Silicone Rubber Filled Wollastonite Mineral Filler For High Voltage Insulation Application

SILICONE RUBBER FILLED WOLLASTONITE MINERAL FILLER

FOR HIGH VOLTAGE INSULATION APPLICATION

SAHRIL BIN RIZALI

B051410192

SILICONE RUBBER FILLED WOLLASTONITE MINERAL FILLER

FOR HIGH VOLTAGE INSULATION APPLICATION

This report is submitted in accordance with requirement of the University Teknikal Malaysia Melaka (UTeM) for Bachelor Degree of Manufacturing Engineering

by

SAHRIL BIN RIZALI B051410192 950211-01-5771

Disahkan oleh:

_____________________________ ______________________________ Alamat Tetap: Cop Rasmi:

NO 35A, JALAN LIMAU KAMPUNG PASIR 81200 JOHOR BAHRU JOHOR.

Tarikh: 25 Mei 2018 Tarikh: _______________________

*Jika Laporan PSM ini SULIT atau TERHAD, sila lampirkan surat daripada pihak berkuasa/organisasi berkenaan dengan menyatakan sekali sebab dan tempoh laporan PSM ini perlu dikelaskan sebagai SULIT atau TERHAD.

UNIVERSITI TEKNIKAL MALAYSIA MELAKA

BORANG PENGESAHAN STATUS LAPORAN PROJEK SARJANA MUDA

Tajuk: SILICONE RUBBER FILLED WOLLASTONITE MINERAL FILLER FOR HIGH VOLTAGE INSULATION APPLICATION

Sesi Pengajian: 2017/2018 Semester 2

Saya SAHRIL BIN RIZALI (950211-01-5771)

mengaku membenarkan Laporan Projek Sarjana Muda (PSM) ini disimpan di Perpustakaan Universiti Teknikal Malaysia Melaka (UTeM) dengan syarat-syarat kegunaan seperti berikut:

1. Laporan PSM adalah hak milik Universiti Teknikal Malaysia Melaka dan penulis. 2. Perpustakaan Universiti Teknikal Malaysia Melaka dibenarkan membuat salinan

untuk tujuan pengajian sahaja dengan izin penulis.

3. Perpustakaan dibenarkan membuat salinan laporan PSM ini sebagai bahan pertukaran antara institusi pengajian tinggi.

4. *Sila tandakan (√)

(Mengandungi maklumat yang berdarjah keselamatan atau kepentingan Malaysiasebagaimana yang termaktub dalam AKTA RAHSIA RASMI 1972)

(Mengandungi maklumat TERHAD yang telah ditentukan oleh organisasi/ badan di mana penyelidikan dijalankan)

SULIT

TERHAD

DECLARATION

I hereby, declared this report entitled “Silicone Rubber filled Wollastonite Mineral Filler for High Voltage Insulation Application” is the result of my own research except as cited

in references.

Signature : ……… Author’s Name : SAHRIL BIN RIZALI

APPROVAL

This report is submitted to the Faculty of Manufacturing Engineering of Universiti Teknikal Malaysia Melaka as a partial fulfilment of the requirement for Degree of Manufacturing Engineering (Engineering Materials) (Hons). The member of the

supervisory committee are as follow:

………...

i

Abstrak

Getah Silikon dianggap sebagai salah satu penebat yang paling kukuh dalam industri voltan tinggi. Getah Silikon mempunyai keupayaan fungsi seperti ringan, rintangan haba yang tinggi dan ciri-ciri penebat elektrik. Penyelidikan yang dinamik telah dijalankan di seluruh dunia untuk meneroka perlakuan unik penebat Getah Silikon tetapi, tidak banyak perhatian yang diberikan kepada analisis terhadap kerintangan permukaan, kepelbagaian relatif dan Getah Silikon walaupun kedua-duanya penting dalam menentukan prestasi Getah Silikon secara elektrik. Kerintangan permukaan yang tinggi melamabngkan keteguhan Getah Silikon dari luar manakala pembacaan ketelusan relatif yang baik terutama pada frekuensi tinggi mewakili keupayaan pukal bahan tersebut untuk menahan tekanan elektrik yang tinggi. Oleh itu, dalam kajian ini, empat faktor bahan mentah dan parameter pemprosesan telah diperkenalkan untuk mengkaji kesannya ke atas prestasi elektrikal Getah Silikon. Faktor-faktor tersebut adalah isipadu getah silicon, isipadu CaSiO3, kelajuan

