WO1996036575A2 - Process for production of alumina/zirconia materials - Google Patents
Process for production of alumina/zirconia materials Download PDFInfo
- Publication number
- WO1996036575A2 WO1996036575A2 PCT/US1996/005145 US9605145W WO9636575A2 WO 1996036575 A2 WO1996036575 A2 WO 1996036575A2 US 9605145 W US9605145 W US 9605145W WO 9636575 A2 WO9636575 A2 WO 9636575A2
- Authority
- WO
- WIPO (PCT)
- Prior art keywords
- alumina
- zirconia
- melt
- azs
- weight
- Prior art date
Links
Classifications
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B35/16—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 silicates other than clay
- C04B35/18—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 silicates other than clay rich in aluminium oxide
-
- C—CHEMISTRY; METALLURGY
- C04—CEMENTS; CONCRETE; ARTIFICIAL STONE; CERAMICS; REFRACTORIES
- C04B—LIME, MAGNESIA; SLAG; CEMENTS; COMPOSITIONS THEREOF, e.g. MORTARS, CONCRETE OR LIKE BUILDING MATERIALS; ARTIFICIAL STONE; CERAMICS; REFRACTORIES; TREATMENT OF NATURAL STONE
- 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
- C04B35/16—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 silicates other than clay
-
- C—CHEMISTRY; METALLURGY
- C09—DYES; PAINTS; POLISHES; NATURAL RESINS; ADHESIVES; COMPOSITIONS NOT OTHERWISE PROVIDED FOR; APPLICATIONS OF MATERIALS NOT OTHERWISE PROVIDED FOR
- C09K—MATERIALS FOR MISCELLANEOUS APPLICATIONS, NOT PROVIDED FOR ELSEWHERE
- C09K3/00—Materials not provided for elsewhere
- C09K3/14—Anti-slip materials; Abrasives
- C09K3/1409—Abrasive particles per se
- C09K3/1427—Abrasive particles per se obtained by division of a mass agglomerated by melting, at least partially, e.g. with a binder
Definitions
- This invention relates to fused alumina/zirconia materials which have found wide applicability, especially in the field of abrasives.
- the invention relates particularly to a process for making such materials that has significant cost advantages over those currently practiced in the art. It is well known from patents such as USPP 3,454,385;
- alumina and zirconia can be co-fused in the same vessel and then formed in to very useful abrasive grains, particularly when the process is manipulated to ensure that the zirconia in obtained in the tetragonal form.
- the very high cost of the zirconia component has made it difficult for the grain to be as widely accepted as its undoubted utility as an abrasive would seem to justify.
- the present invention provides a process for the production of alumina/zirconia abrasives which comprises forming a melt comprising alumina/zirconia/silica (AZS) scrap, adding to the melt an amount of a reducing agent sufficient to reduce the silica content to a level below about 0.8% by weight and then forming abrasive grits from the melt.
- alumina/zirconia abrasives which comprises forming a melt comprising alumina/zirconia/silica (AZS) scrap, adding to the melt an amount of a reducing agent sufficient to reduce the silica content to a level below about 0.8% by weight and then forming abrasive grits from the melt.
- AZS scrap refers to waste material generated as a result of the use of large AZS blocks to line glass furnaces. Periodically these linings have to be replaced and the discarded blocks of AZS become scrap to be disposed of as economically as possible.
- the original composition of AZS blocks used to line glass furnaces is from about 48 to about 50 wt% of alumina; from about 30 to about 35 wt% of zirconia; and from about 12 to about 18 wt% of silica.
- Scrap generated in the production of such blocks is one preferred source of AZS scrap.
- Scrap generated when such blocks are replaced is a secondary though occasionally less desirable source.
- the AZS blocks may become contaminated with up to about 2-3% of glass.
- Certain components of the glass such as silica and soda can be quite detrimental to the abrasive properties of any grains produced from such starting materials unless special precautions are taken to eliminate them, or at least to reduce them to acceptable levels during the production process.
- Other components such lead, (when the glass produced in the furnace is a lead crystal) , produce other very significant environmental problems such that AZS contaminated in this way is very much less preferred as a feedstock.
- AZS scrap materials can be used effectively, either alone or in admixture with appropriate amounts of alumina and zirconia to adjust the final composition to the desired alumina/zirconia ratio, if a reducing agent selected from the group consisting of carbon, aluminum, magnesium, zirconium and mixtures of the above is added to a melt of the AZS and any other starting materials in an amount sufficient toreduce the silica content of the final product to below 0.8 wt% and more preferably below 0.4wt%.
