PRODUCTION OF EMULSION PAINT USING LOCALLY SOURCED SILICON DIOXIDE AND ALUMINOSILICATE

Paint serves a dual function of providing both protection and aesthetic enhancement to surfaces, yet the high cost and reliance on imported raw materials, particularly fillers like calcium carbonate (CaCO3), pose significant challenges for manufacturers in developing economies. This project explored the use of a mixture of locally sourced rice husk ash (RHA) and kaolin clay as a sustainable and economical extender in water-based emulsion paints, with the goal of determining if these abundant, low-cost materials could effectively replace traditional fillers without compromising important paint properties. The methodology involved the preparation of both materials, which included sun-drying the rice husk before calcining it in a furnace and oven-drying the kaolin clay. The materials were then characterized using Scanning Electron Microscopy (SEM) and Energy Dispersive X-ray (EDX) Spectroscopy, which revealed a porous silica-rich RHA and a plate-like aluminosilicate kaolin. The prepared materials were then mixed in equal ratios and incorporated into a standard paint formulation. Performance tests showed that the RHA-kaolin blend produced a paint with properties highly comparable to a commercial CaCO3 control sample, including a slightly lower pH (7.08), higher viscosity (10700 mPa•s), and lower density (1.30 g/ml), while both formulations demonstrated excellent adhesion. In conclusion, these findings suggest that the blend of RHA and kaolin clay is a promising and cost-effective option for the paint and coatings industry, offering a sustainable solution for industrial waste and a viable product with acceptable performance characteristics that can help reduce a nation's reliance on imported raw materials.