Laterite Clay For Refractory Material

DEVELOPMENT OF A REFRACTORY MATERIAL FROM LATERITE OF
AJEGUNLE IN LAGOS FOR FURNACE LINING APPLICATIONS
M.ENG ORAL EXAMINATION

BY
BALOGUN TEMITOPE OLUWAPELUMI

(MME/08/3593)
SUBMITTED TO:
DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING,

SCHOOL OF ENGINEERING AND ENGINEERING TECHNOLOGY,
FEDERAL UNIVERSITY OF TECHNOLOGY, AKURE.
SUPERVISED BY: DR. S.O SEIDU
APRIL, 2019
OUTLINE
 Introduction
 Statement of Problem
 Research Background
 Aim
 Objectives
 Scope of the Research
 Contribution to knowledge
 Research Methodology
 Results
 Conclusion
INTRODUCTION
Laterite is a soil and rock type
rich in iron and aluminum, and is
commonly considered to have
formed in hot and wet tropical
areas. Nearly all laterites are of
rusty-red coloration, because of
high iron oxide content. They
develop by intensive and long-
lasting weathering of the
underlying parent rock.
(Bourman, 1993).
Laterite: weathered rock found in tropical and subtropical
humid regions of the world.
REFRACTORY MATERIAL
 A material having the ability to retain its physical

shape and chemical identity when subjected to
high temperatures.
 Refractories are inorganic, nonmetallic, porous and
heterogenous materials composed of thermally
stable mineral aggregrates, a binder phase
additives.
 Refractories are heat resistant materials used in all
processes involving high temperatures and/or
corrosive environment.
STATEMENT OF PROBLEM
.
Most refractory lining won’t last for more than 3-5

melting cycle, as a matter of fact, degradation of
refractories in use is inevitable. Normal procedure
in industry is that refractories in a kiln are
controlled and/or replaced at a regular basis
during planned maintenance shut-downs.
Hence this project work is based on how Laterite
clay can be adapted for refractory application
without failure and how additives such as saw
dust, graphite can enhance the properties of the
laterite clay.
RESEARCH BACKGROUND
AUTHOR & YEAR RESEARCH AREA FINDINGS
Amkpa J.A. Thermal Conductivity of Aloji Fireclay The Aloji Fireclay based on the results of thermal
(2016) as Refractory Material. conductiviry value of 0.05 K(W/m.k), the specific heat
capacity changes with change in temperature, the
refractoriness (PCE) was 1665 °C, Thermal shock
resistance was 25 cycles, DSC, TGA and DTA was
found to be within the standard values for refractory
fireclay bricks, hence, they are suitable for
production of refractory fireclay brick for furnace
lining.
Akinola A.O (2015) Investigation into the Properties of Akure laterite has been investigated for furnace lining in
Akure Laterite for Furnace Lining this study. The result of the chemical analysis revealed that
the laterite sample contain more of SiO2 (42.5%), followed
by Alumina (23%) and calcium oxide (11.8%). It has a
shrinkage percentage of 9%, bulk density of 1.91 g/cm3 and
a high cold crushing strength of 64 kg/cm2. This inferred
that it would best be used to build silica bricks.
Folorunso D.O. The Purification and Adaptation of The addition of graphite has greatly improved the
(2015) Termite Hill Clay for Furnace Lining by refractory performance of the termite hill clay,
Graphite and Rice Husk Addition especially when added in the appropriate quantity of
15 %. The porosity of refractory lining material
AIM
The aim of the project work is to develop a

refractory material from laterite of Ajegunle in
Lagos State for furnace lining.
OBJECTIVES
The specific objectives are to
 develop a laterite refractory material with
varying amount of graphite and
 determine the properties of the developed

refractory material
SCOPE OF THE RESEARCH
This research would cover:
 the development of laterite clay obtained in Ajegunle
for furnace lining applications.
 evaluate mechanical properties such as porosity, bulk
density, cold crushing strength, linear shrinkage,
refractoriness, thermal shock resistance, moisture
content, permeability and thermal conductivity.
CONTRIBUTION TO KNOWLEDGE
The research on completion has:

I. Extend the frontiers of knowledge on the
application of Laterite clay for high temperature
applications.
II. Enhance the use of Laterite clay for the production
of low cost, reduced weight, eco-friendly, high
strength and wear resistant furnace lining for
refractories and other engineering applications.
RESEARCH METHODOLOGY
MATERIALS
Laterite cat Graphite

RESEARCH METHODOLOGY (Contd.)
Experimental Procedure
Materials Sourcing
Sample Preparation
Mould Production
Physical Test Thermomechanical

Test
Cold crushing strength
Thermal shock
Tensile resistance
porosity refractoriness
Permanent linear
Bulk density change
RESULTS
SAMPLES REFRACTORINESS 0C
A 1450
B 1600
C 1600
D 1600
E 1600
F 1600
Fig 4.1: The refractoriness 0C of the samples

SAMPLE INITIAL LENGTH FINAL LENGTH % LINEAR
(CM) (CM) SHRINKAGE
A 10 9.70 3.00
B 10 9.80 2.00
C 10 9.85 1.50
D 10 9.90 1.00
E 10 9.96 0.40
F 10 9.96 0.40
Figure 4.2 Variation of Linear Shrinkage with % graphite

