Ceramics : ceramic stoneware, porcelain China and electro-porcelain

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LIMITED

16 December 1966

BE GUSH

Original: EflMCS

ECONOMIC COMMISSION FOR AFRICA' Sub-regional Meeting on .Economic

Co-operation in West Africa

Niamey 10 - 22 October 1966

CERAMICS

(Ceramic stoneware, porcelain ohina and electro-porcelain)

M66-1229

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TABLE 0^ CCBTEMS

Page

I. INTRODUCTION x

II. THE PBESEHT POSITION 2

III. PROJECTION UP TO 1980 6

IV. HAW MATERIALS l2

(i) Stoneware ceramics J-3

(ii) Ceramic materials in porcelain, china and vitreous 16

v, i^coMMrmTiors ahd summaby 20

% A brief description of the ceramic factories at

Bamako and Saltportd

JOTEX II. Growth rates of industry and private consumption

in West Africa up to 1980

AlffiBX III Imports of ceramic materials into West Africa in

I96O-I964 classified technologically

IY0 Price of ceramic products in various countries of the world and in West Africa in I963

V. The breadkowi of expenditure for the manufacture of

. ceramic sandstone

ANNEX VI, Imports of ceramics in West Africa in I96I-64

\ /

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CERAMICS

1. Ceramics covers a wide range of products prepared from natural clay-

raw materials, whence it derives its distinctive characteristics when

"baked. Some of the products require to have their surface improved "by-

glazing" or varnishing. Ceramic products are as follows:

(i) For building:

- Bricks, tiles, hollow ceiling pots, girdersj etc. ■

- Stoneware productss Floor tiles, stoneware pipes,

stoneware tiles, etc, - Wall tiles made of china

- Ceramic materials for'sanitary purposes: sinks,

washbasins, bath-tubs? lavatory bowls, etc.

(ii) Products, for everyday use: . ....

- In chinas tableware, ornamental ware, ceramic materials

for artistic use,

- In porcelain? as 'above*

- Cooking utensils, flower-pots', ornamental vases made of'

pottery*

(iii). Products for industrial use?

-.Refractory products ....

- Products, in porcelain .and stoneware, .for chemistry and.

laboratories .. . .,.-..

- Electro-technical porcelain.

2, In this report, we shall deal with ceramic products leaving out of

account the products used in brickworks and refractory products, for

■which separate reports have been prepared. The subjeut of this report is

arranged under three headings:

(i) Ceramic stoneware. Stoneware is prepared from stoneware clay*

It is a clay wHose basic property lies somewhere between the

point' of softening and the point of melting, and is' not much

affected by heating. It is possible to obtain stoneware clay

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Page 2

from a non-stoneware clay of the melting type, for instance,

"by an admixture of nephelinic syenite or feldspar. Stoneware clay invariably takes on a shade of colour when "baked.

(ii) Ceramic materials in china, vitreous, or porcelain, prepared

"by means of pressurization either dry or humid. The following products are obtained by this methods covering tiles, some tableware, and some products for industrial use. The raw materials are: clay "burnt white, suitable for moulding, kaolin burnt white, feldspar, nephelinic syenite, pure sand

or broken quartz' and limestone.

(iii) Ceramic materials in china, vitreous or porcelain, prepared

by melting the ceramic paste in gypsum moulds. The following products are then obtained^ .some types of ware, ceramic

materials for sanitary purposes, ceramic products for artistic and ornamental use* The raw materials used are the same as in

the case of (ii).

3. Pure kaolin is never found since it always adulterated with sand, mica, etc. It is absolutely necessary always to wash it in order to extract pure kaolin* The ratio of pure kaolin to kaolinic clay is about Is2, and sometimes as much as Is4« It would be an advantage to put up a ceramics factory near kaolin deposits, extract and concentrate the

kaolin in larger quantities according to the needs of the particular factory and sell the washed, concentrated kaolin to other ceramics factories* We shall confine our attention to this proposal.

II. THE PSESEUT POSITION

1. In West Africa ceramic requirements are pratically over-supplied from imports and handicraft production. There are at present three ,

ceramics factories under construction at Bamako, Saltponcj (Ghana) and . . .

in the eastern region of Nigeria.

2. Ceramic products, except the products from brickworks, refractory and electro—porcelain products are; included in the customs statistics, and follow the SITC and BTN classification so far as the following .categories

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^

E/Gff.l4/orR/ll2

Page 3

are concerned*

662,4(3) Ceramic piping, conduits 69*06 Piping, conduits and guttering

and guttering

662.4(4) Unglazed ceramic setts, 69»O7 Unglaaed setts, flags and paving,

flags and tiles hearth, and wall tiles

662»4(5) Claaed ceramic setts, 69.08 Glased setts, flags and paving,

flags and tiles hearth and wall tiles

663.9(l) Laboratory and industrial 69.09 Laboratory, chemical or industrial

ceramic wares, etc. not ■wares (in stoneware, porcelain);

refractory similar articles of ceramic

materials

663*9(2) Other articles of ceramic 69.14 Other articles of ceramic materials

materials

666.4 Porcelain or china house- 69-11 Tableware and articles for domestic

hold ware purposes

666.5 Householdware of other 69.12 Tableware'and articles for domestic ceramic materials or toilet purposes of other ceramic

materials

666*6 Ornaments and furnishing 69.13 Statuettes and other ornaments

goods of porcelain, china and articles of personal adornment?

Or other ceramic materials articles of furniture

812,2 Sinks, wash basins,"bidets,69*10 Sinks, wash basins, bidets, water baths and other sanitary closet pans, and like sanitary

and furnishing fixtures and fittings of ceramic materials, fittings of ceramic

materials.

Electro-porcelain is included in electrical apparatus and there is no

special classification for this type of ceramic material.

