阅读说明：本技术 用于制备陶瓷颗粒的粘合剂材料 (binder material for producing ceramic particles ) 是由 伊尔达·伊巴图林 维亚切斯拉夫·苏科瓦托夫 于 2018-02-23 设计创作，主要内容包括：本发明涉及制备烧结的陶瓷颗粒的方法,其包括：制备包含粘合剂和含氧化铝原料的水性浆料,所述粘合剂包含原始植物材料；将该浆料形成生球团；以及烧结生球团,以提供烧结的陶瓷颗粒。(The present invention relates to a method of making sintered ceramic particles comprising: preparing an aqueous slurry comprising a binder and an alumina-containing starting material, the binder comprising virgin plant material; forming the slurry into green pellets; and sintering the green pellets to provide sintered ceramic particles.)

1. A method of making sintered ceramic particles, comprising:

Preparing an aqueous slurry comprising a binder and an alumina-containing starting material, the binder comprising virgin plant material;

Atomizing the slurry into droplets;

Coating a seed comprising alumina with the droplets to form green pellets; and is

Sintering at least a portion of the green pellets at a temperature between 1000 ℃ and 1650 ℃ for about 5 minutes to about 90 minutes to form sintered ceramic particles.

2. The process of claim 1, wherein the alumina-containing feedstock comprises from about 40 wt% to about 99 wt% alumina, based on the total weight of the alumina-containing feedstock.

3. The process of claim 1, wherein the alumina-containing feedstock comprises bauxite, kaolin, kaolinite, slag, or fly ash.

4. The method of claim 1, wherein the raw plant material is a raw starch-containing plant selected from the group consisting of barley, rye, wheat, buckwheat, corn rice, peas, fruit shells, rice hulls, corn hulls, wheat hulls, buckwheat hulls, bran, switchgrass, hay, and any mixtures thereof.

5. The method of claim 1, wherein the sintered ceramic particles have a bulk density of less than 3 g/cc.

6. The method of claim 1, wherein preparing the aqueous slurry comprises:

Introducing the alumina-containing feedstock and the binder into a pulverizer to provide a treated feedstock having a reduced particle size comprising a mixture of the alumina-containing feedstock and binder; and is

Introducing the treated feedstock and water into a blender to provide the aqueous slurry.

7. The method of claim 1, wherein preparing the aqueous slurry comprises:

Introducing the alumina-containing feedstock, the binder, and water into a blender to provide the aqueous slurry.

8. The method of claim 1, wherein the sintered ceramic particles are proppants, casting media, scouring media, or grinding media.

9. A method of making sintered ceramic particles, comprising:

Introducing a calcined alumina-containing feedstock into a mill;

Introducing a binder comprising virgin plant material into the mill;

Milling the calcined alumina-containing raw material and the binder to provide a dry, homogeneous particulate mixture having an average particle size of less than about 15 microns;

Introducing water into the mill to provide green pellets; and is

sintering at least a portion of the green pellets at a temperature of 1250 ℃ to 1550 ℃ for about 4 minutes to about 20 minutes to form sintered ceramic particles.

10. The process of claim 9, wherein the alumina-containing feedstock comprises from about 40 wt% to about 99 wt% alumina, based on the total weight of the alumina-containing feedstock.

11. The process of claim 9, wherein the alumina-containing feedstock comprises bauxite, kaolin, kaolinite, slag, or fly ash.

12. the method of claim 9, wherein the raw plant material is a raw starch-containing plant selected from the group consisting of barley, rye, wheat, buckwheat, corn rice, peas, fruit shells, rice hulls, corn hulls, wheat hulls, buckwheat hulls, bran, switchgrass, hay, and any mixtures thereof.

13. The method of claim 9, wherein the sintered ceramic particles have a bulk density of less than 3 g/cc.

14. The method of claim 9, wherein the sintered ceramic particles are proppants, casting media, scouring media, or grinding media.

15. A green pellet for processing into sintered ceramic particles, the green pellet comprising:

Water;

A alumina-containing feedstock; and

Unprocessed starch-containing plants.

16. The green pellet of claim 15, wherein the alumina-containing feedstock comprises bauxite, kaolin, kaolinite, slag, or fly ash.

17. The green pellet of claim 15, wherein the sintered ceramic particles are proppants, casting media, scouring media, or grinding media.

18. The green pellet of claim 15, wherein the raw starch-containing plant is selected from the group consisting of barley, rye, wheat, buckwheat, corn rice, pea, nut shell, rice hull, corn hull, wheat hull, buckwheat hull, bran, switchgrass, hay, and any mixtures thereof.

Technical Field

The present disclosure relates generally to ceramic media and methods of making ceramic particles. In particular, the present disclosure relates to binder materials for making ceramic particles.

background

ceramic particles, such as ceramic proppants, casting media, grinding media, and the like, may be made according to any conventional method, including but not limited to continuous spray atomization, spray fluidization, spray drying, compression, or drop casting. Suitable methods for preparing ceramic particles are disclosed in U.S. Pat. Nos.4,068,718, 4,427,068, 4,440,866, 4,879,181, 5,188,175 and 7,036,591.

These conventional methods often utilize a binder material that can be used to hold the unfired ceramic material together. The binder material may be mixed with the ceramic raw materials at any suitable step in the manufacturing process. Common binder materials (e.g., polyvinyl alcohol and polyvinyl acetate) can represent a significant component of the cost of manufacturing the ceramic particles.

It is desirable to keep the manufacturing cost of the ceramic particles as low as possible to make the final product competitive in the market. Accordingly, there is a need for binder materials that are suitable for use in ceramic particle manufacturing processes and are less expensive than conventional binder materials.