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Abstract

This thesis presents the preparation of artificial reinforcement filler for polymeric composite insulation for high voltage outdoor application. Silicone Rubber (SiR) is considered as one of the most established insulator in High Voltage (HV) industry. SiR possesses great function ability such as its lighter weight, great heat resistance and substantial electrical insulation properties. Dynamic researches were performed all around the world in order to explore the unique insulating behaviour of SiR but not much of attention was given to the analysis of the surface resistivity, relative permittivity and inclined plane tracking and erosion testing of SiR despites of their importance in determining SiR performances electrically. Therefore, this three testing was performed in this research. High surface resistivity represents the sturdiness of SiR from outside while good relative permittivity reading especially at high frequency represents the ability of the material’s bulk to withstand high electrical stress. Inclined plane tracking and erosion represent the electrical resistivity of the of material. Compounding process using open two roll mill and vulcanized process using hot press was the method used to produce SiR/CaSiO3 composites. The

characterization used in this research are Particle size analysis (PSA), X-ray diffraction (XRD) and Scanning electron microscopy (SEM). SiR/40wt.% CaSiO3 composites shows

the good performance as insulator performance for high voltage insulation application compare to other composites equal to 4.70 relative permittivity, 3.7 x 1013 _{Ω/sq for surface}

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DEDICATION

Dedicated to

my beloved father, Rizali Bin Deman my appreciated mother, Ambun Tani Binti Bujang

my adored brother, Mohamad Azri Bin Rizali my helpful friends and housemates,

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ACKNOWLEDGEMENT

In the name of ALLAH, the most gracious, the most merciful, with the highest praise to Allah that I manage to complete this final year project successfully without difficulty.

I would like to express the deepest appreciation and thanks to my great supervisor, Dr. Jeefferie Bin Abd Razak. His kindness, unwavering patience and mentorship guided me through the process, his easily understood explanations and open mind allowed me to grow and learn in such a way that I am now a better researcher and it would be impossible to finish this research without him.

Besides, I would like to express my sincere appreciation to Saiko Rubber (M) Sdn Bhd for the equipment provided during the research.

My appreciation also extends to all FKP lecturer for the knowledge that I gain from them, to En Farihan, En Helmi, En Hairul Hisham, En Azhar, Dr Shahrin, Dr Aminudin and En Wahyudi for permission using equipment, sharing the knowledge for handling machine and for their assistance at various occasions. Their views, comments and tips are very helpful in completing this research

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TABLE OF CONTENT

Abstrak i

Abstract ii

Dedication iii

Acknowledgement iv

Table of Contents v

List of Tables vi

List of Figures vii

List of Abbreviations ix

List of Symbols xi

CHAPTER 1: INTRODUCTION

1.1 Background of Study 1

1.2 Problem Statement 3

1.3 Objectives 4 3

1.4 Scopes 4

1.5 Significant of Study 5

1.6 Thesis Outlines 5

1.7 Summary 6

CHAPTER 2: LITERATURE REVIEW

2.1 Silicone Rubber (SiR) 7

2.1.1 Fundamental of SiR 8

2.1.2 Structure of SiR 9

vi

2.1.3.4 Fire Resistance 13 2.1.3.5 Mechanical Properties 14 2.1.4 Application of SiR 15 2.1.5 Limitation and Advantage of SiR 16 2.1.6 Sir in High Voltage Application 17