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TABLE1 ImportsofoeraminaeterialaintheHeatAfrioanSub-rag

•** DahomeyIvoryOoaBtHigariaSenegalTogotipperVoltaTotalforthe 9countriesEstimateforthe sub-regionunitary prioe

Average mption 1/10£USperkggr.peroapitH 1011IE1314151617E3 662.3(1)Heatinsulatingbricks 662.3(2)Refrantorybricka 662,4(1)Buildingbrioks 662.4(2)Hoofingtilas 662.4(3)Ceramicpiping 662.4(4)Ungl&sedceramicsetta fla^flandtiles 66E.4(5)Glassdoeramicsetts■ flagsendtiles 663.7Hefraotoryproducts otherthanrefractory 663.9(1) 663.9(2) 666.4 666,5 666.6

Labo tria Othe Pore hous Hous Orna

ratoryandin 1ceramicwar xarticlesof eholdware eholdwareof mentsandfur

0.9 2.5 0.3 38.7 19.9 0.2 0.4 1.2 2.7 14-0

0.1 19.0 2.8 191.1 92.7 0.2 0.7 1.0 1.8 31.9

-1.22.8 208.2B59.59.464.I 12.396.40.49-3 111.2314.6 57.0358.51.919.2 78.3534.2305.71454-9 215.7884.E104.0420.1 213.4127.62.42.6 29.37.5S.92.2 2.01.827.6EE.9 174.6402.149.522.4 141.0273-9HI-8233.2 0.41.7564*53917.40.62.6 0.20.41.23.5609.53571.336.2375-6 ---10.E58.95-088.6 0.56.9--279.81021.66E.1762-3 1.65.70.42.730.6122.25.871.9 29.5141.133.3154.5239.76.7265-91383.7 42.199.68,531.4357.71469.2110.0492-4 goodsofporcelain,ohina rials1.92.639.340.822.619.9

0.1...24.099.32.817.6 0.60.21.02.966.472.22.55.0 0.50.51.10.666.372.04.37.7 7.77.3'2.6E.4686.2I609.I33.233.5 13.420.15-17.1321,01006.585.O217.1 0.50.31.01.174.3138.428.130.2

0.2 5.4 - 1.1 17.2 22.9 1-9 0.6 1.9 7.9 8.1 8.4

1.2 32.7 - 9.2 92.8 105.5 2-4 0.2 1.4 10.2 14.5 7-7

0.2 0.1 0.1 64.8 14.4 1.4 1.6 8.8 15.0 4.0

1.3 316.7 58.9 E.6 0.5 2.6 51-3 4.1

567.8 874-6 27-9 453.7 93.8 1073.1 895.2 246.2 111.3 104.9 973.4 714.4 18O.I

3214.0, 4927.4' 253.4 2125.4 592.2 5127.7 3654.0 252-3 91.4 107.9 2291-4 1355.6 245-1

621.2 956.5 30.5 496.3 108.1 1173.8 979.4 269,4 121.8 121.0 IO64.6 781.6 197-3

3516.4 5390.0 277.1 2325-3 647-8 5609.9 3997.4 276.2 99.8 124.7 2508.6 2030.3 262.7 Sinks,Hashbaaina,bidets, bathaendothersanitary "andplumbingfixtures andfittingsof 16.038.0395-0711-0139.O342.023.041.017.038.0747-01366.0122.0372.017.037.024.058.01500.03005.0I640.93287.3 1960-1965 Total662 662.3 662.4 663.7 663.9 666.4 666.5 666.6 812.2 662.3 663.7 666 812,2

(inmillions) +663+666+8lE Total Total

2.25 98.7 3.4 58.9 0,2 1.6 2.7 14.0 '1.9 16.0 98.7 62.3 1.8 '18.6 16.0 98.7

339.9 27.1 286.6 O.2 1.7 1.8 31.9 2.6 33.0 389-9 313-7 1.9 36.3 38.0 389.9

7-11 1677-5 208.2 474-5 213-4 31.3 174-8 141.0 39.3 395-0 1677.5 682.7 244.7 355.1 395-0 1677.5

4612.1 859.5 2167.9 127.6 9.3 402.1 E73.9 40.8 711.0 4612.1 3047.4 136.9 716,8 7U.0 4612,1

3.63 784.4 10.6 412.0 2.4 36.5 49-5 111.8 22.6 139.0 784.4 422.6 38-9 183.9 139-0 764.4

2615.6 66.9 1903.5 2.6 25.1 22.4 233.2 19.9 342.0 2615.6 1970.4 27.7 275.5 342.0 2615.6

