US20010029229A1 - Moulded spherical ceramic body, production process and use - Google Patents
Moulded spherical ceramic body, production process and use Download PDFInfo
- Publication number
- US20010029229A1 US20010029229A1 US09/117,227 US11722798A US2001029229A1 US 20010029229 A1 US20010029229 A1 US 20010029229A1 US 11722798 A US11722798 A US 11722798A US 2001029229 A1 US2001029229 A1 US 2001029229A1
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- Prior art keywords
- moulded
- suspension
- sintered body
- spherical sintered
- spherical
- Prior art date
- Legal status (The legal status is an assumption and is not a legal conclusion. Google has not performed a legal analysis and makes no representation as to the accuracy of the status listed.)
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- 238000004519 manufacturing process Methods 0.000 title claims abstract description 19
- 239000000919 ceramic Substances 0.000 title description 13
- 238000000034 method Methods 0.000 claims abstract description 32
- 230000008569 process Effects 0.000 claims abstract description 28
- 239000000725 suspension Substances 0.000 claims description 23
- 239000011805 ball Substances 0.000 claims description 20
- 238000000227 grinding Methods 0.000 claims description 20
- 239000008187 granular material Substances 0.000 claims description 16
- 239000011230 binding agent Substances 0.000 claims description 14
- 239000007787 solid Substances 0.000 claims description 14
- 239000007921 spray Substances 0.000 claims description 12
- 239000013078 crystal Substances 0.000 claims description 10
- 238000005469 granulation Methods 0.000 claims description 9
- 230000003179 granulation Effects 0.000 claims description 9
- 229910052594 sapphire Inorganic materials 0.000 claims description 9
- 238000005245 sintering Methods 0.000 claims description 9
- 239000002245 particle Substances 0.000 claims description 8
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- 235000010443 alginic acid Nutrition 0.000 claims description 2
- JXLHNMVSKXFWAO-UHFFFAOYSA-N azane;7-fluoro-2,1,3-benzoxadiazole-4-sulfonic acid Chemical compound N.OS(=O)(=O)C1=CC=C(F)C2=NON=C12 JXLHNMVSKXFWAO-UHFFFAOYSA-N 0.000 claims description 2
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- FAHBNUUHRFUEAI-UHFFFAOYSA-M hydroxidooxidoaluminium Chemical compound O[Al]=O FAHBNUUHRFUEAI-UHFFFAOYSA-M 0.000 claims description 2
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- NTHWMYGWWRZVTN-UHFFFAOYSA-N sodium silicate Chemical compound [Na+].[Na+].[O-][Si]([O-])=O NTHWMYGWWRZVTN-UHFFFAOYSA-N 0.000 claims description 2
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- PNEYBMLMFCGWSK-UHFFFAOYSA-N aluminium oxide Inorganic materials [O-2].[O-2].[O-2].[Al+3].[Al+3] PNEYBMLMFCGWSK-UHFFFAOYSA-N 0.000 description 12
- 229910052593 corundum Inorganic materials 0.000 description 12
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- ZMANZCXQSJIPKH-UHFFFAOYSA-N Triethylamine Chemical compound CCN(CC)CC ZMANZCXQSJIPKH-UHFFFAOYSA-N 0.000 description 3
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- RVTZCBVAJQQJTK-UHFFFAOYSA-N oxygen(2-);zirconium(4+) Chemical compound [O-2].[O-2].[Zr+4] RVTZCBVAJQQJTK-UHFFFAOYSA-N 0.000 description 3
- 238000004663 powder metallurgy Methods 0.000 description 3
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- QGZKDVFQNNGYKY-UHFFFAOYSA-N Ammonia Chemical compound N QGZKDVFQNNGYKY-UHFFFAOYSA-N 0.000 description 2
- 239000004150 EU approved colour Substances 0.000 description 2
- GRYLNZFGIOXLOG-UHFFFAOYSA-N Nitric acid Chemical compound O[N+]([O-])=O GRYLNZFGIOXLOG-UHFFFAOYSA-N 0.000 description 2
- VYPSYNLAJGMNEJ-UHFFFAOYSA-N Silicium dioxide Chemical compound O=[Si]=O VYPSYNLAJGMNEJ-UHFFFAOYSA-N 0.000 description 2
- 229920002125 Sokalan® Polymers 0.000 description 2
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- XBDQKXXYIPTUBI-UHFFFAOYSA-N dimethylselenoniopropionate Natural products CCC(O)=O XBDQKXXYIPTUBI-UHFFFAOYSA-N 0.000 description 2
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- XOOUIPVCVHRTMJ-UHFFFAOYSA-L zinc stearate Chemical class [Zn+2].CCCCCCCCCCCCCCCCCC([O-])=O.CCCCCCCCCCCCCCCCCC([O-])=O XOOUIPVCVHRTMJ-UHFFFAOYSA-L 0.000 description 2
- ZSLUVFAKFWKJRC-IGMARMGPSA-N 232Th Chemical compound [232Th] ZSLUVFAKFWKJRC-IGMARMGPSA-N 0.000 description 1
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- 238000002485 combustion reaction Methods 0.000 description 1
- 239000002826 coolant Substances 0.000 description 1
- 229910052906 cristobalite Inorganic materials 0.000 description 1
- 238000011161 development Methods 0.000 description 1
- 230000018109 developmental process Effects 0.000 description 1
- KZHJGOXRZJKJNY-UHFFFAOYSA-N dioxosilane;oxo(oxoalumanyloxy)alumane Chemical compound O=[Si]=O.O=[Si]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O.O=[Al]O[Al]=O KZHJGOXRZJKJNY-UHFFFAOYSA-N 0.000 description 1