- This amount will depend on the amount of impurity in the AZS and the silica content of the AZS itself. However for most purposes an amount that is from about 5 to about 30%, and more preferably from about 10 to about 20%, based on the weight of the molten components, may be used with advantage.
- the preferred reducing agents are carbon and aluminum and mixtures of these. Magnesium and zirconium both raise handling problems and for that reason are less preferred.
- the most preferred reducing agent is a mixture of carbon and aluminum in a weight ratio of from 1:0 to 1:2.
- the reducing agent chosen was a mixture of carbon and aluminum metal in the form of chips.
- the AZS fed in to the melt comprised about 49% alumina, about 37% zirconia and about 14% silica, all proportions being by weight.
- the AZS scrap did not have any glass contamination.
- the zirconia content of the materials made in the following Examples was to be at least 25% by weight.
- all the zirconia was supplied by AZS scrap and the reducing agent used was carbon alone in the form of petroleum coke.
- the feed comprised alumina, AZS scrap and coke.
- the same AZS scrap used in Example 1 was used in this Example.
- the coke was added in two increments: the first, (I), with the feedstock and the second, (II) , during the "fuseout" period after the molten mass had been formed but before the molten mass was tapped off and the cooling process had begun.
- the results are set forth in Table 2 below.
- the Power value for Test “A” includes the energy used to start and heat up the furnace.
- the high value for Test “D” results from the small amount of the product tapped from the furnace due to the presence of unburned carbon in the melt because of the small size of the furnace. Such conditions would not be created in a production-size furnace. It is considered that, at steady state operations, a power consumption of around 2 K H per pound of grain produced is enirely achievable.
Abstract
Description
Claims
Priority Applications (4)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
AT96912746T ATE187979T1 (en) | 1995-05-03 | 1996-04-12 | METHOD FOR PRODUCING MATERIALS CONTAINING ALUMINUM AND ZIRCONIA |
DE69605785T DE69605785T2 (en) | 1995-05-03 | 1996-04-12 | METHOD FOR THE PRODUCTION OF ALUMINA AND ZIRCONIA CONTAINING MATERIALS |
AU55447/96A AU5544796A (en) | 1995-05-03 | 1996-04-12 | Process for production of alumina/zirconia materials |
EP96912746A EP0823934B1 (en) | 1995-05-03 | 1996-04-12 | Process for production of alumina/zirconia materials |
Applications Claiming Priority (2)
Application Number | Priority Date | Filing Date | Title |
---|---|---|---|
US08/434,087 US5567214A (en) | 1995-05-03 | 1995-05-03 | Process for production of alumina/zirconia materials |
US08/434,087 | 1995-05-03 |
Publications (2)
Publication Number | Publication Date |
---|---|
WO1996036575A2 true WO1996036575A2 (en) | 1996-11-21 |
WO1996036575A3 WO1996036575A3 (en) | 1997-03-13 |
Family
ID=23722775
Family Applications (1)
Application Number | Title | Priority Date | Filing Date |
---|---|---|---|
PCT/US1996/005145 WO1996036575A2 (en) | 1995-05-03 | 1996-04-12 | Process for production of alumina/zirconia materials |
Country Status (8)
Country | Link |
---|---|
US (1) | US5567214A (en) |
EP (1) | EP0823934B1 (en) |
AT (1) | ATE187979T1 (en) |
AU (1) | AU5544796A (en) |
DE (1) | DE69605785T2 (en) |
TW (1) | TW340835B (en) |
WO (1) | WO1996036575A2 (en) |
ZA (1) | ZA963097B (en) |
Families Citing this family (38)
Publication number | Priority date | Publication date | Assignee | Title |
---|---|---|---|---|
FR2872157B1 (en) * | 2004-06-24 | 2006-10-13 | Saint Gobain Ct Recherches | FROZEN ALUMINA-ZIRCONE GRAIN MIXTURE |
EP2221286B1 (en) * | 2007-12-06 | 2014-03-12 | Agc Ceramics Co., Ltd. | Process for producing refractory particles |