2.2 Wollastonite Mineral 18

2.2.1 Wollastonite 18

2.2.2 Structure of Wollastonite 19 2.2.3 Composition of Wollastonite 20 2.2.4 Processing of Wollastonite 21 2.2.5 Physical and Optical Properties of Wollastonite 22 2.2.6 Application of Wollastonite 22 2.2.7 Synthetic of Wollastonite 23 2.3 High Voltage Application (HVA) 23 2.3.1 Insulation Principe in HVA 24 2.3.2 Insulation Materials for HVA 24 2.3.3 Related Testing in HVA 25 2.3.3.1 Inclined plane tracking and erosion testing (IPT) 25 2.3.3.2 Surface resistivity testing 26 2.3.3.3 Relative permittivity testing 26 2.3.4 Past Study for HVA 27

2.4 SiR based Composites 28

2.4.1 Theory of Composites 28 2.4.2 Past Study on SiR based Composites 28 2.4.3 Application of SiR based Composites 29 2.4.4 Related Performance of SiR Based Composites 29 2.4.4.1 Mechanical Properties of SiR based Composites 29 2.4.4.2 Physical Properties of SiR based Composites 32 2.4.4.3 Electrical Properties of SiR Based Composites 33 2.4.4.4 Morphological Properties of SiR based Composites 36

vii

CHAPTER 3: METHODOLOGY

3.1 Overview of Methodology 36 3.2 Development of SiR/CaSiO3 38

3.2.1 Development of Artificial Wollastonite 38 3.2.1.1 Curing, Crushing and Making of Raw Material 39 3.2.1.2 Particle Sizing and Compounding Ratio of Raw Material 40 3.2.1.3 Synthesis and Calcination Process of CaSiO3 41

3.2.1.4 XRD Study of Raw Material and CaSiO3 42

3.2.2 Preparation Process of SiR/AW Polymeric Composite 42 3.2.2.1 SiR/AW Preparation 43 3.2.3 Composite Fabrication 45 3.3 Testing Performance of SiR/CaSiO3 46

3.3.1 Surface Resistivity Test 46 3.3.2 Relative Permittivity Test 49 3.3.3 Tracking and Erosion Testing 51 3.4 Morphological Observation using SEM 52

CHAPTER 4: RESULTS AND DISCUSSION

4.1 Overview 53

4.2 Raw Material Characterization 54 4.2.1 Particle Size Analysis (PSA) For Raw Materials 54 4.2.2 XRD Analysis for Raw Materials 57 4.2.3 SEM Observation of Artificial Wollastonite Filler 60 4.3 SiR/CaSiO3 Compounding by Using Two-Roll Mill 61

4.3.1 Curing Time of SiR/CaSiO3 Composites 62

4.4 Testing 63

4.4.1 Surface Resistivity Testing for SiR/CaSiO3 composites 63

4.4.2 Relative Permittivity Testing for SiR/CaSiO3 Composites 64

4.4.3 Inclined Plane Tracking and Erosion Testing (IPT Test) 66 4.5 SEM Observation for SiR/CaSiO3 Composites 69

viii

CHAPTER 5: CONCLUSION AND RECOMMENDATIONS

5.1 Conclusions 74

5.2 Recommendations for Future Work 76 5.3 Sustainability Element 77

vi

List of Table

Table 2.1: Type of SiR, processing and the related properties 8 Table 2.2: Advantage and limitation of SiR 17 Table2.3: Summary of the previous study for HVA by using SiR 27 Table 2.4: Summary of the previous study based on the objective, testing

and system

35

Table 3.1: SiR rubber compound formulation 43

Table 4.1: PSA results for the CaCO3 55

Table 4.2: PSA results for SiO2 56

Table 4.3: PSA results for artificial wollastonite (CasiO3) 57

Table 4.4: Calculation pphr of material 62 Table 4.5: Curing time for SiR respectively with percentage wollastonite 63 Table 4.6: Surface resistivity result 64 Table 4.7: Relative permittivity result of SIR/CaSiO3 at different

percentage

vii

List of Figure

Figure 2.1: Type of SiR organic groups 9 Figure 2.2: The comparison of various rubber properties based on natural

rubber as reference

10

Figure 2.3: The graph volume resistivity vs temperature of various rubber 11

Figure 2.4: The difference of thermal conductivity of different insulator based materials