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- 235000003599 food sweetener Nutrition 0.000 description 1
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- 229910052751 metal Inorganic materials 0.000 description 1
- 239000002184 metal Substances 0.000 description 1
- 150000002736 metal compounds Chemical class 0.000 description 1
- 150000002739 metals Chemical class 0.000 description 1
- 239000011806 microball Substances 0.000 description 1
- 238000000465 moulding Methods 0.000 description 1
- 229910052863 mullite Inorganic materials 0.000 description 1
- GQPLMRYTRLFLPF-UHFFFAOYSA-N nitrous oxide Inorganic materials [O-][N+]#N GQPLMRYTRLFLPF-UHFFFAOYSA-N 0.000 description 1
- 235000015097 nutrients Nutrition 0.000 description 1
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- TWNQGVIAIRXVLR-UHFFFAOYSA-N oxo(oxoalumanyloxy)alumane Chemical compound O=[Al]O[Al]=O TWNQGVIAIRXVLR-UHFFFAOYSA-N 0.000 description 1
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- IUVKMZGDUIUOCP-BTNSXGMBSA-N quinbolone Chemical compound O([C@H]1CC[C@H]2[C@H]3[C@@H]([C@]4(C=CC(=O)C=C4CC3)C)CC[C@@]21C)C1=CCCC1 IUVKMZGDUIUOCP-BTNSXGMBSA-N 0.000 description 1
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Classifications
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- B—PERFORMING OPERATIONS; TRANSPORTING
- B01—PHYSICAL OR CHEMICAL PROCESSES OR APPARATUS IN GENERAL
- B01J—CHEMICAL OR PHYSICAL PROCESSES, e.g. CATALYSIS OR COLLOID CHEMISTRY; THEIR RELEVANT APPARATUS
- B01J2/00—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic
- B01J2/16—Processes or devices for granulating materials, e.g. fertilisers in general; Rendering particulate materials free flowing in general, e.g. making them hydrophobic by suspending the powder material in a gas, e.g. in fluidised beds or as a falling curtain
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- C04B35/00—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products
- C04B35/01—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics
- C04B35/10—Shaped ceramic products characterised by their composition; Ceramics compositions; Processing powders of inorganic compounds preparatory to the manufacturing of ceramic products based on oxide ceramics based on aluminium oxide
- C04B35/111—Fine ceramics
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- C04B35/62625—Wet mixtures
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Definitions
- the present invention relates to a moulded microcrystalline spherical Al 2 O 3 sintered body, a process for manufacturing this, and the use thereof.
- the processes used to manufacture ceramic balls can be divided into mechanical, chemical, conventional (fusion) metallurgy, and powder metallurgy methods.
- the mechanical process are essentially restricted to achieving the spherical shape by mechanical processing using such methods as grinding, polishing, or smoothing.
- One prerequisite is that an appropriately prepared moulded body be used, this then being subjected to further processing to form a ball.
- the mechanical production of balls frequently requires that a conventional metallurgy, chemical, or powder metallurgy method be used beforehand in order to obtain the appropriate moulded body that is then subjected to further processing.
- sol gel process so-called colloidal solutions are formed with suitable solvents, starting from metallic salts.
- the solvent is usually water and contains the metal compound in the form of nano-scale oxides or hydroxides that are present, dissolved colloidally with the help of appropriate dispersants or stabilisers.
- Gelling can be brought about by modifying the pH value, temperature change, or aging/adding electrolytes.
- Spherical gel particles are obtained by dropping the sol into a medium that promotes formation of the gel, or exposing it to such a medium in gaseous form. The spherical gel particles are then dried, calcined, and sintered.
- Sol-gel processes for manufacturing ceramic balls are described, for example, in GB-A 1 032 105, DE-A 3 035 845, DE-A 2 147 472, DE-A 2 733 384, and DE-B 2 753 503. In most cases, these processes relate to the production of combustion or fuel particles based on thorium or uranium.
- EP-A 0 224 375 describes the production of transparent spherical microballs based on zirconium oxide, using the sol-gel method.
- the sol-gel processes are techically costly, and require relatively costly raw materials; in addition, they are not without problems from the ecological standpoint because inorganic acids, such as nitric acid and hydrochloric acid, are frequently used a stabilisers for the sol; these are then liberated once again as chlorine or nitrous gases during the calcining or sintering processes.
