Assessment of the Suitability of Wusasa Clay for Refractory Bricks Production

• Ameh RICHARD

  Author

• Sani B. MUHAMMAD

  Author

• Terver AUSE

  Author

• Umar SHEHU

  Author

This study assessed the physicochemical and thermal properties of Wusasa clay from Zaria, Kaduna State, Nigeria, for refractory brick production, addressing Nigeria's reliance on costly imported refractories which are essential for high-temperature processes in metallurgy, despite abundant local clays remaining largely underexplored. Clay samples were characterization using X-ray fluorescence (XRF) for chemical composition, X-ray diffraction (XRD) for mineralogy and standardized tests for bulk density, plasticity index (Atterberg limits), linear shrinkage, apparent porosity, cold crushing strength (CCS), thermal shock resistance and thermal conductivity following firing at 1000-1200 °C with 2-4 h soaking. XRF analysis revealed a kaolinitic composition of Wusasa clay dominated by SiO₂ (47.81 wt%), Al₂O₃ (28.52 wt%), and Fe₂O₃ (16.06 wt%), with bulk density of 1.91 g/cm³ (suitable for lightweight insulation) and plasticity index of 8.17% (moderately plastic). After firing at 1000-1200 °C with 2-4 h soaking, the clay showed low shrinkage (1.04%), porosity reduction (3.12%), cold crushing strength (CCS) increase from 11.24 MN/m² at 1000 °C/2 h, to 16.83 MN/m² at 1100 °C/4 h and 34.46 MN/m² at 1200 °C/4 h, alongside thermal shock resistance up to 26 cycles at 1200 °C (20 cycles at 1100 °C) and low thermal conductivity. X-ray diffraction (XRD) confirmed primary phases of kaolinite (59%), illite (11%), orthoclase (11.1%), quartz (5.3%), and muscovite (9.2%). These properties indicate that clay complies with ASTM/ISO standards for refractory bricks and non-ferrous furnace linings, offering a sustainable, cost-effective local alternative. This research work provides new baseline data on the refractory potential of Wusasa clay and identifies it as a locally available material suitable for low- to medium-duty refractory brick production.

• 40_Richard et al. (2026)

Copyright (c) 2026 Ameh RICHARD, Sani B. MUHAMMAD, Terver AUSE, Umar SHEHU (Author)

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