Optimizing Performance of Porcelain Insulators: How does Particle Size Influence Dielectric and Mechanical Strengths?

Porcelain insulators are mostly created from the combination of the particles of Clay, Silica, Kaolin, and Feldspar. This implies that different particle sizes contribute to the insulating properties of the materials. In this paper, we attempt to create a set of model porcelain materials by critically analysing the particle sizes that are most likely to yield the best insulator results. Materials sourced from Edo State, Nigeria were processed to produce Porcelain insulator samples. For each of the component minerals, a 65g mass was compacted and pressed at 500 Psi (3.4 KN) into a steel cylindrical mould via hydraulic press, this was closely followed by firing at 1200°C. Porosity, bulk density, insulation volume resistivity, as well as dielectric strength, and their relationship with particle sizes were evaluated. Results obtained showed that porosity of the Porcelain materials shared a direct relation with particle sizes, while the bulk density showed an inverse relationship. It was also observed that the 150 µm particles yielded the most effective insulators, given higher insulation volume resistivity and dielectric strength. Altering particle size from 150 µm tends to lower the insulation volume resistivity and dielectric strength.