- inorganic acids such as nitric acid and hydrochloric acid
- Ceramic balls can be manufactured using conventional metallurgical methods by dropping the liquid smelt into a cooling medium, by blowing the smelt with air, or by atomizing the liquid smelt with an air/water mixture.
- One elegant process is the production of spherical ceramic particles using rotating disks, the smelt being poured onto the rotating disks that then throw off the still-liquid smelt in the form of droplets.
- the droplets harden relatively quickly to form ceramic balls.
- Powder metallurgy processes have recently become increasingly important for the production of spherical ceramic particles.
- One of the most important processes within this group is agglomeration.
- the underlying principle of agglomeration is based on the clustering of individual powder particles as the result of systematic movement of a powder bed.
- a binder must be added to the powder, when either a liquid or solid binder is selected, depending on the type of powder that is being used.
- liquid binders are the most important; in these, the water and alcohol systems dominate because they are easier to handle.
- waxes or stearates are added as agents that enhance adhesion.
- containers or mixers that can be moved systematically in different ways are uses for powder agglomeration; several types of movement can also be combined with each other.
- GB-A 1 344 870 and GB-A 1 344 869 describe the production processes for moulded spherical ceramic bodies, in which wax and stearates are used as binders.
- JP-A 05 137 997 describes the production of moulded spherical zirconium oxide, aluminum oxide, and mullite bodies, using water, aqueous solutions of carboxymethylcellulose, polyvinyl alcohol, and/or polyethylene-glycol as binder.
- DE-B 1 229 055 describes the production of argillaceous-earth balls by rolling activated argillaceous earth in a cylindrical ball-moulding machine while simultaneously spraying it with water.
- DE-A 3 507 376 describes a process and an apparatus for manufacturing granulates with a very narrow grain-size distribution, in which the product that is to be granulated is sprayed into a fluid bed and there applied to appropriate nuclei. The grain size is adjusted by the strength of the flow of separating gas of a zigzag separator. Similar processes or developments of the so-called fluid-bed spray granulation process are described in DE-A 3 808 277 and DE-A 4 304 405.
- the fluid-bed spray granulation process is usually used for drying and agglomerating agrochemical substances (fungicides, insecticides, herbicides, growth regulators, and fertilizers), pest control agents, pharmacologically effective substances, nutrients, sweeteners, colouring agents, and inorganic and organic chemicals.
- agrochemical substances fungicides, insecticides, herbicides, growth regulators, and fertilizers
- pest control agents pest control agents
- pharmacologically effective substances nutrients, sweeteners, colouring agents, and inorganic and organic chemicals.
- nutrients nutrients
- sweeteners colouring agents
- inorganic and organic chemicals inorganic and organic chemicals.
- the granulate particles that are obtained by fluid-bed spray granulation are distinguished by their uniform shape and great solidity; these characteristics make it simpler to handle, measure and process the original, finely powdered material, and in some instances even make these operations possible for the first time. Because of their microporous structure and the large surface areas associated therewith, the granulates can be redispersed spontaneously, which means that the process is predestined for processing agrochemical substances, pest-control agents, and pharmacologically effective substances.
- the object of the present invention are moulded microcrystalline spherical sintered bodies that are based on ⁇ -aluminum oxide, the average grain size d 50 of the primary crystals being preferably smaller than 3 ⁇ m, the diameter of the moulded sintered bodies being between 0.01 and 10 mm, and the moulded sintered bodies being of a hardness of>16 Gpa (HV 200 ) and a density of>95% of the theoretical density TD.
- the moulded microcrystalline spherical sintered bodies according to the present invention which have an average grain size of the primary crystals d 50 ⁇ 1 ⁇ m, in particular d 50 ⁇ 0.4 ⁇ m, exhibit particularly good properties.
- the moulded sintered bodies according to the present invention have hardnesses (HV 200 )>19 Gpa and densities of >98% of the theoretical density TD. It is preferred that the moulded sintered bodies according to the present invention have an ⁇ -Al 2 O 3 content >99% -wt. In addition to ⁇ -Al 2 O 3 , they can also contain one or more constituents of the oxides of elements such as Co, Cr, Fe, Hf, Mg, Mn, Nb, Ni, rare earths, Si, Ti, V, Zn, and Zr, these amounting to less than 50%-wt, preferably less than 20%-wt, and in particular less than 10%-wt, relative to the total quantity of solids.
- HV 200 hardnesses
- TD theoretical density
- the moulded sintered bodies according to the present invention have an ⁇ -Al 2 O 3 content >99% -wt.
- they can also contain one or more constituents of the oxides of elements such as Co, Cr, Fe
- a further object of the present invention is a process for manufacturing the moulded microcrystalline spherical sintered bodies, a suspension containing ⁇ -Al 2 O 3 being subjected to fluid-bed spray granulation, the green bodies so obtained then being sintered at temperatures between 1200 and 1600° C.
- finely divided solids are used as the initial substances, and these are ground down and/or broken up to an average particle size of ⁇ 3 ⁇ m, preferably ⁇ 1 ⁇ m, and especially ⁇ 0.4 ⁇ m, and used to produce the suspension.