4-34 119.6 0.2 73.7 - 1.1 7-7 13-4 0.5 23.0 119.6 73.9 1.1 21.6 23.0" 119.6

323.1 0.4 253.3 - 0-7 7.3 20.1 0.3 41.0 323.1 253.7 0.7 27.7 .41.0 323.1

3.05 71-7 1.6 42.2 0.1 2,1 2.6 5-1 1.0 17.0 71.7 43.8 2.2 8.7 17.0 71-7

245.9 5.2 18fl.6 3.5 2.4 7.1 1.1 38.0 245.9 193.8 3.5 10.6 33.0 245.9

54.00 4077.2 1174.0 918.0 24.O 132.7 686.E 321.0 74.3 747.0 4077-2 2092.0 156-7 1081.5 747.0 4077.2

14862.8 6766.7 3530.6 99-3 144.2 1609.1 1006.5 136.4

3.29 765.5 38.8 446.3 2.8 6.8 33.2 85.O 26.1 1368.0122.0 I4864.8 10299.3 243.5 2954.0 1366.0 14864.8

765.5 437.6 9.6 146.3 122.0 765.5

3880.6 378.4 28I9.I 17.6 12.7 33.5 217-1 30.2 372.0 3880.6 3197.5 30.3. 280.8 372.0 3880.6

1.54 92.6 5.6 41.2 1-9 2.5 7.9 8.1 B.4 17.0 92.6 46.8 4.4 £4.4 17-0 92.6

314.8 33.9 207.5 2.4 1.6 10.2 14.5 7.7 37-0 314-8 241.4 4.0 .32.4 37.0 314.8

4.54 134-4 O.2 79.4 1-4 1.6 8.6 15-0 4.0 24.O 134.0 79.6 3.0 27.8 24.0 134.4

496.0 1.3- 375.6 2.6 0.5 2.6 51-3 4.1 58.O 496-2 376.9 3.1 58.0 58.0 496.0

33.75 7821.6 1442.6 2548.7 246.2 216.2 973.4 7H.4 180.1 1500.0 7821.6 3991.3 462.4 1867.9 1500.0 7621.6

27742.8 8141.4 11752.7 252.3 199.3 2E91.4 1655.6 245.1 3005.0 27742.8 19894.1 451.6 4392.1 3005.0 27742.8

91.62 8562.4 1577.7 278B.1 269.4 242.8 1064.6 781.6 197.3 1640.9 8562.4 4365.8 512.2 2043.5 I640.9 B562.4

30353.5 8906.4 12857-5 276.2 224.5 2508.6 2030.3 262.7 3287.3 30353.5 21763.9 500.7 4801.6 3287.3 30353.5

176.6 177.5 110.1 213.4 166.9 209.2 245.0 975-4 1220.4 970.3 424.4 365.0 282.1 177-1 216.8 975-4 1081.5 424.4 335-0 751-0 499.2 282.1 200.6 1023.0 425.6 499.2 282.1

38.4 58.8 3.0 25.0 7.1 61.2 42.6 3.0 1.1 1.4 27.4 22.2 35.9 331.3 97.2 140.3 3.0 2.5 27.4 22.2 2.9 35.9 331.3 237.5 5-5 52-4 35-9 331.3

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Page 5

3. Imports of these particular categories for the period 1961-64 are to

be found in Annex VI9 and imports for all types of ceramic materials in Table 1.

4. We may separate the customs classifications into technological classifi cations, in accordance with the three classifications of ceramic materials given in Ch. I par, 2, and the following estimate of percentages mil be

obtained.!

662.4(3) 662,4(4)

662.4(5)

663,9(1) 663,9(2) 666.4 666.5

666*6 812.2

TABLE 2 Percentage of technological

Products in, ceramic stone

ware- ' : ■

100 80 70

■ ! 75

- . '-

■ - ■

- ■ ."

_

classifications Pressurized products

—

20 30 25 50

-

50 - ■

-

Molten i-roducts

-

_

50 100 50 100 100

The import figures in tons of these technological classifications are to be found in Annex III. The results for West Africa are as follows for the years 196I-64; ,

(i) Products of ceramic stoneware 8.C10 tons per year 1961/64 (ii) Pressurized products 3-430 tons per year 1961/64 . (iii) Molten products 7*130 tons per year 1961/64

Totd-1 18,570 tons per year in 196l/64

5. There is practically no local manufacture of ceramic materials at

present in West Africa because the Bamako factory is still under construction, and in the case of the Saltpond factory, it was only this year that a

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Page 6

contract was signed for "building operations to "begin. Another.factory

in the eastern region of Nigeria came into production also, only this

year.

Ill, PROJECTION UP TO 1980

1, For projection purposes,, two methods may be used in principle* one

based on the direct calculation of requirements in ceramic products for industry and new constructions, the other on the link between.consumption of ceramic products and the growth rate in building, industry and private

consumption.

The first method is complicated because ceramic materials are needed

not only for buildings and new factories but also for maintenance. The

life span of ceramic materials for sanitary purposes is about 10-12 years.

The life span of wall or floor tiles of ceramic materials is about 15-20

years, which means that the maintenance is considerable. ..

Statistics regarding, the number of houses equipped with ceramic

materials for sanitary purposes, wall tiles and floor tiles, are practically non-existent where West Africa is concerned, and that is why direct

"calculation cannot supply more accurate results than the second method.

Direct calculation is relatively complicated, but in spite of this complica

tion in these ineffective circumstances, we shall rely upon the present

"Consumption and the use of the earna growth rate for ceramic "■

materials, .as proposed for development in the building industry and private consumption.

2. Before starting to make the calculation, it is necessary to separate the customs classifications of merchandize for bur.lding, industry and private consumption,

■ (i) The building industry includes the following classifications:

; 662.4(3) ceramic piping, conduits and guttering 662,4(4) unglazed ceramic setts, flags and tiles 662*4(5) glazed ceramic setts, flags and tiles

812.2 sinks, wash basins, bidets, baths and other sanitary and

plumbing fixtures and fittings of ceramic materials.

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fe3^-5«i^

Page 7

(ii) Industry includes the following classifications:

663,9(l) Laboratory and industrial ceramic wares, etc.,;not

refractory

: 663.9(2) Other articles of ceramic materials.

(iii) Private consumption includes; ■ ■ . ;

: ; 666*4 Porcelain or ohina householdware ;

\ \ 666,5 Householdware of other ceramic materials.

\ . 666.6 Ornaments and furnishing goods of porcelain, ohina

: ; or .other ceramic materials. .; \

3. The consumption of chese various classifications is indicated in the

following table for the period 1961 to 1964*

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Page8

Total

(ii)Industry

663.9(1) 663-9(2)

Total

(iii)PrivateConsumption^

666.4666.5666,6

Total TABLE3

Consumption of ceramic materials in wflat. Africa in 1961 to 1964

1000$

fi)Construction

6624(3) 662.4(4) . 662.4(5)

812.2 74.2

,1,124.0

979-91,824.1

132.2

130.7262.9

1213-7■870.8

208.5

2293-0 440.04874.34258.93611.7

253.6 1,608.4 45-6 1069=2 4,884.9 II87.O 966.4 3,862,9 1018.2

1594-63,055=81552*4

4,002.2 '13184.9 3883.8 13,412.0 3803=2

129*2

152,7

281.9

2634-1

2271.7

"272.5 1128.6

734-2

217-9 2660.51858.9297.6

5178.3 • 2080.7 4817-0

241.27063.7

4348.5

3282.8

2

58.7

86.6

145-3

2375-3

1550.4

290.0 59.0

1315=1

952.5

1537.0

1015.6

845.9

138.7 301.4

5615.5

3519.03335.5

1961/1964

^1000$

T

108.1647-81173.85609.9

979.43997-4

1640.9 3287.3

3863,6 12771.4 3902,2 13542-4

121.899.8

121.0124.4

242.8224.2

2365.32438.8

190.7 IO64.678I.6197.3 2508.62030.3

262.7

4215.7 2000.2 4994*8 2043.5 4801.6

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Page 9

4. The proposed growth rates for these industrial sectors for the period

1965-1980 are as follows for West Africa? .

