Silica sand was sourced from Igbokoda, ondo state, this was washed, dried and the percentage clay and organic matter present in the silica sand determined. Some percentage of the silica sand was used to compose different batches of  enamel compositio and was fired to a temperature of 1200oC. The compositions were fritted in metallic bucket and then pulverized to form powder. The powder was mix with gum arabic to form a paste and this was used to print on ceramic wares and glass cups. The printed wares were tested to determine the resistance of the wares to acid and base environment. From the test, the result showed that the enamel produced exhibit a good resistance to acid and base. Keywords: Enamel, frits and  Igbokoda silic

B.O, Fatile

O.T, Sanya,

T.S, Ogundare

Y.D, Lamidi

English

International Institute for Science, Technology and Education (IISTE): E-Journals

Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  40 Production of Enamel Stains from Igbokoda Silica Sand  Fatile B.O1      Lamidi Y.D1      Ogundare T.S2      Sanya, O.T1 1. Department of Glass and Ceramic Technology, Federal Polytechnic Ado-Ekiti 2. Industrial Design Department, Federal University Of Technology, Akure.  ABSTRACT Silica sand was sourced from Igbokoda, ondo state, this was washed, dried and the percentage clay and organic matter present in the silica sand determined. Some percentage of the silica sand was used to compose different batches of  enamel compositio and was fired to a temperature of 1200oC. The compositions were fritted in metallic bucket and then pulverized to form powder. The powder was mix with gum arabic to form a paste and this was used to print on ceramic wares and glass cups. The printed wares were tested to determine the resistance of the wares to acid and base environment. From the test, the result showed that the enamel produced exhibit a good resistance to acid and base. Keywords: Enamel, frits and  Igbokoda silica  Introduction Silica sand is one of the most common mineral in the Earth Crust. It is made up of  broken quartz crystals which has been broken down into tiny granules over years through the action of water and Weathering (Edem, 2014). Silica sand granules can be used for different purpose such as glass production, glass stains, enamel production and this is found deposited in most non tropical region of the world (Carr,1971;Hecketal,2002;Freestone,2005).  In Africa, especially in Nigeria silica sand deposit are mostly found deposited in most parts of the country particularly in riverin ,estuaries and beaches(Chang, 1991; Claude, 2002;Malu and Bassey,2003). One of the major deposit of silica sand in Nigeria is Igbokoda. Igbokoda is located in Ondo state . It has a river which is one of the major and important river in Nigeria which lies on latitude 4o.40-5o.00N and 6o.00-60-20E. The river is noted for artisanal fishing activities, transportations and mining of silica sand (Olaniyan, 2016). The mineral resources department of Ondo state estimated that Ondo state  silica sand has an estimated reserve of 3 billion MT where igbokoda is one of the principal location for the silica sand. Igbokoda  silica sand is available for commercial exploration and exploitation for the production of glass and ceramic production. Igbokoda silica has been characterized by Ojuri 2015 to have about 94.24% SiO2 content, this is an evident of a good silica for glass industries. Research Objectives i  access Igbokoda silica sand for enamel stain composition. ii        vary the different composition with metallic oxides. ii frit the various batches at melting temperature of the metallic oxides iii Pulverise the melted batch iv.  mix the pulverized sample with mixing agent v examine   he effect of the enamel produced wares at 600-700oC firing temperature; vi test the enamel produced to determine the resistance to acid and base.   Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  41  Fig. 1 Hydrological network within study area (Ondo State) showing where samples were taken (Adapted from Federal Surveys) Materials and Equipment Washing and water bowl: This is a container used for holding materials e.g water or wet materials. Pulverizer: This is used for the reduction of materials to a powdery form. Kiln: The kiln is used for heating in the ceramic studio. This is used to fire to the required temperature before fritting Screen/Mesh : This is used to transfer designs on the surface of the glass and ceramic wares. Weighing balance(Electronic): A weighing balance allows to determine the mass of various materials used for the experiment. Crucibles: These are used to hold materials to be fired. It is a refractory material that can withstand a very high temperature of above 1200oC. Design : This is the printed on the glass and ceramic  surface which is in form of logo or art work. This is done with the use of the computer. Silica Sand: The silica sand is the major raw material required for the stain production. It is the glass former hence increases the mechanical strength of the stain and gives the stain a higher    Ceramic metallic oxides : These are the oxides that are responsible for the various types of colourations in stains. Mixing agent: This is the medium that allows the enamel to flow so that it will be able to stay on the printed material. Auxilliary materials: These are the other raw materials added to the composition to aid the melting process.   Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  42 Methods Flow chart of the production process. Washing ↓ Drying ↓ Milling ↓ Mixing ↓ Melting ↓ Fritting ↓ Grinding ↓ Mixing ↓ Application using the mesh (screen printing)  ↓ Reheating  PROCEDURE The samples of the silica sand was gotten from the site, these were poured in a bowl and washed using water. This is done in order to remove the impurities that might be present in the silica sand from the deposit, it was then air dried and stored in a sack.  The silica sand was weighed and combined in various ratios with other fluxes, opacifiers and metallic oxides respectively. The fluxes, opacifiers and the metallic oxides were  to reduce the melting temperature of the silica sand, make the enamel stain translucent and to add colourants respectively. The samples were weighed in different proportion according to the tables below and then poured into different crucibles and fired to a temperature of 1200oC in a muffle kiln. At that temperature, most of the batches had form glass. The various crucibles were removed from the kiln and poured differently into an Iron container in order to frit the composition. The various fritted batches were then put in a pallet and labeled accordingly.  The pallets were later taken to the workshop to pulverize the samples so as to have a powder form of the frit. The powder was mix with gum arabic for it to form a paste, the paste was necessary so that the enamel stain produce can stick to the body of the  glass and ceramic wares. Various tests were then carried out on the wares to know the acid and base resistant of the enamel produced. Table 1 Composition A1 Oxides   Percentage Composition  Weight in Gramme  Silica sand   15%    75g Feldspar   10%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   44%    220g Cullet           14%    70g Iron Oxide               4%    10g    100%    500g Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  43 Table 2 Composition B2 Oxides   Percentage Composition  Weight in Gramme  Silica sand   20%    100g Feldspar   9%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   40%    220g Cullet           14%    70g Cobalt               4%    10g    100%    500g Chromium   2%    10g    100%    500g Table 3 Composition A2 Oxides   Percentage Composition  Weight in Gramme  Silica sand   15%    75g Feldspar   10%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   44%    220g Cullet           14%    70g Manganese oxide   4%    10g    100%    500g Table 4 Composition B2 Oxides   Percentage Composition  Weight in Gramme  Silica sand   20%    100g Feldspar   9%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   40%    220g Cullet           14%    70g Copper oxide  4%    10g    100%    500g Table 5 Composition A3 Oxides   Percentage Composition  Weight in Gramme  Silica sand   15%    75g Feldspar   10%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   44%    220g Cullet           14%    70g Cobalt  Oxide       4%    10g    100%    500g Table 6 Composition B3 Oxides   Percentage Composition  Weight in Gramme  Silica sand   20%    100g Feldspar   9%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   40%    220g Cullet           14%    70g Cobalt               4%    10g    100%    500g Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  44 Table 7 Composition A4 Oxides   Percentage Composition  Weight in Gramme  Silica sand   15%    75g Feldspar   10%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   44%    220g Cullet           14%    70g Cobalt               4%    10g    100%    500g Table 8 Composition B4 Oxides   Percentage Composition  Weight in Gramme  Silica sand   20%    100g Feldspar   9%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   40%    220g Cullet           14%    70g Cobalt               4%    10g    100%    500g Table 9 Composition A5 Oxides   Percentage Composition  Weight in Gramme  Silica sand   15%    75g Feldspar   10%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   44%    220g Cullet           14%    70g Cobalt               4%    10g    100%    500g Table 10 Composition B5 Oxides   Percentage Composition  Weight in Gramme  Silica sand   20%    100g Feldspar   9%    70g Calcium Oxide   8%    40g Zirconium Oxide  5%    25g Sodium Oxide   40%    220g Cullet           14%    70g Cobalt               4%    10g    100%    500g The various materials were ground, weighed in the various proportions  and mix in various crucibles, theses were then fired to a temperture of 1200oC in a muffle kiln.  Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  45                                        Plate 1: The crucibles were placed in the mufffle kiln for firing   Plate 2: the process of firing the samples   Plate 3: Fritting of the melt Results of frit Figure  A1, A2, A3, A4 and A5 represent composition A with different metallic oxides.  The result showed that the composition required a melting temperature of 1150oC to melt than sample B.  Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  46                                    FIGURE A1: Iron oxide                                 FIGUREA2:Chromium Oxide  FIGUREA3: Manganese oxide                                         FIGURE A4: Copper Oxide                        FIGURE A5: Torques Cobalt Oxide Figure B1, B2, B3, B4 and B5 represent composition B with various metallic oxide. The compositions  required a higher temperature to melt  than composition A, the required melting temperature was 1250..     