DEVELOPMENT AND CHARACTERIZATION OF CLAY COMPOSITE FOR INDUSTRIAL APPLICATIONS

ABSTRACT Refractory materials are indispensable in high-temperature industrial operations but suffer from premature failure due to thermal shock, mechanical stress, and corrosion. This study focused on the development of sustainable self-healing refractory composites using Oshiri clay, silicon carbide (SiC), and limestone dust additives. The chemical oxide compositions were determined using X-ray fluorescence, while the mineralogical phase composition was determined using an X-ray diffractometer. The clay samples were separately mixed with silicon carbide and limestone dust at different formulations, moulded, dried, and thereafter fired at sintering temperatures of 1100, 1150, and 1200°C. The physical-mechanical properties were evaluated using standard experimental procedures. Result showed that apparent porosity values ranged from 10 28.3% within the range of formulations studied. Bulk density decreased at lower densification. Water absorption followed the same trend with porosity, but higher sintering temperatures improved the thermal shock resistance significantly from 4 cycles in the control to 20-22 cycles in the composites. Crack-healing tests revealed that ~70% induced cracks sealed limestone, which produced glassy healing phases. The study concludes that SiC and limestone additives enhance the thermal shock resistance, refractoriness, and self-healing performance of Oshiri clay, making it a viable, sustainable refractory material for high-temperature industrial applications.