- Reduction can advantageously be effected using a vibration mill, an attrition-type mill, or an agitator-ball mill, or by additional wet grinding to the desired grain size.
- the suspension contain 5 to 70%, preferably 15 to 50% solids, the suspension also containing 0.5 to 5% organic stabilisers, relative to the solids content, as auxiliary dispersants.
- the solvent be water.
- other solvents such as alcohols, ketones, or other polar organic fluids is also possible. Very often, however, ecological and economic factors militate against this.
- the suspension can be stabilized sterically or electrostatically.
- auxiliary dispersants can be used.
- Polyacrylic acids, polyglycol acids, polymethacrylic acids, organic bases such as triethylamine or carboxylic acids such as acetic acid or propionic acid are suitable for this purpose. It is preferred that the suspension contain between 0.5 and 5%-wt of appropriate organic stabilisers.
- electrostatic stabilisation volatile inorganic acids such as nitric acid or hyrochloric acid, as well as ammonia as a base, can be used to advantage.
- the suspension is stabilised either prior to grinding, or after grinding, with the help of a disperser; this ensures rapid and even distribution of the stabiliser.
- Sintering additives and binders can be added to the suspension, this being done preferably prior to, but also during and after stabilisation. All known sintering aids for Al 2 O 3 or its precursors can be used as sintering additives.
- the suspension according to the present invention contain 0.5 to 10%-wt of one or a plurality of binders from the group that includes methylcellulose, dextrin, sugars, starches, alginates, glycols, polyvinylpyrrolidon, lignin sulphonate, gum arabic, polyvinylalcohol and polyvinylacetate, relative to the solids content of the suspension.
- the suspension can contain 0.5 to 10%-wt of one or more binders from the group that contains water glass, silicic sol, and boehmite sol.
- Granulation is preferably carried out in air, and can be initiated in a fluid-bed apparatus that already contains the starting granulate. However, it is also possible to begin granulation in an empty apparatus, fluid-bed granulation being started as spray drying and nuclei being generated in situ.
- the suspension that is to be granulated is introduced into the fluid bed by way of spray nozzles.
- the use of binary nozzles is particularly advantageous. Any gas that is inert under the prevailing working conditions can be used as the atomising gas. It is preferred that air be used for Al 2 O 3 .
- the quantity of atomising gas that is used can be varied within a very wide range, and is generally determined by the size of the apparatus and the type and quantity of product that is to be sprayed in.
- the temperature of the flow of atomising gas or the air entry temperature can similarly be within a wide range. Generally speaking, work is carried on at temperatures between 20 and 350° C.
- the separating-gas temperatures can vary within a wide range, and here, too, it is preferred that work be done in a range between 20 and 350° C.
- the quantity and velocity of the separating gas is determined by the density and the desired grain size of the granulate.
- the grain size can be controlled primarily by the gas flow and velocity of the separator gas.
- the gas flow and velocity of the separator gas In the case of Al 2 O 3 , using the zigzag separator as described in DE-A 3 507 376, it is possible to select a narrow grain band in the grain size range between 0.01 and 10 mm with a band width ⁇ 21 mm.
- the prepared granulate can be sintered directly—or preferably after a calcining intermediate step at temperatures between 300 and 600° C. at temperatures between 1200 and 1600° C.
- Rotating cylindrical kilns, sliding-bat kilns, or chamber kilns can be used as the sintering kilns. It is particularly advantageous if the sintering be carried out in a rotating cylindrical kiln that is heated directly or indirectly, by which it is possible to obtain high heating rates combined with short dwell times, since this facilitates the production of dense sintered bodies without excessively vigorous crystal growth.
- the process according to the present invention makes it possible to manufacture extremely dense moulded microcrystalline sintered bodies of great purity that are extremely hard and resistant to wear, the average primary crystal size of which is preferably smaller than 1 ⁇ m and whose diameter can be selected to be anywhere between 0.01 and 10 mm.
- the sintered bodies according to the present invention are particularly well suited for use as grinding balls, insulation materials, fillers, for use as wear-resistant additives for laminates and lacquers, for use in ball bearings, as catalyst carriers, or the like.
- One object of the present invention is thus the use of the sintered bodies according to the present invention as grinding balls, insulation materials, fillers, additives for laminates and lacquers, for use in ball bearings, as catalyst carriers, or the like.
- the suspension was processed in a fluid-bed spray granulator (AGT 150, Glatt, Germany) at an air entry temperature of 95° C., a layer temperature of 45° C., a spray pressure of 3 bar, and a spray rate of 70 g/min.
- 70%-wt of the granulate so obtained had a diameter between 0.8 and 1.2 mm, in approximately 20%-wt the diameter was between 0.3 and 0.8 mm, and in approximately 10%-wt the granulate had a diameter of ⁇ 1.2 mm.
- the residual moisture content of the granulate was less than 1%.
- the granulate was calcined at 500° C. and then sintered at 1480° C. in a chamber kiln.
- the average primary crystal size was 0.8 ⁇ m.
