Influence of Palm Fruit Fibe and High Alumina Cement on Omifun Kaolin for Furnace Insulation

Objective: This work is designed to enhance the insulating properties of Omifun kaolin from Ose Local Government of Ondo State, Nigeria for furnace insulation by reinforcing it with some additives such as high alumina cement and oil palm fruit fiber. This was aimed at developing local technology for the production of insulating bricks in such a way as to reduce the sole dependency on importations of insulating bricks to service the available furnaces in the country. Methods: Sieve analysis was performed on the Omifun kaolin. Characterization by X-ray Fluorescence (XRF), X-ray Diffraction (XRD), and Scanning Electron Microscopy/ Energy Dispersive Spectroscopy (SEM/EDS). Subsequently, the samples of kaolin reinforced with pulverized palm fruit fiber (1,2,3,4, and 5%) were prepared and tested for permeability. The sample with the best potential was further mixed with varying weight percent (3, 6, 9, 12, 15, 18, 21, and 24%) of high alumina cement, fired within 800-1200℃, and further tested for bulk density, compressive strength, thermal shock resistance (TSR), and linear expansion. Results: The characterization revealed, in the acceptable limits, the relative quantities of the desired oxides (SiO2, Al2O3, and CaO) with phases (kaolinite, quartz, and plagioclase) expected of good insulating bricks. From the samples containing fixed 3% palm fruit fiber and varying percentages (3, 6, 9, 15, 18, 21, and 24%) of high alumina cement, the sample containing 3% palm fruit fiber and 9% addition of high alumina cement exhibited the most promising qualities desired of good material for furnace insulation applications. Conclusion: The characterization techniques adopted in this study; XRD, XRF, and SEM/EDS revealed, in the acceptable limits, the relative quantities of the desired oxides (SiO2, Al2O3, and CaO) and phases (kaolinite, quartz, and plagioclase) expected of good insulating bricks are present in Omifun kaolin. With permeability of 44.69%, crushing strength of 54.09KN/cm2, linear expansion of -0.39mm, TSR of 24 cycles, and bulk density of 1.93g/cm3 at firing temperature range 800-1200℃, Omifun kaolin can compete and successfully replace imported insulating bricks.