CN101560074B (en) * | 2008-04-16 | 2012-11-21 | 万方 | Water reducer produced by utilizing zirconium silica residues and production method thereof |
BR112013016734A2 (en) | 2010-12-31 | 2019-09-24 | Saint Gobain Ceramics | abrasive particles with particular shapes and methods of deformation of such particles |
WO2013003831A2 (en) | 2011-06-30 | 2013-01-03 | Saint-Gobain Ceramics & Plastics, Inc. | Liquid phase sintered silicon carbide abrasive particles |
US8986409B2 (en) | 2011-06-30 | 2015-03-24 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive articles including abrasive particles of silicon nitride |
US9517546B2 (en) | 2011-09-26 | 2016-12-13 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive articles including abrasive particulate materials, coated abrasives using the abrasive particulate materials and methods of forming |
CN104114664B (en) | 2011-12-30 | 2016-06-15 | 圣戈本陶瓷及塑料股份有限公司 | Form molding abrasive grains |
EP3517245B1 (en) | 2011-12-30 | 2023-12-13 | Saint-Gobain Ceramics & Plastics Inc. | Shaped abrasive particle and method of forming same |
CN104114327B (en) | 2011-12-30 | 2018-06-05 | 圣戈本陶瓷及塑料股份有限公司 | Composite molding abrasive grains and forming method thereof |
WO2013106602A1 (en) | 2012-01-10 | 2013-07-18 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive particles having particular shapes and methods of forming such particles |
CA2987793C (en) | 2012-01-10 | 2019-11-05 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive particles having complex shapes and methods of forming same |
US9242346B2 (en) | 2012-03-30 | 2016-01-26 | Saint-Gobain Abrasives, Inc. | Abrasive products having fibrillated fibers |
KR101888347B1 (en) | 2012-05-23 | 2018-08-16 | 생-고뱅 세라믹스 앤드 플라스틱스, 인코포레이티드 | Shaped abrasive particles and methods of forming same |
BR112014032152B1 (en) | 2012-06-29 | 2022-09-20 | Saint-Gobain Ceramics & Plastics, Inc | ABRASIVE PARTICLES HAVING PARTICULAR FORMATS AND ABRASIVE ARTICLES |
CN104822494B (en) | 2012-10-15 | 2017-11-28 | 圣戈班磨料磨具有限公司 | The method of abrasive particle and this particle of formation with given shape |
WO2014106173A1 (en) | 2012-12-31 | 2014-07-03 | Saint-Gobain Ceramics & Plastics, Inc. | Particulate materials and methods of forming same |
CN107685296B (en) | 2013-03-29 | 2020-03-06 | 圣戈班磨料磨具有限公司 | Abrasive particles having a particular shape, methods of forming such particles, and uses thereof |
TW201502263A (en) | 2013-06-28 | 2015-01-16 | Saint Gobain Ceramics | Abrasive article including shaped abrasive particles |
WO2015048768A1 (en) | 2013-09-30 | 2015-04-02 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particles and methods of forming same |
JP6290428B2 (en) | 2013-12-31 | 2018-03-07 | サンーゴバン アブレイシブズ,インコーポレイティド | Abrasive articles containing shaped abrasive particles |
US9771507B2 (en) | 2014-01-31 | 2017-09-26 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particle including dopant material and method of forming same |
BR112016023880A2 (en) | 2014-04-14 | 2017-08-15 | Saint Gobain Ceramics | abrasive article including molded abrasive particles |
AU2015247826A1 (en) | 2014-04-14 | 2016-11-10 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive article including shaped abrasive particles |
WO2015184355A1 (en) | 2014-05-30 | 2015-12-03 | Saint-Gobain Abrasives, Inc. | Method of using an abrasive article including shaped abrasive particles |
US9914864B2 (en) | 2014-12-23 | 2018-03-13 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particles and method of forming same |
US9707529B2 (en) | 2014-12-23 | 2017-07-18 | Saint-Gobain Ceramics & Plastics, Inc. | Composite shaped abrasive particles and method of forming same |
US9676981B2 (en) | 2014-12-24 | 2017-06-13 | Saint-Gobain Ceramics & Plastics, Inc. | Shaped abrasive particle fractions and method of forming same |
WO2016161157A1 (en) | 2015-03-31 | 2016-10-06 | Saint-Gobain Abrasives, Inc. | Fixed abrasive articles and methods of forming same |