' ' ' Construction ■ 8.6 per cent Industry . 14*3 per cent Private consumption .-6.2 per cent ■

The gro-wth rates for particular countries are to 'be found in Annex II The detailed calculation of consumption will be found in Annex III, .and the results in respect of West Africa1s requirements in 1980 (in tons)

are as follows s

(i) The "building industry 662.4(3) ,

* ' 662.4(4)' '

■ . . 662.4(5)- ., >i; 812.2 "■.'./

'Total 13,548 -46,752

1965

648 5,610 4,00ft 3,290

33m:

2,232 19,320 9 13,800 11,400

(ii)

(m)

Industry

663.9(1)

■663,9(2)

Total

Erivate consumption

666,4.

666,5

666.6

m ": Total

■100

■' l25

225

2,510 2,030

263 ■ 4,803

741 927 1,668

6,180 5,000 650 11,830

(iv)a Total ceramic

" products? ;.. 18,576 :■. ■■ 60f250'

•1

5, If proposals are t» be put forward' for developing the ceramics the customs classifications will have to be divided int« technological

•lassifications in accordance with chapter Ijpar«\2»-

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Page 10

TABLE 4

Requiremenlia in ceramic materials in 1980, divided technologically

;D,ahomey Ghana

Ivory Coast. . Mali

Higer Nigeria- ■■■

Senegal Tog©

Upper Volta'

-' Total

Other countries Total for the sub—regions

Pressurized ceramic :. ■ materials

:l9Q. ..

1,280 1,830 230 180 4*650 1,350 190 56O 10,460 740'

11,200

Molten ceramic materials

110 . 2,090 . .2,700 170 150 12,540 1,250 180 410 i?,6.no 1,600

21,200

Ceramic stoneware

420 3,860

: 5,140

700 58O

9,'8OO

3,900 550 1,680 26,630 1,370

28,000

Total

720 7,230

9,670

1,100 910 26,990 6,50a 920 2,650 56,690 3,710

.. 60,400

6o There are at present tw> factories which manufacture cermiP mate t» meet these needs, one at Bamako and t&e other at Saltpond (Ghana) *

A brief description of these factories can be found in Annex I# The.

capacity of the Bamako factory is 550 tons a year, and the one at Saltpond 2,100 tons a year with the following manufacturing programme

(in tons per year)s

H*uaeholdware

For sanitary purposes Setts.

. . . . . ' Total..

Bamako 110 220 220

■ 550

Saltpond

600 1,500

Total lie 826 .. 1,720

2,650

2,100

In the eastern region '*f Nigeria there is a ceramics factory f«3?

sanitary purposes which has just come into production, "but there is"n#

information nor any data about this factory.

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e/cct.

Page 11

7- .There are two factories under consideration, one in the. Niger based on the kaolin deposits at Gogare and Say and the feldspar deposits at.

Tillabery, which will have a capacity of 1,400 tons in 1970. and 2,000 tons in 1975* ^ks second is to "be found in the Ivory Coast, based on the kaolin deposits at Gounioube where a few layers exist. Its total resources are 1.35 million cubic metres, although.the capacity and

other relevant data concerning this factory have not yet been established*

8. The complete breakdown of ceramic materials in West Africa is as

follows in tonss

; . ■ TABLE 5

Break-down of West Africals requirements in ceramic materials in 1980

Requirements in 1980

(in tons)

Production in 1965-70

(in tons)

Dahomey Ghana

Ivory Coast Mali

Niger Nigeria

Senegal Togo

Upper Volta Other countries Sub.—region

White "

ceramic materials ,, 300

3,370 4,530 400 330 17,190 2,600 370 970 2,340 32,400

Ceramic stoneware

480 3,860 5,140 700 58O 9,800 3,900

550 "" '■

1,680 1,370

■28,000

White ceramic materials

.2.100

550 2,000

■ 4,650

Ceramic stoneware

To these figures must be added also the requirements in electro- porcelain, with estimates of requirements in 1980, between 3,500 and 5,000 tons per year, and the requirements in enamel for household enamel metalware, with an estimate of approximately 5j000 tons a year of enamel

frit in 1980. ■

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Page 12

IV. RAW MATERIALS ' , : . ■ ■ '

1, . The raw materials required are' clays burnt white, kaolin burnt white,

feldspar, pure sand, pure.limestone (possibly) nephilinic syenite, gypsum

forms and glazing. Up to the present, kaolinic clay deposits are known to exist in the following countries^

Ghana - Saltpond, Kibi

Ivory Coast - Gounioube

Mali ' - Yanfolila and the banks of the Saakorani river'

Niger - Godare, Say

Nigeria - Sokoto, Abeokuta (Onibode, Muroko-Lisabi, Kenta- . Ijeja, Aiyetoro, Bamajo Base, Totogangan) Ojumbulu.

Senegal -A search is "being made for kaolin deposits in the eastern part of Senegal-

Guinea - Koyah, Kankan, Boke»

2, Deposits of pure sand are known to .exist in,Liberia, Mali (Faguib^ne and M'Bouna), in Higeria (Snugu, Mokwa, Bida), and Senegal (Cape Verde), in the Ivory Coast (near Abidjan) and in Ghana (a number of deposits)-*

Feldspar deposits are known to exist in Nigeria and Ghana. There are

nephilinic syenite deposits in Sierra Leone( Kenema), Ghana (Senchi) and in Higeria (Ogoja).