- the moulded sintered bodies had a density of 96.5% of the TD, and a hardness of 17.6 Gpa (HV 0.2).
- the average primary crystal size was 0.8 ⁇ m.
- Example 2 As in Example 1, the separation of the desired granulate was effected by a separator chamber tha incorporates a series of zig-zag separators. The quantity of air was so adjusted that 98%-wt of the granulate that was removed had a diameter between 0.5 and 0.7 mm. The sintering was carried out directly, without calcining as an intermediate step, in a rotating cylindrical kiln at 1480° C.
- the moulded sintered bodies had a density of 98.6% of the TD, and a hardness of 19.5 Gpa (HV 0.2).
- the average primary crystal size was 0.6 ⁇ m.
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Abstract
Description
- The present invention relates to a moulded microcrystalline spherical Al2O3 sintered body, a process for manufacturing this, and the use thereof.
- The processes used to manufacture ceramic balls can be divided into mechanical, chemical, conventional (fusion) metallurgy, and powder metallurgy methods.
- The mechanical process are essentially restricted to achieving the spherical shape by mechanical processing using such methods as grinding, polishing, or smoothing. One prerequisite is that an appropriately prepared moulded body be used, this then being subjected to further processing to form a ball. The mechanical production of balls frequently requires that a conventional metallurgy, chemical, or powder metallurgy method be used beforehand in order to obtain the appropriate moulded body that is then subjected to further processing.
- The chemical processes are particularly suitable for obtaining materials that are as pure as possible. One process that has recently been used more and more frequently is the so-called sol gel process, In this sol-gel process, so-called colloidal solutions are formed with suitable solvents, starting from metallic salts. The solvent is usually water and contains the metal compound in the form of nano-scale oxides or hydroxides that are present, dissolved colloidally with the help of appropriate dispersants or stabilisers. Gelling can be brought about by modifying the pH value, temperature change, or aging/adding electrolytes. Spherical gel particles are obtained by dropping the sol into a medium that promotes formation of the gel, or exposing it to such a medium in gaseous form. The spherical gel particles are then dried, calcined, and sintered.
- Sol-gel processes for manufacturing ceramic balls are described, for example, in GB-A 1 032 105, DE-A 3 035 845, DE-A 2 147 472, DE-A 2 733 384, and DE-B 2 753 503. In most cases, these processes relate to the production of combustion or fuel particles based on thorium or uranium. EP-A 0 224 375 describes the production of transparent spherical microballs based on zirconium oxide, using the sol-gel method.
- The sol-gel processes are techically costly, and require relatively costly raw materials; in addition, they are not without problems from the ecological standpoint because inorganic acids, such as nitric acid and hydrochloric acid, are frequently used a stabilisers for the sol; these are then liberated once again as chlorine or nitrous gases during the calcining or sintering processes.
- Ceramic balls can be manufactured using conventional metallurgical methods by dropping the liquid smelt into a cooling medium, by blowing the smelt with air, or by atomizing the liquid smelt with an air/water mixture. One elegant process is the production of spherical ceramic particles using rotating disks, the smelt being poured onto the rotating disks that then throw off the still-liquid smelt in the form of droplets. The droplets harden relatively quickly to form ceramic balls. However, it is difficult to obtain pure and compact spherical ceramic particles using these processes, which are particulary well-suited for extracting metals.
- Powder metallurgy processes have recently become increasingly important for the production of spherical ceramic particles. One of the most important processes within this group is agglomeration. The underlying principle of agglomeration is based on the clustering of individual powder particles as the result of systematic movement of a powder bed. In most instances, a binder must be added to the powder, when either a liquid or solid binder is selected, depending on the type of powder that is being used. From the technical standpoint, liquid binders are the most important; in these, the water and alcohol systems dominate because they are easier to handle. In the case of processes that use solid binders, in most instances waxes or stearates are added as agents that enhance adhesion.
- Air humidity plays an important role in the dry processes, which work without the addition of adhesion enhancing additives.
- In the normal course of events, containers or mixers that can be moved systematically in different ways are uses for powder agglomeration; several types of movement can also be combined with each other.
- GB-A 1 344 870 and GB-A 1 344 869 describe the production processes for moulded spherical ceramic bodies, in which wax and stearates are used as binders. JP-A 05 137 997 describes the production of moulded spherical zirconium oxide, aluminum oxide, and mullite bodies, using water, aqueous solutions of carboxymethylcellulose, polyvinyl alcohol, and/or polyethylene-glycol as binder. DE-B 1 229 055 describes the production of argillaceous-earth balls by rolling activated argillaceous earth in a cylindrical ball-moulding machine while simultaneously spraying it with water.
- The demand for low-priced, very pure, wear-resistant ceramic balls that possess great mechanical strength, to be used, for example, as grinding bodies, ball bearings, etc., cannot be satisfied, or can be satisfied to only a limited degree, by using the processes referred to above.