TWI634200B (en) | 2015-03-31 | 2018-09-01 | 聖高拜磨料有限公司 | Fixed abrasive articles and methods of forming same |
JP2018516767A (en) | 2015-06-11 | 2018-06-28 | サン−ゴバン セラミックス アンド プラスティクス,インコーポレイティド | Abrasive articles containing shaped abrasive particles |
EP4071224A3 (en) | 2016-05-10 | 2023-01-04 | Saint-Gobain Ceramics and Plastics, Inc. | Methods of forming abrasive articles |
EP4349896A2 (en) | 2016-09-29 | 2024-04-10 | Saint-Gobain Abrasives, Inc. | Fixed abrasive articles and methods of forming same |
US10563105B2 (en) | 2017-01-31 | 2020-02-18 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive article including shaped abrasive particles |
US10759024B2 (en) | 2017-01-31 | 2020-09-01 | Saint-Gobain Ceramics & Plastics, Inc. | Abrasive article including shaped abrasive particles |
US10865148B2 (en) | 2017-06-21 | 2020-12-15 | Saint-Gobain Ceramics & Plastics, Inc. | Particulate materials and methods of forming same |
CN107541189A (en) * | 2017-08-22 | 2018-01-05 | 郑州威源新材料有限公司 | A kind of production method for ensureing that fused alumina zirconia abrasive grain composition is stable |
KR20220116556A (en) | 2019-12-27 | 2022-08-23 | 세인트-고바인 세라믹스 앤드 플라스틱스, 인크. | Abrasive articles and methods of forming same |
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GB150116A (en) * | 1919-06-18 | 1920-09-02 | Otis Hutchins | An improved process for purifying aluminous materials |
DE1205882B (en) * | 1961-09-08 | 1965-11-25 | Carborundum Co | Process for producing an abrasive grain from aluminum oxide and zirconium oxide |
US3781172A (en) * | 1970-12-14 | 1973-12-25 | G Kinney | Process for the manufacture of microcrystalline fused abrasives |
US3891408A (en) * | 1972-09-08 | 1975-06-24 | Norton Co | Zirconia-alumina abrasive grain and grinding tools |
US5143522B1 (en) * | 1979-11-09 | 1998-01-06 | Washington Mills Electro Miner | Abrasive products containing fused alumina zirconia and reduced titania |
FR2499061A1 (en) * | 1981-01-30 | 1982-08-06 | Sofrem | METHOD AND APPARATUS FOR RAPID CONTINUOUS CASTING SOLIDIFICATION AND COOLING OF MOLDED OXIDES BASED ON METAL OXIDES |
US4457767A (en) * | 1983-09-29 | 1984-07-03 | Norton Company | Alumina-zirconia abrasive |
AT379979B (en) * | 1984-08-01 | 1986-03-25 | Treibacher Chemische Werke Ag | METHOD FOR PRODUCING ABRASIVES |
JPS62100412A (en) * | 1985-10-25 | 1987-05-09 | Japan Carlit Co Ltd:The | Production of alumina-zirconia compound powder body |
US5183610A (en) * | 1987-07-22 | 1993-02-02 | Cooper Indusries, Inc. | Alumina-zirconia ceramic |
US4992396A (en) * | 1987-12-16 | 1991-02-12 | Corhart Refractories Corporation | Fused AZS refractory composition |
US5214011A (en) * | 1991-08-30 | 1993-05-25 | Bfd, Incorporated | Process for preparing ceramic-metal composite bodies |
-
1995
- 1995-05-03 US US08/434,087 patent/US5567214A/en not_active Expired - Lifetime
-
1996
- 1996-04-12 DE DE69605785T patent/DE69605785T2/en not_active Expired - Lifetime
- 1996-04-12 AU AU55447/96A patent/AU5544796A/en not_active Abandoned
- 1996-04-12 AT AT96912746T patent/ATE187979T1/en active
- 1996-04-12 EP EP96912746A patent/EP0823934B1/en not_active Expired - Lifetime
- 1996-04-12 WO PCT/US1996/005145 patent/WO1996036575A2/en active IP Right Grant
- 1996-04-17 TW TW085104570A patent/TW340835B/en not_active IP Right Cessation
- 1996-04-18 ZA ZA963097A patent/ZA963097B/en unknown
Non-Patent Citations (1)
Title |
---|
None |
Also Published As
Publication number | Publication date |
---|---|
ZA963097B (en) | 1996-10-24 |
DE69605785D1 (en) | 2000-01-27 |
EP0823934B1 (en) | 1999-12-22 |
TW340835B (en) | 1998-09-21 |
US5567214A (en) | 1996-10-22 |
ATE187979T1 (en) | 2000-01-15 |
DE69605785T2 (en) | 2000-07-27 |
EP0823934A2 (en) | 1998-02-18 |
WO1996036575A3 (en) | 1997-03-13 |
AU5544796A (en) | 1996-11-29 |
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