3, From the above information it will be observed that sufficient raw material can be found in ¥est Africa for ceramics,, but up to the present

the geological services have not paid sufficient attention to it, and these deposits are known only in part- It may be assumed that the ^ . development of ceramics, which is a thing to be. desired, can be based on these deposits.

4* Before making any calculations a few prerequisites must be stated,, because there- is-no accurate knowledge of the raw- material- deposits.. It-

may be assumed.that.it is possible to secure basic raw materials, but

provision must be made- for the import of a certain percentage- of the needs

in pure kaolin and othejfc.raw materials• ; This report ir divided in two r

sections* stoneware cer'amics and white .ceramics, porcelain, china and :.

vitreous * ...-'■..

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13

(i) Stoneware ceramics ■ ■

(a) Stoneware ceramics includes a range of products as follows!

... piping and conduits for guttering, setts, tiles, stoneware tiles, industrial and agricultural.stoneware. Although it is difficult to suggest specialized factories.for each of these products,, it is possible at this stage to propose the setting'up of.factories for the manufacture of various ceramic stoneware products. Proposals in regard to specialized factories can be put forward only after correct knowledge is obtained of the necessary conditions, such as the properties of the raw materials and their location? etc.

(b) On the basis of the foregoing assumptions we may now advance

the following proposals;

:— Three ceramic stoneware factories, one in. the Ivory Coast, another in Senegal or Guinea each of 7?000 tons a year, and the third in Nigeria of 14,000 tons a year0

- The manufacturing programme might be on the averages 8 per cent piping and conduits

55 Per cent non-glazed setts 35 P.e:r cent glazed setts

. 2 per cent industrial and agricultural stoneware.

- The requirements in energy for productions Piping

Non-glazed setts Glazed'setts

Industrial stoneware Average production

80 J 72

95 80

n

it

6.40

'39.60

33.25

■ ' ' ' 1.60

80,85 k¥h/

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Page 14

- Productivity for various capacities? ...

... 14,000 tons a year 7«000 tons a year

Piping ' 100 ■t/empl./yr. 8.0 -90■ t/empl./yr. 7*2

Non-glased setts 75 " 41.2, 6$ " 35-8

: Glazed-setts- 40 n 14.0 35 " 12.3

Industrial' stoneware 90 " 1.8 80 " 1^6

Average productivity t/empl./yr# ^50 t/empl./yr. 5^9

- Requirements in fuels ,

'Piping' 1,800 kcal/kg ' 144

Non-glazed setts 20,000 " 1,100 Glased setts ■ 2,500 " . 875.

Industrial stoneware 1,800 -.-" . 36

Average production ■ kcal/kg .2,1-55

- The price of raw materials

Kaolin 21 %/% Hephelinic syenite 17-20 &/t

Clay 14 "' Quartz ' 18-20 "

Pegmatite 17-20 ". '■■■.. Metallic colouring

matter 300 "

- Composition and price of raw materials*

Sstts Piping and stoneware

QuartZ ''lO9& at $ 18 = 1.8 1C$ at $ 12 = 1.2

Pegmatite or

syenite 3<# at $ 20 «. 6.0 20f* at $ 17 = 3.4 Kaolin or clay 57^ at $ 21 = 12.0 " 68/0 at $ 14 - 9.5

Colouring

matter ' ■. 2$ at'$300= 9.0 2$> at $300 *= 6.0

Total 28.8 $/t 20.1 $/t

(17)

®ftllliM<tBS&lFp*S&*2^iSltfli'lK^^

B/CN.14/EETR/112

Page 15

Piping Bfo at 20.1 $/t 1*61

Non-glazed

setts 5^0 at 28.8 " 15.84 Glazed setts y$> at 30.0 " 10.50

Industrial ■ • ■ ■ .

stoneware 2$ at 20.1 " 0.40

Total 28,35 &A

- The import prices of various merchandize in Europe and West Africa for 1963 are to fee found in hm&x IV9 aad are as follows!

Europe West Africa

662.4(3) 32,5 $A 166.8 $/t

662,4(4) 118,1 " 209.2. "

662,4(5) 194.0 " 245.0 »■"■"

663.9(1) 366.6 " 1,220.4 M

The prices for the proposed production are as folltvws, in accordance with the latest statistics: ...

662.4(3) I 662.4(4) 5!

662.4(5) V.

663*9(1) '"■'-"'J

Average production

Europe

$ at 32.

jfo atll8.

j/o atl94.

$ at366.

5 i*A

1 "

0 "

6 ■ ■ « "■■

2,60$

. 64.96S

= 67.90$

«■ 7.33$

167

209

. :245

1,218 '

142.791A

West

•A -

« _

n „■

«'•■ _

Africa 13.36 *

114*95 1 85.75 s

. 24.36- $

238.42 * (*) Annex V, is ."based on the foregoing data, and the following

: results are given■in $ per yeari '

(Table on next page).

(18)

Page 16

TABLE 6

Capacity Tons

Amortisation Maintenance Interest Insurance, miscellaneous Salaries plus charges ...

Profits Fuel

Raw materials ' Interest on

working capital

Electricity'

a year -

Senegal

9,630

23,580'

7,000

Ivory Coast 207,760- .

71,540

29,400 , .

15,680

106,920 274*400

35,420-•' -

198,450 *

9,560 15,900

14,000 Nigeria 445?200 153,300 63,000

33,600

175,440 588,. 000 20,130 396,900

19,300 54,430

Gross turnover 972,780 965,030 1,949,300

Value added: 589,080 .„'. • 589,080 .1,028,640

Selling Price - Europe 1,001,000 . : . 2*002,000

-West Africa " 1,666.,000 . . 3,332,000

(ii) Ceramic materials in porcelain, china and vitreous

" (a) These ceramic materials include a range of products as ."" follows* glazed and.non-glazed setts, householftware and

pottery, ceraKfic 'materials for-sanitary and "artistic

purposes. For the time being. we; must.,, assume* that there

will be a production programme for each factory with

facilities for importing these commodities. But account

must be taken of future specialization. It is also hoped

that there will be handicraft or artistic production as is

done in other countries with a tradition in this type of

(19)

^

Page 17:

• ..production. The factory manufactures the ''"biscuits1' and

sells them partly to the artisans to make ornaments., paintings and'glazingso ■ Consequently, account must be taken of the

combined production of various products,- using more complicated equipment such'as one finds in specialized factories as well as higher investment units.

