Preparation of Zirconia from Zircon
Zirconia is a unique form of ceramic material with a variety of properties and applications. It is made from zircon, which is a mineral form of the element zirconium, and it is naturally occurring in many places throughout the world. Zirconia is used for a wide range of industries, from medical and dental fields to industrial applications such as abrasives and refractories. As with many other ceramic materials, zirconia can be prepared from its source material through various processes. This article will discuss the preparation of zirconia from zircon.
The first step in the preparation of zirconia is to obtain the zircon. This can be accomplished through mining or extraction from sedimentary deposits. In general, zircon is found in several countries around the world, including Australia, India, Brazil, Canada, and the United States. Once the zircon is obtained, it must be crushed into a more manageable form. This can be done in several ways, including hammer mills, ball mills, or other mechanical mills. Following crushing, the material must be screened to remove impurities.
The next step in the preparation of zirconia is the purification process. This process is often done through a series of subjecting the crushed zircon through various chemical treatments, including oxidation, leaching, and precipitation. Many of these treatments involve strong acids and can also be dangerous if not done properly. The purification process also includes refinement of the particle size and granularity of the zircon.
Once the zircon is purified, the next step is to convert it into zirconia. This is done through a roasting process, which involves heating the zircon to high temperatures in the presence of oxygen. This process is performed in a variety of ways, including fluidized bed roasting and high pressure conversion. Each one has its advantages and limitations, and the selection of the process type will depend on the desired properties and applications.
Following the roasting process, the zirconia will then undergo a thermal treatment. This process is used to modify the microstructure of the material, which can improve its properties such as strength, toughness, abrasiveness, and resistance to wear. This process is usually done in an annealing oven at specific temperatures and times.
Finally, the zirconia will be ready for use. It can be stored as a powder, or it can be formed into a variety of shapes and sizes for various applications. The material can also be further modified through the addition of other materials such as ceramic coatings or binder materials.
Overall, the preparation of zirconia from zircon requires several steps, with each one having its own unique set of challenges. However, the end result is a unique form of ceramic material with many practical and versatile applications.
