production.

Keyword
fireclay refractory, kaolin, clay
National Category
Materials Engineering
Identifiers
urn:nbn:se:kth:diva-15957 (URN)000240182900001 ()2-s2.0-33748313398 (Scopus ID)
Note

QC 20100525

Available from: 2010-08-05 Created: 2010-08-05 Last updated: 2017-12-12Bibliographically approved

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