(b) H present, since the necessary conditions are not accurately determined, we shall make the following proposals

- 7 new factories - one in Ghana (with room for ernansion)

2,000 tons a year? one in the Ivory Coast, 10,000 tons per years two in Nigeria, 5,000 and 7,000 tons a year respectively; one in Guinea or Senegal 5,000 tons a years and one in Nigeria for electro-porcelain, 5,000 tons a year with the proviso that this capacity is subject to review*

- The percentage"of commodities and their unit prices according to Annex IV. ;

662,4 6.300 t/yr = 2

663.9 1,100 " =

666 11,900 " B 812.2 10,600 "

115

336 924 370

Euroge

$/t 24-15

13-. 44 369.60

!1 129.50

¥es_t_

224 %/i

1080 "

426 "

500 "

.Africa J 47*04

43-20 170,40 175*00

29,900 t/yr =100$ Average Average

production 536O69 production 435*64 - Heeds in kWh and fuelc

662,4 100 kflh/t 21.00 2,800 kcal/kg 588

663-9 130 » 5.20 3,300 " 132

666 120 » 48.00 3,800 t! 1,520

812.2 110 " 38.50 3,400 " 1,190'

Average production 112*70 Average production

3,430 kcal/kg * o,36 t/t of fuel

oil

(20)

E/GU.14/OTH/112

Page 18

- Productivity

2,000t/yr. 5,OOPt/yr. 7,Q00t/yr. 10,000t/yr. #

662.4 38t/yr. 7.98 4lVy^- 8.61 42t/yr* 8.82 45"t/yr. 9.45

663.9 5 " 0.20 5 " 0.20 5 " 0.20 5 " 0.20*

666 15 « 6.00 18 " 7.20 19 " ' 7.60 22 » 8.80 812,2 30 " 10.50 34 " 11.90 36 " 12.60 40 " 14.-

Average / , / „„ _

productivity ■ 24-68 t/yr. 27-91 t/yr. 29-22 t/yr, 32.45

- Composition and price of raw materialss

Quartz 10$ at 20 S/t 2.00

Pegmatite 3Ofo at 28 " 8.40

Kaolin 60/o at 60 " 36.00

46.40

6f<~ glazing at 300 $/t 18.- 10^ gypsum at 40 " 4-- jfa fire clay at 100 " 7--

Average production iss 75*40 $/t .

(c) Annex V was drawn up in accordance with the foregoingj and the

following results obtained in $ per years

(21)

i^^

Page i9

Ghana 2 154 58 54

,000 ,770 ,750 ,400

TABLE 7 Guinea

5,000 - 362,

- 137,

- 130, 700 800 000

Nigeria 5,000

-

_

7,000 486,200 184,800

'176,000

Ivory 10,

656,

249, 240,

Coast 000 400 600 000 Countries

Capacity t/yr.

Amortization Maintenance Interest Insurance,

miscellaneous 13,600 - 32,500 - 44*000 60,000

Salaries,1 :; ■ ■ " ■■■■:■■.■ ./■■■•■

charges .. .. , . 73,920 .. - 151,200, .. - 184,920. 234,000

Profits 190,400 . - 455,000 -. . 616,000 840,000

Fuel 15,840 45»GOO .11*270 15,750 79,200

Raw materials 150,800 - 377,000 527,800 754,000

73,920 190,400 15,840 150,800

5*810.'

8,250

45

13 21

- 151,

- 455, ,G00

- 377,

,920 ,570

200 poo

000 Interest on

working ,

capital 5,8l0_ 13,920 13,700 17*900 26,550

Electricity 8,250 21,570 27,460 38,450 ' 32,090

Gross turnover 726,540 1,726,690 1,698,630 ,2291,820, -3,171,840

Value added 419,090 968,900 968,900 1287,120 1,730,400 Selling price

-Europe^ 1,074,000 2,685,000 3759,000 5,370,000

- West . ■■ ■ . ' ■ ■

Africa 870,000 2,175,000 3045,000 4,350,000

Account must be taken of the fact. that, approximately 55 per cent production is first class, 30 per cent second class and 15 per cent third class,

whereas the .selling price is .based on first class quality. Consequently, prices must be scaled down as "follows!

Percentage Index Percentage of pri«*e

1 55 " ' ' l.oo ' 55.00

30 ' . .- . . 0t70. 2:uoo

■""15 ■ 0.50 '" 7.50

100 per cent 83.50 per cent

" 83,50 per cent of 435 %/\:-? 3^3 $A

and the selling price in Ghana Guinea and Nigeria Iv«ry Coast

■ West Africas ■ "■ ■ ' ■ - Nigeria ^____ .

726,000 1,815,000 2,541,000 3,630,000

(22)

Page 20

(&) Mention must again "be made of the electro—porcelain problem. It

may "be assumed that the needs for this commodity as far as West . . ' : Africa is concerned, may "be about 4~5 thousand tons per year in

1980. For this type of porcelain one needs special raw' materials and at present, since the conditions are not known, it is difficult . . to put forward a proposal' for establishing-an electro-porcelain'

factory in West Africa. It is quite possible that the necessary . .' . raw materials may be obtainable in the West African countries,

and with such a reserve one might count on a factory with a capacity of 5?000 tons' per/year, .for instance, in Nigeria with an index similar to the one for fine ceramic products, namely

5)000 tons per year. ,

V. -BECOMMEETDATiaBTS AMD SUMMARY ' "'

3,#, Imports of. ceramic stoneware and fine ceramic products in West Africa are at present considerable,..'being approximately 13-5 thousand tons. The estimate of requirements for 1980 is■-about 60 thousand tons andapproximately 5,000 tons of electro-porcelain- ■ . '.