FIGURE B1: Iron Oxide    FIGURE B2: Iron Oxide  Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  47     FIGURE B3: Manganese oxide   FIGURE B4: Copper oxide   FIGURE B5: Copper oxide The various samples were later pulverized to obtain the various enamel stain.                                                                     Plate4:   Pulveriser        Plate 5: Pulverised frit Testing of the enamel stain Mixing agent: The mixing agent allows the powder material to flow so that it can stick to the body of the ware. It also allows the powdery enamel to pass through the mesh used. Reheating: To make the enamel permanent on the glass surface, there is need to reheat the enamel in the kiln to a certain temperature. This involved placing the decorated item in the kiln  and reheating to a temperature of 680oC. Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  48  Plate6: The kiln and the test samples   Plate7: The result of some of the test piece. The various results gotten from the experiment was used to print on a glass and ceramic cup using a mesh of size 100.. A print out logo was designed on a com puter system and transferred to the mesh using the required transfer technique.  DESIGN OF A LOGO  TO PRINT ON A CUP USING THE ENAMEL The various stages involved in the design of the logo on the cup are:- Design of the logo on the computer:  The logo was designed on the computer system and reduced to the size of 2cm by 2cm. Expose of the design on the mesh: The design from the computer system was transferred to a fine mesh.  Plate8: The fine mesh Printing on the cups: The produced enamel was placed on the mesh and printed on the ceramic and cups. Chemistry and Materials Research                                                                                                                                                    www.iiste.org ISSN 2224- 3224 (Print) ISSN 2225- 0956 (Online) Vol.10 No.4, 2018  49   DISCUSSION From samples A1, A2, A3, A4, A5, the result showed that the enamel required a lower temperature to melt than sample B. The reheating melting temperature of the enamel was 680oC compared to that of B1,B2, B3, B4 and B5 which was 790oC. The colours of composition A came out on the wares brighllaintly than that of composition B which is matt in colour.. The sagging of the glass panel was as a result of the reheating temperature of sample B being too high in an attempt to fuse the enamel unto the glass surface.   CONCLUSION The use of silica from Igbokoda for the production of enamel  was discovered to make the production of enamel cheaper in term of procurement of raw material and the fuel cost compared to some other methods of enamel production. It can be inferred from the experiment that the silica can be used for commercial production of enamel of a lower melting temperature with good resistance to acidic and basic attack.  RECOMMENDATION I hereby recommend the use of Igbokoda silica for the production of enamel stain in Nigeria.  REFERENCE Akomolafe, I .I. (1990). Utilization of some locally identifiable materials for glass mold making in Nigeria. Unpublished M.Sc. thesis, Ahmadu Bello University, Zaria, Nigeria. Albinas, E.(1986). The Art of painting and staining-Technique and design for stained glass.  Andrews, A. (1991). Porcelain Enamel the preparation, application and properties of enamel.  Ayilaran, A. (2005). Utilization of cow bone Ash as an Opacifier for Enamel production. (unpublished) M.A Thesis, Department of Industrial Design, A.B.U. Zaria. Ayilaran, A. (2008). Effectiveness of Cow bone Ash in Enamel Batch Modification Process. International Research Journal. Vol2, No1, page 27. Ayilaran, A. (2008). Effectiveness of Cow bone Ash in Enamel Batch Modification Process.    International Research Journal Vol. 2 No1 pg27 Ceramic Review.  Vol 50 No3 Pp8-10 Doremus, R. H. (1973). Glass science. New York: John Wiley, 78-90. Edem, C.A, Malu, S.P and Ita, B.I.(2014). Characterization and Beneficiation of the Glass Making Potentials of Silica Sand Deposit from River Benue North Central Nigeria. Journal of Natural Sciences Research Vol.4, No.19,Pg 49. Fadojutimi, T. (1995). Introduction to Glass Technology (i) Lecture Note. Unpublished. Glass and Ceramic Technology Department, Federal Polytechnic Ado Ekiti. Gudenrath, W. (2006). Enameled vessels. the decoration process journal of Glass studie.  Vol. 48 Pp23 Hammond, C.R. (2004). The Elements in Handbook Chemistry and Physics, 81st Edition CRS Press. London. Hansen J.G. (2012). The ceramic surface: Surface techniques Illinois: Garrard press. Karen L. C (2002). The Art of Fine Enameling. New York: Sterling Publishing Company inc. Kothari, C.R. (2004). Research Methodology: Methods and Technique. New Delhi. New Age International Publishers. Millar.C. (1991). Some  Fundamental aspect of Frit formulation. Journal of International  Morey,W. (1998). Properties and Applications of Glass. London: Oxford University Press. New York: Charles Scribner’s Son. Ogumor, E. (1992). Certificate Art For schools. Ibadan: University Press Plc. Ojutari, O.O, Jonas, S. & Abioudun, D.A  (2017). Spectostropic characterization of a Nigerian Standard Sand: Igbokoda sand, International Journal of GEOMATE, Vol. 12, Issue 29, pp.89-98 Olaniyan, R.F, Ugwumba, A.O & Ayoade, A.A(2016). Physico-chemical Characteristics of Igbokoda River, Ondo state,  International Journal of Science and Science Education. Vol. 6(1), pp. 16 – 20. 

Production of Enamel Stains from Igbokoda Silica Sand

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Production of Enamel Stains from Igbokoda Silica Sand

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