SAMPLE THERMAL SHOCK RESISTANCE
A 10
B 15
C 15
D 20
E 20
F 20
Figure 4.3 Variation of thermal shock resistance with % graphite

SAMPLE DRY WEIGHT SOAKED SUSPENDED % POROSITY
(g) WEIGHT(g) WEIGHT(g)
A 11.49 13.40 5.8485 22.63
B 12.38 15.39 7.6504 38.89
C 13.93 17.13 8.5845 37.45
D 11.43 14.02 6.8519 36.13
E 15.50 18.22 7.2166 33.85
F 10.52 12.69 6.0746 32.80
Figure 4.4 Variation of apparent porosity with % graphite

SAMPLE DRY WEIGHT SOAKED BULK DENSITY AVERAGE
(g) WEIGHT(g) (g/cm3) BULK DENSITY
(g/cm3)
A1 13.02 89.42 1.97 1.97

2 10.91 74.56 1.98
B1 12.93 100.54 1.74 1.70

2 13.36 104.91 1.72
C1 16.60 141.25 1.59 1.60

2 13.74 114.73 1.62
D1 14.43 125.27 1.60 1.60

2 10.62 84.86 1.60
E1 12.15 104.65 1.57 1.50

2 13.14 119.83 1.48
F1 13.41 119.74 1.51 1.50

2 9.65 87.66 1.50
Figure 4.5 Variation of bulk density with % graphite

SAMPLE LENGTH BREATH AREA FORCE MASS COLD
(cm) (CM) (cm2) (KN) (KG) CRUSHING
STRENGTH
(KG/cm2)
A 3.20 2.40 7.68 16.40 1640 213.54
B 3.00 2.30 6.90 14.50 1450 210.40
C 2.50 3.00 7.50 15.60 15.60 208.00
D 2.60 2.60 6.76 12.60 1260 186.39
E 2.45 2.45 5.76 9.66 966 166.60
F 2.45 2.45 5.76 9.20 920 159.20
Figure 4.6 Variation of compressive strength with % graphite

SAMPLE INITIAL FINAL WEIGHT DIFFERENCE IN % MOISTURE
WEIGHT WEIGHT CONTENT
A 50 44.37 5.63 11.26
B 50 45.06 4.94 9.88
C 50 45.87 4.13 8.26
D 50 46.52 3.48 6.96
E 50 47.25 2.75 5.50
F 50 47.93 2.07 4.14
Figure 4.7 Variation of Moisture content with % graphite

CONCLUSION
From the results, it can be seen that the addition of graphite to laterite clay
enhances the refractoriness of the material but remains stable regardless of the
percentage of graphite powder added.
It also shows that laterite clay with addition of graphite powder increases the
overall strength of the material and therefore making the material more resistant
to thermal shocking (spalling).
Materials needed for furnace lining and furnace post application possesses high
thermal conductivity, high compressive strength, spalling resistance and weight
loss. From the results obtained, it is shown that the samples with the addition of
graphite powder are suited for this application and sample F gives the desired
result in terms of refractoriness, linear shrinkage, thermal shock resistance,
porosity, bulk density, cold crushing strength and moisture content which can be
compared to the standard value of the imported firebricks refractory.
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DEVELOPMENT OF A REFRACTORY MATERIAL FROM LATERITE OF

AJEGUNLE IN LAGOS FOR FURNACE LINING APPLICATIONS

M.ENG ORAL EXAMINATION

BALOGUN TEMITOPE OLUWAPELUMI

DEPARTMENT OF METALLURGICAL AND MATERIALS ENGINEERING,

SUPERVISED BY: DR. S.O SEIDU

 A material having the ability to retain its physical

Most refractory lining won’t last for more than 3-5

The aim of the project work is to develop a

 determine the properties of the developed

The research on completion has:

Laterite cat Graphite

Physical Test Thermomechanical

Fig 4.1: The refractoriness 0C of the samples

Figure 4.2 Variation of Linear Shrinkage with % graphite

Figure 4.3 Variation of thermal shock resistance with % graphite

A 11.49 13.40 5.8485 22.63

B 12.38 15.39 7.6504 38.89

C 13.93 17.13 8.5845 37.45

D 11.43 14.02 6.8519 36.13

E 15.50 18.22 7.2166 33.85

F 10.52 12.69 6.0746 32.80

Figure 4.4 Variation of apparent porosity with % graphite

A1 13.02 89.42 1.97 1.97

B1 12.93 100.54 1.74 1.70

C1 16.60 141.25 1.59 1.60

D1 14.43 125.27 1.60 1.60

E1 12.15 104.65 1.57 1.50

F1 13.41 119.74 1.51 1.50

Figure 4.5 Variation of bulk density with % graphite

A 3.20 2.40 7.68 16.40 1640 213.54

B 3.00 2.30 6.90 14.50 1450 210.40

C 2.50 3.00 7.50 15.60 15.60 208.00

D 2.60 2.60 6.76 12.60 1260 186.39

E 2.45 2.45 5.76 9.66 966 166.60

F 2.45 2.45 5.76 9.20 920 159.20

Figure 4.6 Variation of compressive strength with % graphite

A 50 44.37 5.63 11.26

B 50 45.06 4.94 9.88

C 50 45.87 4.13 8.26

D 50 46.52 3.48 6.96

E 50 47.25 2.75 5.50

F 50 47.93 2.07 4.14

Figure 4.7 Variation of Moisture content with % graphite

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