AN EVALUATION OF THE SUITABILITY OF CERAMIC RAW MATERIALS IN KEBBI STATE FOR THE PRODUCTION OF TABLEWARE FOR SMALL SCALE INDUSTRY BY ZAURO, TUKUR DIKKO MUHAMMAD A DISSERTATION SUBMITTED TO THE POSTGRADUATE SCHOOL IN PARTIAL FULFILLMENT OF THE REQUIREMENTS FOR THE AWARD OF THE DEGREE OF DOCTOR OF PHILOSOPHY IN INDUSTRIAL DESIGN DEPARTMENT OF INDUSTRIAL DESIGN FACULTY OF ENVIRONMENTAL DESIGN AHMADU BELLO UNIVERSITY ZARIA NIGERIA. DECEMBER, 2007 i DECLARATION I declare that the work in the dissertaton entitled “An evaluation of the Suitability of Ceramic Raw Materials in Kebbi State for the Production of Tableware for Small Scale Industry” has been performed by me in the Department of Industrial Design under the supervision of Professor A. M. Ahuwan, Professor B.A. Kparevzua and Dr. Salihu Maiwada. The information derived from the literature has been duly acknowledged in the text and a list of references provided. No part of this dissertation was previously presented for another degree or diploma at any university. ____________________________ _______________ Zauro, Tukur Dikko Muhammad Date ii CERTIFICATION This dissertation entitled “AN EVALUATION OF THE SUITABILITY OF CERAMIC RAW MATERIALS IN KEBBI STATE FOR THE PRODUCTION OF TABLEWARE FOR SMALL SCALE INDUSTRY” by Zauro, Tukur Dikko Muhammad meets the regulations governing the award of the degree of Doctor of Philosophy in Industrial Design of Ahmadu Bello University, Zaria and is approved for its contribution to knowledge and literary presentation ________________________ __________________ Professor A. M. Ahuwan Date Chairman, Supervisory Committee ________________________ __________________ Professor B. A. Kparevzua Date Member, Supervisory Committee ________________________ __________________ Dr. Salihu Maiwada Date Member, Supervisory Committee ________________________ __________________ Dr. U. A. Sullayman Date Head, Department of Industrial Design ________________________ __________________ Professor S.A. Nkom Date Dean, Postgraduate School iii DEDICATION This dissertation is wholeheartedly dedicated to my late Grand Father Alhaji Aliyu (Dikko Dan Umaru, the 4th Dikkon Zauro) who enrolled me into the school system at a very early age, encouraged and supported me in my educational struggle throughout his lifestime. iv ACKNOWLEDGEMENT As a matter of fact, the success of this study has involved various efforts and interests of many individuals and organizations. On special note, I am most indebted to Professor Abashiya Magaji Ahuwan whose supervision, unfailing patience, constructive and objective criticisms throughout the period have immensely contributed to the richness of the study. I would like to acknowledge the co-operation of Professor B. A. Kparevzua for her critical insight and knowledge and whose useful suggestions have made remarkable improvement for the study. The Post graduate studies coordinator and a member of the supervisory committee of the study, Dr. Salihu Maiwada, has been most helpful and supportive throughout the programme. I am therefore grateful to him. I wish to express my gratitude to the Head of Industrial Design Department, Dr. U. A. Sullayman for his useful suggestions and advice. Special thanks go to Dr. W. B. Qurix, Head, Department of Architecture and the Faculty of Environmental Design, Ph.D Seminar Coordinator for his support and encouragement. Lecturers and staff of Ceramic Section made several suggestions, therefore, I am grateful to them all. Professor P. B. Madakson, Department of Mechanical Engineering made useful suggestions to the success of the study. Contributions made by Dr. B. O Aderemi, Head of Department of v Chemical Engineering and the Technical Staff are appreciated. I must also thank them for allowing me to use some of the facilities in the Department. At Geology Department, I am grateful to the Head of Department and the Technical Staff and in particular Mallam M.L. Garba for the professional assistance he rendered through out the research period. I am also grateful to Mal. Muazu M. Sani, Department of Fine Arts for the photographs. I also wish to register my acknowledgement to the Centre for Energy Research and Training (CERT) Ahmadu Bello University, Zaria and of special mention is Malam Dabai, Again I would like to appreciate the support of the Kebbi State Scholarship Board and staff, especially the Executive Secretary, Alh. Jibril Abubakar and Director Planning, Alh. Muhammed (DT) Ambursa. I am equally grateful to many people who were so vital to the success of the study. They helped the study to identify the locations and collect the raw materials. At Bena, I wish to express my gratitude to the District Head and also Hon (Alh) Muhammed Garba Bena, Sarkin Dogarai and others. Mallam Umar B/Yauri and