2# A few deposits of kaolinic clay, feldspar, nephelinic syenite and

pure sand are khowi'to exist at .present., and there is a definite possibility that deposits ,of the necessary raw materials may be found in .other countries*

There is every justification for the presumption that West Africa .may be

self—sufficient in this .particular field. . ..''■' : ■ ■. f • 3» To meet itte requirements of the sub—region, the following factories

would have to be established:

■*■ (i) Ceramic stonewares two factories of 7>0,00 tons a year proposed

.; for the Ivory Coast, Senegal or Guinea,

one factory of 14,000 tons a year proposed for Nigeria. '

(ii) Fine.ceramics: one factory of 10,000 tons a year in the Ivory

-...■•; . ■ ," ■ . ■ ■ Coas't, . ... . ....

- . . " . . " ,. : '■ : one factory of 7?000 tons a year for Nigeria,

-'- two factories of 5,000 tons a year proposed

for Nigeria, Guinea or Senegal^

(23)

Page 21

one factory of 2,000 tone a year with room for expansion in Ghana$

(iii) Electro-porcelains one factory at 5,000 tone a year proposed

for the Ivory Coast or Nigeria, or in a country where suitable raw materials can be found.

4» At present the Ghana government has signed a contract to set up a

fine porcelain factory with a capacity of 2,100 tons per year at Saltpond,

Judging frojn the results of this report, this capacity is too small.

Compared -with the market, Ghana should have a larger capacity in relation to its kaolin resources* Consequently, this question should be ventilated, and the Ghana Government recommended to enlarge its capacity.

5. It will be necessary to explore the field geologically .and techno- _.

logically for the necessary raw materials? and in the light of the results obtained define the recommendations in this report^ -with a greater degree

•f accuracy.

6m An. educational centre must be established for cadres in connexion with

a research institute in ceramics.

(24)

jT==saa«!:B«aa>»j».w^a»^«=^i^.Ttrfv»iin=i'ww-

*» A brieff description of the ceramic factories at Bamako and. Saltpond BAMAKO - a new factory almost completed,with assistance from North-Korea.

It was originally intended to locate it near Yamfoulila, but the factory was eventually located at Bamako. It has a capacity of 410 to 550 tons of ceramic products a year as followss

20 per .cent porcelain

80. per cent sanitary articles and setts,

This factory is intended to meet the needs of Mali alone*, and there are no plans for export* The production of setts may rise to about 50 per cent. The factory employs 135 hands, 123 for production and 12

for administration* Production is scheduled tft start in June 1966 *

GHANA, SALTPCTO

At Saltpond in Ghana, there is a project for the construction of a ceramics factory to satisfy Ghana's need. The estimated capacity is:

1,500 tons per year of glazed setts 600 tons of sanitary articles a year.

In future this factory -when extended should produce the following articles;

Diameter Unity Weight per Price Price/kg

Hollow and flat plates per doz.

Cups and saucers Bowls

Bowls Jugs

Dessert plates per doz*

cm

23 cm

22 cm

_

22 cm 14 cm 14 cm

20 cm

doz

tt

n

piece

doz.

unit

440 g. ■

380 g.

420 g.

900 g.

290 g.

s/d

9/2 8/8 9/8 29/5 8/5 2/8 11/6

U1F

1/9

2/3

1/U

2/9

2/5

2/9

2/1

(25)

E/CSM4/IHE/112

Annex I Page 2

v«. The. production schedule'^sHould be* -'"'■-.'J/lZ:

.,;.•;,■—■■■■ . -> ;. Plates■ . __ 50 P^ cent"

,„..■.;:." ' ; Oups. and saucers 20 per cent

Bowls 10 per cent

Jags 10 per cent

..-.-■. ■ ■ . . ... JUSTNEX J. ,: . ■ . • . . . .■;''.' The "breakdowi of expenditure for the manufacture of ceramic sandstone

Capacity

Unitary investments Equipments "buildings' Total investment Equipment ' Buildings

Amortisations 16 per cent

equipment 4 per cent

"building ■ .. ..Total

Maintenances 5 per,cent equipment

2 per cent building

; Total

Interests 3 .per cent on.

half of the capital . Insurance, miscellaneous?

0*8 per cent of capital

Productivity :

Employees Salary unit Total salary Holidays, charges

(per cent)

. . Total Profits, 14 per.cent.

of investment Raw materials at

28.35 Electricity 80 kWh/t Fuel t/yr0 or 1000 nr/yro

Total price of electricity

Unit price of fuel $/t or

_ & /i nnnr

Total price of fuel

t/yr.

fo-4

No

7,ooo 280

55-45

1,960,000 1,078,000 882,000

172,480

1000 kWh/yr.

Senegal

23,580.

207,760

53,900 17,640 71,540

29,400

15,680 57 123 725 89,100

17,820 106,920

274,400

198,450

56O 1,610 Ivory Coast

15,900

14,000 300

55-45

2,310,000 1,890,000

369,600 75,600 445,200

37 153

63

33

146

■ 29

175

,800 ,300

,000

,600

65 215

680

,20b

,240 ,440

588,000

396,900 1,120 3,220

54,430

(30)

Annex V Page 2

Breakdo-wn of expenditure for the manufacture of white ceramic materials Capacity . . t/yr. 2>00o . 5,000 7-,000 10,000;

Investment

units »A ■■ 680 650 630 600

Equipment: . ...

buildings fotfo 38s42 56544 55145 ,54.46

Total

investment $' 1,360,000 3250,000 4,400,000 6,000,000 Equipment $ 788,800 1,820,000 2,420,000 3,240,000 Buildings . $ "571,200 1430,000 1,980,000 2,760,000

Amortizations

16 per cent ■

equipment $ 126,208 291,200 387,200 518,400

5 per cent

building $ 28,560 71,500 99,000 138,000

Total « 154,768 362,700 486,200 656,400

Maintenances \ 6 per cent

equipment $ 47 ? 330 109,200 145,200 194,400

2 per cent

building ft 11,420 28,600 39,600 55,200,

Total : 58*750 137,800 184,800 - 249.600

Interest:

4 Per cent

of invest. $ 54,400 130,000 176,000 240,000

Insurance, miscellaneous:

1 per cent ■ ■" .

of invest. I ■ 13,600 32,500 44s000 60,000

Productivity t/yr./empl. 25 28 30 33

Employees . Io. 80 180 230 300

Salary unit $/yr. 770 700 670 650

Annual salary I 61,600 126,000 154,100 195,000

Charges 9 ' ■ ■ ■

holidays

20'per cent $ 12,320 25,200 30,820 39,000

Toi^ * . 73,920 151,200 184,920 .■■ 234,000

Profits, .' ■ ■ .