12

Figure 2.5: Dielectric strength with added silicone percentages 13 Figure 2.6: Comparison of tear strength of SiR 14 Figure 2.7: Compression set of SiR based product at various temperature ranges 15

Figure 2.8: Application of SiR 16

Figure 2.9: Time frame of polymeric insulator 17 Figure 2.10: SEM micrograph of wollastonite crystals 19 Figure 2.11: The structure of pyroxene group and wollastonite 20 Figure 2.12: Characterizing chemical composition of CaSiO3 21

Figure 2.13: Preparation of artificial wollastonite 22 Figure 2.14: Insulation material for high voltage application 25 Figure 2.15: The flexural strength vs temperatures for SRAAM 30 Figure 2.16: Tensile-strain behaviour of SR-H, SR-L and their GO filled

composites

31

Figure 2.17: The (a) tensile stress, (b) tensile strain and (c) Young’s modulus of the mixed SiR and SiR/GO composites

31

Figure 2.18: Size distributions of Al2O3 particles with various size particle diameters

32

Figure 2.19: Effective thermal conductivity with varying with volume fraction of Al2O3 fillers

33

viii

Figure 3.1: Flow chart of overall methodology 37 Figure 3.2 (a): The granule and powder form of waste glass and seashell 39 Figure 3.2 (b): Insmart System-Planetary Mill Machine 40 Figure 3.3: The vibration rotary mill 40 Figure 3.4: The particle size analyser 41 Figure 3.5: Ball milling machine. 41 Figure 3.6: PanAnalytical XRD machine 42 Figure 3.7: Open two roll mill (Saiko Rubber (M) Sdn Bhd) 44 Figure 3.8: Rheometer machine (Saiko Rubber (M) Sdn Bdn) 44 Figure 3.8: Hot press machine 45 Figure 3.10 (a): Sample specimen for surface resistivity test 45 Figure 3.10 (b): Sample specimen for tracking erosion test 46 Figure 3.11: Portable resistivity meter 47 Figure 3.12: The set-up used in measuring sample’s surface resistivity 47 Figure 3.13: Confidence check performed on piece of paper 48 Figure 3.14: Dielectric Probe Kit with PNA-X Vector Network Analyser 49 Figure 3.15: The summary diagram of relative permittivity measurement using

VNA

50

Figure 3.16: Schematic diagram of tracking resistance experimental setup 51

Figure 4.1: Particle size range for CaCO3 54

Figure 4.2: Particle size range of SiO2. 55

Figure 4.3: Particle size range of CaSiO3 56

Figure 4.4: XRD pattern of CaSiO3 58

Figure 4.5: XRD graph of CaCO3 59

Figure 4.6: XRD result of SiO2 59

ix

Figure 4.13: Mass loss for the inclined plane erosion test. 68 Figure 4.14: Erosion in the sample 69 Figure 4.15 (a): SiR/40% CaSiO3 interaction not very well 70

Figure 4.15 (b): SiR/40% CaSiO3 defects 70

Figure 4.15 (c): Dispersion of SiR/40% CaSiO3 71

ix

LIST OF ABBREVIATIONS

IP - Incline Plane

ASTM - American Society for Testing and Materials

SEM - Scanning Electron Microscopy

TNB - Recently, Tenaga Nasional Berhad

SiR - Silicone Rubber

AW - Artificial Wollastonite

HTVSR - High Voltage Temperature Vulcanized Silicone Rubber

HPTT - Hexakis-cyclotriphoslhazene-triazine-triamine

HVA - High Voltage Application

IPT - Inclined Plane Tracking and Erosion Test

HTV - High-Temperature Vulcanized

ATH - Aluminum Hydroxide

Pt - Platinum

NS - Nitrogen-containing Silane

GNR - Graphene Nanoribbon

GO - Graphene Oxide

SRAAM - SiR/ammonium polyphosphate/aluminium hydroxide/mica composites

SiR/AW - Silicone rubber/Artificial Wollastonite

x

SiO2 - Silica

XRD - X-Ray Diffraction

PPHR - Part Per Hundred Rubber

LC - Leakage Current

DCP - Dicumylperoxide

Ca - Calcium

Si - Silicon

PSA - Particle Size Analyzer

xi

LIST OF SYMBOLS

wt.% - Weight Percentage

℃ - Degree Celsius µm - Micro Meter

̊ - Degree

Ω - Ohm

g - Gram

cm - centimetre

kV - Kilo Volt

1

CHAPTER 1

INTRODUCTION

This chapter explain briefly about the study of this subject. This chapter includes background of study, problem statement, scope, significant of study, thesis overview and summary of the chapter one.