Danfulani Mai Chemist assisted the study to obtain quartz samples in Yauri and Kanya. Similarly, I wish to express my gratitude to the District Head of Giro as well as Mallam Mahe Giro while I also thank Tukur Baba Kaoje, Alh. Muhammad Ibrahim (Gemu) and Alhaji Bello Sani Zauro for their valuable assistance in the course of procurement of the raw materials. vi I wish to express my sincere thank to Alhaji Adamu Ahmed who has always been instrumental to most of my academic persuasion. Initially, he was the person who encouraged me to take on the postgraduate programme. Indeed, Dr. Rahamatu Y. H. needs to be mentioned especially for her growing concern, moral support and encouragement that have really enhanced strong backing to the success of the study. Her actions served as a source of strength to me. I would like to thank some people whose encouragement, friendship and hospitality during the period of the study were significant and important. They include Alh. Adamu Giris, Alh. Abubakar (AC) Ladan, Umaru Kambaza (Ministry of Finance, Kebbi State) Alh. Isa Tunga (KBHS and Loans Ltd) and Alhaji Atiku Gwandu (WUFP). Others are Alh. Haruna Illo Jega, Abubakar A. Kalgo, Alh. Shehu Usman Randali, Alh. Lawal Suraj Gusau, Alhaji Aliyu Galadima, Alh. Armiya’u Usman and Bello Aguro. Assistant Commissioner of Police, Umar Shehu Umar (Area Commander, Zaria) deserves special thanks for his concern. I am very much indebted to my uncles: Alhaji Kindi Zauro, Alhaji Ahmed Dikko, Alhaji Ibrahim (5th Dikkon Zauro) and Alh. Mahe Dikko. My special gratitude and appreciation to my brothers Alhaji (Mal.) Muhammadu Yalaudo Ladan, Alh (Mal.) Ibrahim Ladan and Mal. Bagudu Bawa. I also wish to register my thanks to Alhaji Aliyu Manu Zauro, Alh. Ahmed Shehu, Muhammed Altine, Mallam Sani Alhaji, Bafashi Bagudu, vii Atiku (Mass) and Abubakar Wakkala for their concern and assistance. Supports from Hajiya Mariya Haruna Rasheed are acknowledged and her efforts were useful to the study in many ways. I highly appreciate and acknowledge the moral support and encouragement of my Mother Hajiya Hauwa Joda Dikko Aliyu for her constant and fervent prayer for success. I also acknowledge the rally round of my children namely Zainab, Rahilu, Muktar, Usman, AbduRRahman, Yahaya and Hafsat. Finally, I want to particularly register my appreciation to my wives Hajiya Hannatu Haruna Rasheed and Halima Ibrahim Dikko for their endurance and for bearing different sort of difficulties throughout the long period of the programme. viii ABSTRACT The Industrial development of a nation could be achieved through the effective and efficient utilization of the available raw materials and Ceramic Industries are some of the enterprises that rely heavily on such raw materials. Kebbi State has been endowed with natural resources including ceramic raw materials. Data from geological documents and information received from respondents aided the identification of locations and subsequent collection of the raw materials. These are kaolin, ball clay, quartz, feldspar and limestone. Chemical analyses and physical property tests were conducted. The triaxial blend method was adapted to study the effect of the materials while slip casting technique was used to shape the sample wares and the samples were fired in the kerosene kiln. Based on the chemical analyses and physical tests performed, the study found that Kaoje, Koko and Giro Kaolins; Birnin Kebbi and Felande ball clays; Aliero, Dangamaji and Katanga limestones; Bena feldspar and Bena quartz are suitable raw materials for the production of table ware. ix TABLE OF CONTENTS TITLE PAGE - - - - - - - - ii DECLARATION - - - - - - - - - iii CERTIFICATION - - - - - - - - iv DEDICATION - - - - - - - - - v ACKNOWLEDGEMENT - - - - - - - vi ABSTRACT - - - - - - - - - x TABLE OF CONTENT - - - - - - - - xi LIST OF TABLES - - - - - - - - xvii LIST OF FIGURES - - - - - - - - xix LIST OF PLATES - - - - - - - - xx ABBREVIATIONS - - - - - - - - xxi CHEMICAL SYMBOLS - - - - - - - xxii DEFINITION OF OPERATIONAL TERMS - - - - xxiii CHAPTER 1 INTRODUCTION - - - - - 1 1.1 Statement of the Problem - - - - - 5 1.2 Aim and Objectives - - - - - - 5 1.3 Research Questions - - - - - - - 6 1.4 Basic Assumptions - - - - - - - 6 1.5 Limitation - - - - - - - - - 7 1.6 Delimitation - - - - - - - - 8 1.7 Justification for the Study - - - - - 8 x CHAPTER 2 LITERATURE REVIEW - - - - 12 2.0 Introduction - - - - - - - 12 2.1 Ceramic Raw Materials - - - - - - - 12 2.2 Plastic Raw Materials - - - - - - 14 2.2.1 Clay - - - - - - - - - 14 2.2.2 Kaolin - - - - - - - - 20 2.2.3 Ball Clay -- - - - - - - - 25 2.3 Non-Plastic Material - - - - - - 26 2.3.1 Feldspar - - - - - - - - 26 2.3.2 Quartz - - - - - - - - 29 2.3.3 Limestone - - - - - - - - 31 2.4 Identification of Minerals