- DE-A 3 507 376 describes a process and an apparatus for manufacturing granulates with a very narrow grain-size distribution, in which the product that is to be granulated is sprayed into a fluid bed and there applied to appropriate nuclei. The grain size is adjusted by the strength of the flow of separating gas of a zigzag separator. Similar processes or developments of the so-called fluid-bed spray granulation process are described in DE-A 3 808 277 and DE-A 4 304 405.
- The fluid-bed spray granulation process is usually used for drying and agglomerating agrochemical substances (fungicides, insecticides, herbicides, growth regulators, and fertilizers), pest control agents, pharmacologically effective substances, nutrients, sweeteners, colouring agents, and inorganic and organic chemicals. In addition to the active components and thinners, there may also be inert fillers, dispersants, binders, and/or other additives, for example, preservatives and colouring agents, in the liquid product that is to be sprayed in.
- The granulate particles that are obtained by fluid-bed spray granulation are distinguished by their uniform shape and great solidity; these characteristics make it simpler to handle, measure and process the original, finely powdered material, and in some instances even make these operations possible for the first time. Because of their microporous structure and the large surface areas associated therewith, the granulates can be redispersed spontaneously, which means that the process is predestined for processing agrochemical substances, pest-control agents, and pharmacologically effective substances.
- It is the task of the present invention to provide moulded spherical sintered bodies that do not have the disadvantages found in the prior art. Surprisingly, it was found during drying trials with ceramic powder suspensions based on Al2O3 that by using fluid-bed spray granulation, it is possible to obtain extremely dense green bodies that can be sintered directly to form a dense ceramic body, without any additional manipulation, such as compacting. Because of the high basic density of the granulate and the fineness and sinter activity of the initial powder, for all practical purposes it is possible to suppress grain growth almost completely during the sintering process, so that a moulded microcrystalline spherical sintered ceramic body that is distinguished by particular toughness and wear resistance results.
- The object of the present invention are moulded microcrystalline spherical sintered bodies that are based on α-aluminum oxide, the average grain size d50 of the primary crystals being preferably smaller than 3 μm, the diameter of the moulded sintered bodies being between 0.01 and 10 mm, and the moulded sintered bodies being of a hardness of>16 Gpa (HV200) and a density of>95% of the theoretical density TD. The moulded microcrystalline spherical sintered bodies according to the present invention, which have an average grain size of the primary crystals d50<1 μm, in particular d50<0.4 μm, exhibit particularly good properties. In addition, the moulded sintered bodies according to the present invention have hardnesses (HV200)>19 Gpa and densities of >98% of the theoretical density TD. It is preferred that the moulded sintered bodies according to the present invention have an α-Al2O3 content >99% -wt. In addition to α-Al2O3, they can also contain one or more constituents of the oxides of elements such as Co, Cr, Fe, Hf, Mg, Mn, Nb, Ni, rare earths, Si, Ti, V, Zn, and Zr, these amounting to less than 50%-wt, preferably less than 20%-wt, and in particular less than 10%-wt, relative to the total quantity of solids.
- A further object of the present invention is a process for manufacturing the moulded microcrystalline spherical sintered bodies, a suspension containing α-Al2O3 being subjected to fluid-bed spray granulation, the green bodies so obtained then being sintered at temperatures between 1200 and 1600° C.
- In the process according to the present invention, finely divided solids are used as the initial substances, and these are ground down and/or broken up to an average particle size of<3 μm, preferably <1 μm, and especially <0.4 μm, and used to produce the suspension. Reduction can advantageously be effected using a vibration mill, an attrition-type mill, or an agitator-ball mill, or by additional wet grinding to the desired grain size. It is preferred that the suspension contain 5 to 70%, preferably 15 to 50% solids, the suspension also containing 0.5 to 5% organic stabilisers, relative to the solids content, as auxiliary dispersants. It is preferred that the solvent be water. The use of other solvents such as alcohols, ketones, or other polar organic fluids is also possible. Very often, however, ecological and economic factors militate against this.
- The suspension can be stabilized sterically or electrostatically. In the case of steric stabilisation, all known auxiliary dispersants can be used. Polyacrylic acids, polyglycol acids, polymethacrylic acids, organic bases such as triethylamine or carboxylic acids such as acetic acid or propionic acid are suitable for this purpose. It is preferred that the suspension contain between 0.5 and 5%-wt of appropriate organic stabilisers. In the case of electrostatic stabilisation, volatile inorganic acids such as nitric acid or hyrochloric acid, as well as ammonia as a base, can be used to advantage.
- The suspension is stabilised either prior to grinding, or after grinding, with the help of a disperser; this ensures rapid and even distribution of the stabiliser. Sintering additives and binders can be added to the suspension, this being done preferably prior to, but also during and after stabilisation. All known sintering aids for Al2O3 or its precursors can be used as sintering additives.
- It is preferred that the suspension according to the present invention contain 0.5 to 10%-wt of one or a plurality of binders from the group that includes methylcellulose, dextrin, sugars, starches, alginates, glycols, polyvinylpyrrolidon, lignin sulphonate, gum arabic, polyvinylalcohol and polyvinylacetate, relative to the solids content of the suspension. To equal advantage, the suspension can contain 0.5 to 10%-wt of one or more binders from the group that contains water glass, silicic sol, and boehmite sol.