1.1 Background of Study

Insulator is a material that the electron cannot flow freely. Therefore, it is very high resistance. Insulator does not only provide mechanical support to conducting part, but it also used to separate conductors to wipe out conduction amongst them and to store a charge when voltage is connected (Kuffelet et al., 2001). Thus, insulator is called dielectrics. Dielectric strength means the ranking of a material to the voltage breakdown. Therefore, to produce the good insulator, the material must have highest dielectric strength. Recently, insulator act as cable protection under DC conditions has got more consideration because of the quick improvement of high voltage DC and it would offer extraordinary help on enhancing the security and unwavering quality for power transmission system (Zhang et al., 2017).

2

insulator has been replaced by polymeric insulator in the electrical insulation of power system in the last decades. Xie et al. (2017) stated that, the uses of silicone rubber composite insulators have increased on transmission and distribution voltage around the world. The some of the reason are the light weight, convenience for transportation and installation, hydrophobicity and resistance to vandalism. Since polymeric insulation are accepted in high voltage application, a lot of research studies had been performed to improve the polymeric insulation performance. One key to resolve the development of high performance is by improve the tracking resistance and flame retardancy of polymeric insulation.

Filler in matrix is important to increase the polymeric performance. As an insulator, the good candidate for the polymeric material is ceramic. The heat resistivity of the ceramic, can enhance the performance of the polymeric insulator. The proposed polymeric insulation material under study is SiR as a matrix with wollastonite (CaSiO3) mineral filler as a

reinforcement. SiR has excellent dielectric strength that can contribute for a superior high voltage. The addition of inorganic filler is the method in modifying polymer materials. Wollastonite as an inorganic filler is a unique functional mineral. Its acicular crystal habit, great hardness and produced polymer composites fortifying properties (Meng & Dou, 2008).

1.2 Problem Statement

3

Besides, the problem related to removal of the large number of waste glass and waste cockles shell are met. The serious action must be taken because of the continuous amount of the waste increase. Therefore, to overcome this problem, converting waste into wealth by recycling of both and it provide benefits to our environment and economy. Aman et al. (2013) have studied to applied a recycle waste material like glass and seashell with thermoplastic polymeric material to produce polymer composite as high voltage insulation. Therefore, this recycle material can reduce the environment effect to the society.

Polymeric materials such as silicone rubber (SiR) is increasingly being used as exterior insulator in electrical and electronic applications, such as high voltage transmission lines, bushings and cable terminations, due to its advantages of light weight, high insulation and superior resistance to contamination. However, when being employed as exterior insulator in polluted environment, the pollutant and moisture covered on the surface of SiR will result in leakage current and arc discharge. Due to dry band arcing, SiR is prone to tracking and even smouldering combustion, which severely threatens the reliability of the insulation system. Therefore, this research is going to solve the problem related to the high voltage insulation application.

4

1.3 Objective

The objectives of this research are:

i. To evaluate the physical insulation behavior at high voltage exposure of SiR/CaSiO3

based composites.

ii. To evaluate the electrical properties insulation behavior at higher voltage exposure of SiR/CaSiO3 based composites.

iii. To observe surface morphological of SiR/CaSiO3 composites and correlate it with

the resulted physical, and electrical properties using SEM observation.

1.4 Scope of Study

The scope of this study are:

i. Raw material with is the silicone rubber (SiR) polymeric materials and waste materials like glass and cockles to produce artificial wollastonite (AW) to establish the new polymeric composite.

ii. The methodology used is only open two-roll mill (compounding), Hot press (Cur-ing), 60℃ oven post-cured.