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Th.--Sci. nat.--Nancy--I.N.P.L., 1979.

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Development of products which can be produced from acountry's natural resources is very important as far as theindustrialization of a nation and saving foreign exchange isconcerned. Presently, industries in Uganda and the other statesin the Lake Victoria region import allrefractory-related-consumables, as the demand cannot be metlocally. Based on the abundance of ceramic raw materials forhigh temperature applications in the region and the demand forrefractories by industries it is pertinent to develop andmanufacture firebricks by exploiting the locally available rawmaterials. This thesis thus, concerns the characterisation of ceramicraw mineral powders from in the Lake Victoria region, moreparticularly, Uganda, with the aim of developing firebrickrefractories from the minerals. Two main deposits of kaolin anda fireclay deposit, located in the Lake Victoria Region,Uganda, were investigated to assess their potential in themanufacture of refractory bricks. Raw- and processed samplepowders were investigated by means of x-ray diffraction (XRD),thermal analysis (DTA-TG) and Scanning Electron Microscopy(SEM). In addition, the chemical composition, particle sizedistribution, density, and surface area of the powders weredetermined. A general production process scheme for manufacture offirebricks starting with raw powder minerals (Mutaka kaolin andMukono ball clay) was used to make six groups of samplefirebrick. Experimental results from the characterization offormulated sample bricks indeed reveal the viability ofmanufacturing firebricks from the raw minerals.Characterization of the sample bricks has been done fordetermination of physical and mechanical properties; density,shrinkage, porosity, water absorption, and phaseidentification. Formation of mullite, which is a principalcompound for aluminous refractories, is evidenced in thepowders with DTA tests and for the fired samples with XRD; thefired samples are dominated by mullite peaks. Keywords: kaolin; clay; powders characterization; ceramics;mullite; Lake Victoria region; / NR 20140805

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Ces travaux de thèse visent à améliorer la densification et la résistance à la rupture de céramiques silicatées élaborées principalement à partir de kaolin. Cette amélioration est effectuée en substituant une partie du kaolin par de l’halloysite. En effet, cette voie permet également de mettre en évidence l’influence de la morphologie et de l’organisation des particules sur les propriétés microstructurales. Premièrement, la dispersion des suspensions contenant soit du kaolin soit un mélange de kaolin et d’halloysite, a été optimisée en réduisant la taille des agglomérats et en augmentant la valeur absolue du potentiel zêta. Deuxièmement, les paramètres (broyage, rapport liant/plastifiant…) contrôlant le procédé de mise en forme de coulage en bande ont également été optimisés. Enfin, l’influence de deux types de traitement thermique à 1200°C (frittage conventionnel et par voie micro-ondes) sur les propriétés mécaniques (contrainte à la rupture en flexion biaxiale) des matériaux finis a été mise en évidence. Les résultats obtenus montrent que plusieurs compromis entre le taux de porosité, l’organisation de la microstructure et les propriétés mécaniques ont été obtenus i) soit avec un taux d’halloysite de 10 % en masse associée à un traitement thermique par voie micro-ondes à 1200°C ii) soit avec un taux de substitution d’halloysite égal à 50 % en masse associé à un frittage conventionnel à la même température. / This thesis is devoted to improve both densification and stress to rupture values of silicate ceramics mainly elaborated from kaolin. This improvement is achieved by replacing a proportion of kaolin by halloysite. Indeed, this way also allows to highlight the influence of the shape of particles and their organization on microstructural properties. First, the dispersion of suspensions containing only kaolin or a mixture of kaolin and halloysite was optimized by reducing the size of agglomerates and by increasing the absolute value of zeta potential. Second, parameters (milling, ratio binder/plasticizer...) controlling the tape casting shaping process were also optimized. Finally, the influence of two types of thermal treatment at 1200°C (conventional and micro-waves sintering) mechanical properties (stress to rupture determined by bixial bending tests) of final products was studied. Results obtained show that several compromises regarding porosity, the organization of microstructure and mechanical properties i) a proportion equals to 10 mass % of halloysite combined with a micro-waves thermal treatment at 1200°C ii) a substitution content equals to 50 mass % of halloysite combined with a conventional thermal treatment at the same temperature.

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