14 per cent $ 190,400 455*000 616,000 840,000

Haw materials

Ceramics : ceramic stoneware, porcelain China and electro-porcelain

16 December 1966

Niamey 10 - 22 October 1966

(Ceramic stoneware, porcelain ohina and electro-porcelain)

I. INTRODUCTION x

II. THE PBESEHT POSITION 2

III. PROJECTION UP TO 1980 6

IV. HAW MATERIALS l2

(i) Stoneware ceramics J-3

(ii) Ceramic materials in porcelain, china and vitreous 16

v, i^coMMrmTiors ahd summaby 20

% A brief description of the ceramic factories at

in West Africa up to 1980

AlffiBX III Imports of ceramic materials into West Africa in

IY0 Price of ceramic products in various countries of the world and in West Africa in I963

V. The breadkowi of expenditure for the manufacture of

ANNEX VI, Imports of ceramics in West Africa in I96I-64

1. Ceramics covers a wide range of products prepared from natural clay-

"baked. Some of the products require to have their surface improved "by-

(i) For building:

- Stoneware productss Floor tiles, stoneware pipes,

- Ceramic materials for'sanitary purposes: sinks,

(ii) Products, for everyday use: . ....

- In chinas tableware, ornamental ware, ceramic materials

- Cooking utensils, flower-pots', ornamental vases made of'

(iii). Products for industrial use?

2, In this report, we shall deal with ceramic products leaving out of

■which separate reports have been prepared. The subjeut of this report is

(i) Ceramic stoneware. Stoneware is prepared from stoneware clay*

It is a clay wHose basic property lies somewhere between the

point' of softening and the point of melting, and is' not much

affected by heating. It is possible to obtain stoneware clay

(ii) Ceramic materials in china, vitreous, or porcelain, prepared

(iii) Ceramic materials in china, vitreous or porcelain, prepared

the case of (ii).

ceramics factories under construction at Bamako, Saltponcj (Ghana) and . . .

E/Gff.l4/orR/ll2

662,4(3) Ceramic piping, conduits 69*06 Piping, conduits and guttering

662.4(4) Unglazed ceramic setts, 69»O7 Unglaaed setts, flags and paving,

flags and tiles hearth, and wall tiles

662»4(5) Claaed ceramic setts, 69.08 Glased setts, flags and paving,

flags and tiles hearth and wall tiles

663.9(l) Laboratory and industrial 69.09 Laboratory, chemical or industrial

ceramic wares, etc. not ■wares (in stoneware, porcelain);

refractory similar articles of ceramic

663*9(2) Other articles of ceramic 69.14 Other articles of ceramic materials

666.4 Porcelain or china house- 69-11 Tableware and articles for domestic

666.5 Householdware of other 69.12 Tableware'and articles for domestic ceramic materials or toilet purposes of other ceramic

666*6 Ornaments and furnishing 69.13 Statuettes and other ornaments

812,2 Sinks, wash basins,"bidets,69*10 Sinks, wash basins, bidets, water baths and other sanitary closet pans, and like sanitary

Electro-porcelain is included in electrical apparatus and there is no

special classification for this type of ceramic material.

3. Imports of these particular categories for the period 1961-64 are to

662.4(3) 662,4(4)

662.4(5)

663,9(1) 663,9(2) 666.4 666.5

■ ! 75

(i) Products of ceramic stoneware 8.C10 tons per year 1961/64 (ii) Pressurized products 3-430 tons per year 1961/64 . (iii) Molten products 7*130 tons per year 1961/64

Totd-1 18,570 tons per year in 196l/64

in the eastern region of Nigeria came into production also, only this

based on the direct calculation of requirements in ceramic products for industry and new constructions, the other on the link between.consumption of ceramic products and the growth rate in building, industry and private

The first method is complicated because ceramic materials are needed

The life span of wall or floor tiles of ceramic materials is about 15-20

Statistics regarding, the number of houses equipped with ceramic

Direct calculation is relatively complicated, but in spite of this complica

■ (i) The building industry includes the following classifications:

; 662.4(3) ceramic piping, conduits and guttering 662,4(4) unglazed ceramic setts, flags and tiles 662*4(5) glazed ceramic setts, flags and tiles

812.2 sinks, wash basins, bidets, baths and other sanitary and

(ii) Industry includes the following classifications:

663,9(l) Laboratory and industrial ceramic wares, etc.,;not

: 663.9(2) Other articles of ceramic materials.

: ; 666*4 Porcelain or ohina householdware ;

\ \ 666,5 Householdware of other ceramic materials.

\ . 666.6 Ornaments and furnishing goods of porcelain, ohina

3. The consumption of chese various classifications is indicated in the

following table for the period 1961 to 1964*

663.9(1) 663-9(2)

Consumption of ceramic materials in wflat. Africa in 1961 to 1964

662*4(3) 662.4(4) * . 662.4(5)

253.6 1,608.4 45-6 1069=2 4,884.9 II87.O 966.4 3,862,9 1018.2

6624(3) 662.4(4) . 662.4(5)

6o There are at present tw> factories which manufacture cermiP mate t» meet these needs, one at Bamako and t&e other at Saltpond (Ghana) *

Average productivity t/empl./yr# ^50 t/empl./yr. 5^9