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Feldspar---how it works as an important industrial mineral
Feldspar---how it works as an important industrial mineral

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FELDSPAR comprises a group of minerals containing potassium, sodium, calcium and aluminium silicates. They are the most common rock-forming minerals. The common feldspar is potassium feldspar, namely, orthoclase (K2O, Al2O3, 6SiO2). Sodium feldspar is albite (Na2O, Al2O3, 6SiO2) and calcium feldspar is anorthite (CaO, Al2O3, 2SiO2).

 

The commercial feldspar is orthoclase. The potassium molecule is replaced by sodium to some extent and hence, orthoclase feldspar usually contains a small percentage of sodium. The composition range of the commercial feldspar varies within the limits of potash, soda and upto oligoclase.

Potash and soda feldspar occur as essential constituents of granite, syenite and gneisses. However, workable deposits are found in pegmatite veins consisting mainly of feldspar, quartz-feldspar veins and also occur with mica pegmatites. Feldspar is of widespread occurrence and is mined in almost all countries

 

Feldspar is generally used for three purposes

In making the body composition of several types of procelain, china and earthenware and also in the preparation of glazes and enamel. As an important ingredient in the glass sand batch. As a bonding agent in the manufacture of bonded abrasives like wheels and discs of garnet, corundum, emery etc.

The glass and ceramic industries are the major consumers of feldspar and account for 95% of the total consumption.

In ceramic bodies, the main vitrifying (fluxing) agent is feldspar. The majority of white ware bodies contain good proportions of feldspar. It acts as a flux. In the ceramic industry, the flux is defined as that portion of the body which develops glass phase. This is provided mostly by feldspar. The amount of flux in a ceramic body should be only in such a proportion as to develop the desired amount of vitrification. If excess of flux is added, the fired body becomes very glassy and consequently, brittle.

Feldspar is used in varying proportions in porcelain, china and earthenware. Earthenware contains on an average

12% feldspar 25% ball clay 28% china-clay 35% quartz

This proportion of feldspar varies in different products like

Wall tile -5% Floor tile -30% Statutory porcelain -50% Sanitary china and prodelain bodies -30%

In the glass industry also, potash feldspar is used in varying proportions. It may contain 10 to 15% of the batch. Feldspar, in this industry, is valued for two purposes, firstly, it acts as a flux and secondly, for alumina content. Alumina provides the resistance in glass to impact, bendings, and thermal shock.

In ceramic bodies, potash feldspar is preferred although soda feldspar works as a good flux and can be satisfactorily used in developing ceramic bodies. Potash feldspar has p.c.e. value 10, while soda feldspar has 8-9. Anorthite (the calcium feldspar), though it contains twice as much alumina as soda and potash feldspars and also contains lime which is an important ingredient of glass, is not preferred in the glass industry because it is more refractory (p.c.e. 12). Glass industry prefers to use mainly orthoclase (potash feldspar) because it tends the melt to clear glass while albite (soda feldspar) tends the melt to a translucent glass.

Feldspar is used as bonding agent along with magnesium oxide, magnesium chloride and other synthetic glue in the manufacture of abrasives, wheels, discs and other shapes. In the preparation of glazes the fine powder of feldspar is mixed with silica powder and a thin slurry is made. The fired up goods are dipped into the slurry and fired again. This imparts glaze to the surface. Some other ingredients are also added to the slurry to impart glaze and lustre. Each pottery factory has its own technique of preparing slurry which is regarded as a trade secret.

Market Specifications
In the manufacture of high-class, colourless glass, feldspar should have a maximum of 0.1% Fe2O3 though upto 0.3% is permissible. The presence of iron in the batch composition for glass is not liked because its presence, even in very small quantity, tends to colour the glass. The mesh size required is 40-80 BSS in the glass industry. A still finer mesh can be utilized in the ceramic industry. In this industry, a little higher percentage of iron content in feldspar is not objected to. However, in the preparation of white wares feldspar containing below 0.4% Fe2O3 is preferred.

Feldspar is also an important constituent for the preparation of white and coloured enamels for metallic and ceramic surfaces. Of late research is being done to utilize feldspar in the production of good quality, white portland cement.

In recent years, nepheline syenite has been found as a good substitute for potash feldspar and is being used in an increasing amount in Canada and USA. Nepheline syenite is an igneous rock consisting chiefly of nepheline, microcline and albite.

 

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