- Granulation is preferably carried out in air, and can be initiated in a fluid-bed apparatus that already contains the starting granulate. However, it is also possible to begin granulation in an empty apparatus, fluid-bed granulation being started as spray drying and nuclei being generated in situ.
- The suspension that is to be granulated is introduced into the fluid bed by way of spray nozzles. The use of binary nozzles is particularly advantageous. Any gas that is inert under the prevailing working conditions can be used as the atomising gas. It is preferred that air be used for Al2O3. The quantity of atomising gas that is used can be varied within a very wide range, and is generally determined by the size of the apparatus and the type and quantity of product that is to be sprayed in. The temperature of the flow of atomising gas or the air entry temperature can similarly be within a wide range. Generally speaking, work is carried on at temperatures between 20 and 350° C. The separating-gas temperatures can vary within a wide range, and here, too, it is preferred that work be done in a range between 20 and 350° C. The quantity and velocity of the separating gas is determined by the density and the desired grain size of the granulate.
- The grain size can be controlled primarily by the gas flow and velocity of the separator gas. In the case of Al2O3, using the zigzag separator as described in DE-A 3 507 376, it is possible to select a narrow grain band in the grain size range between 0.01 and 10 mm with a band width ≦21 mm.
- The prepared granulate can be sintered directly—or preferably after a calcining intermediate step at temperatures between 300 and 600° C. at temperatures between 1200 and 1600° C. Rotating cylindrical kilns, sliding-bat kilns, or chamber kilns can be used as the sintering kilns. It is particularly advantageous if the sintering be carried out in a rotating cylindrical kiln that is heated directly or indirectly, by which it is possible to obtain high heating rates combined with short dwell times, since this facilitates the production of dense sintered bodies without excessively vigorous crystal growth.
- The process according to the present invention makes it possible to manufacture extremely dense moulded microcrystalline sintered bodies of great purity that are extremely hard and resistant to wear, the average primary crystal size of which is preferably smaller than 1 μm and whose diameter can be selected to be anywhere between 0.01 and 10 mm.
- Because of these properties, the sintered bodies according to the present invention are particularly well suited for use as grinding balls, insulation materials, fillers, for use as wear-resistant additives for laminates and lacquers, for use in ball bearings, as catalyst carriers, or the like.
- One object of the present invention is thus the use of the sintered bodies according to the present invention as grinding balls, insulation materials, fillers, additives for laminates and lacquers, for use in ball bearings, as catalyst carriers, or the like.
- The present invention will be described in greater detail below on the basis of the following examples, which should not be considered restrictive as to the present invention.
- 70 kg α-Al2O3 with an average grain size of d501.5 μm, in the form of a 50-% aqueous slip stabilised with a polyacrylic acid as an auxiliary dispersant, was ground in an agitator-type ball mill to an average grain size of d50=0.4 μm. The d90 value of the suspension was 0.9 μm. The suspension was diluted with water to a solids content of 30%-wt, and 10 l of a 10-% aqueous solution of a polyvinylalcohol was added as a binder (Mowiol 8/88, Hoechst AG, Germany).
- Next, the suspension was processed in a fluid-bed spray granulator (AGT 150, Glatt, Germany) at an air entry temperature of 95° C., a layer temperature of 45° C., a spray pressure of 3 bar, and a spray rate of 70 g/min. A fine granulate fraction with an average grain size of 0.2 mm, which had been obtained previously by fluid-bed spray granulation by way of in situ nucleus formation, was used for nucleus formation. Separation of the desired granulate was effected by a zig-zag separator that was operated a 9 Nm3/h air. 70%-wt of the granulate so obtained had a diameter between 0.8 and 1.2 mm, in approximately 20%-wt the diameter was between 0.3 and 0.8 mm, and in approximately 10%-wt the granulate had a diameter of ≧1.2 mm. The residual moisture content of the granulate was less than 1%.
- The granulate was calcined at 500° C. and then sintered at 1480° C. in a chamber kiln.
- The moulded sintered bodies had a density of 98.3% of the TD and a hardness of 18.7 Gpa (HV=0.2). The average primary crystal size was 0.8 μm.
- As in Example 1, although 2%-wt polyvinylpyrrolidon, relative to the Al2O3 content, was used as binder.
- The moulded sintered bodies had a density of 96.5% of the TD, and a hardness of 17.6 Gpa (HV 0.2). The average primary crystal size was 0.8 μm.
- As in Example 1, the separation of the desired granulate was effected by a separator chamber tha incorporates a series of zig-zag separators.. The quantity of air was so adjusted that 98%-wt of the granulate that was removed had a diameter between 0.5 and 0.7 mm. The sintering was carried out directly, without calcining as an intermediate step, in a rotating cylindrical kiln at 1480° C.
- The moulded sintered bodies had a density of 98.6% of the TD, and a hardness of 19.5 Gpa (HV 0.2). The average primary crystal size was 0.6 μm.
- Commercially available α-Al2O3 with an average grain size d50 of 1.5 μm was wet ground in an agitator-type ball mill (Type PMC 25 TEX, Drais) for 8 hours. The slurry had a solids content of 50%-wt. The grinding was carried out cyclically, each batch size amounting to 70 kg Al2O3. The grinding body charge in all tested cases was 65%-vol. The grinding body wear was determined after each grind, by weighing.
- When reading the result obtained with YTZ (yttrium-stabilized zirconium oxide) grinding bodies, it should be remembered that the grinding balls are much more costly than the moulded spherical sintered bodies according to the present invention so that—given equally good results—grinding costs will be at least ten times greater compared to the costs associated width the use of grinding balls according to the present invention.
Commer- Commer- Commercially cially cially Grinding available available available body Al2O3 YTZ Al2O3 as in grinding grinding grinding Example 1 body body body Chemical 95% Al2O3 99.5% Al2O3 95% ZrO2 86% Al2O3 composition 5% Y2O3 11% [%-wt] SiO2 3% other Ball 1 mm 1 mm 1 mm 1 mm diameter Wear on 3%-wt 20%-wt 5%-wt 7%-wt grinding body Product 0.95 μm 1.18 μm 0.95 μm 1.22 μm fineness d90 Product 0.46 μm 0.60 μm 0.42 μm 0.63 μm fineness d50
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DE19602525A DE19602525A1 (en) | 1996-01-25 | 1996-01-25 | Spherical shaped ceramic bodies, process for their production and their use |
DE19602525.7 | 1996-01-25 | ||
PCT/EP1997/000126 WO1997027154A1 (en) | 1996-01-25 | 1997-01-13 | Moulded spherical ceramic body, production process and use |
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DE3035845C2 (en) * | 1980-09-23 | 1986-05-22 | Gesellschaft zur Förderung der industrieorientierten Forschung an den Schweizerischen Hochschulen und weiteren Institutionen, Bern | Method and device for the production of microspheres by internal gelation of mixed feed drops |
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DE3808277A1 (en) * | 1988-03-12 | 1989-09-21 | Bayer Ag | METHOD AND DEVICE FOR SPIRAL LAYER SPRAY GRANULATION |
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JPS6279841A (en) * | 1985-10-02 | 1987-04-13 | Teikoku Kako Kk | Production of inorganic spherical body |
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DE19503854C2 (en) * | 1995-02-06 | 1997-02-20 | Starck H C Gmbh Co Kg | Process for the production of sintered alpha-Al¶2¶O¶3¶ bodies and their use |
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FR2755435A1 (en) * | 1996-11-04 | 1998-05-07 | Pechiney Aluminium | MANUFACTURE OF CALCINE ALUMINA WITH CRYSTALLITE SIZE ADJUSTED ON DEMAND WITH LOW DISPERSION |
-
1996
- 1996-01-25 DE DE19602525A patent/DE19602525A1/en not_active Withdrawn
-
1997
- 1997-01-13 AT AT97901013T patent/ATE188199T1/en not_active IP Right Cessation
- 1997-01-13 KR KR10-1998-0705695A patent/KR100380338B1/en not_active IP Right Cessation
- 1997-01-13 EP EP97901013A patent/EP0876309B1/en not_active Expired - Lifetime
- 1997-01-13 DE DE59700928T patent/DE59700928D1/en not_active Expired - Lifetime
- 1997-01-13 CA CA002244172A patent/CA2244172C/en not_active Expired - Fee Related
- 1997-01-13 US US09/117,227 patent/US6284694B1/en not_active Expired - Lifetime
- 1997-01-13 JP JP52648297A patent/JP3468527B2/en not_active Expired - Fee Related
- 1997-01-13 RU RU98115716/03A patent/RU2167841C2/en not_active IP Right Cessation
- 1997-01-13 WO PCT/EP1997/000126 patent/WO1997027154A1/en active IP Right Grant
- 1997-01-13 ES ES97901013T patent/ES2142141T3/en not_active Expired - Lifetime
- 1997-01-13 AU AU14413/97A patent/AU709521B2/en not_active Ceased
Also Published As
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CA2244172A1 (en) | 1997-07-31 |
JP3468527B2 (en) | 2003-11-17 |
AU709521B2 (en) | 1999-09-02 |
ATE188199T1 (en) | 2000-01-15 |
KR19990081977A (en) | 1999-11-15 |
EP0876309B1 (en) | 1999-12-29 |
JP2000503294A (en) | 2000-03-21 |
KR100380338B1 (en) | 2003-06-18 |
DE59700928D1 (en) | 2000-02-03 |
CA2244172C (en) | 2004-09-14 |
US6284694B1 (en) | 2001-09-04 |
DE19602525A1 (en) | 1997-08-07 |
WO1997027154A1 (en) | 1997-07-31 |
EP0876309A1 (en) | 1998-11-11 |
RU2167841C2 (en) | 2001-05-27 |
AU1441397A (en) | 1997-08-20 |
ES2142141T3 (en) | 2000-04-01 |
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