Zircon Sand Research Articles

A New Partially Phosphorylated Polyvinyl Phosphate-PPVP Composite: Synthesis and Its Potentiality for Zr (IV) Extraction from an Acidic Medium

A newly synthesized partially phosphorylated polyvinyl phosphate derivative (PPVP) was functionalized to extract Zirconium (IV) from Egyptian zircon sand. The specifications for the PPVP composite were approved effectively via different techniques, namely, FT-IR, XPS, BET, EDX, TGA, 1H-NMR, 13C-NMR, GC-MS, XRD and ICP-OES analyses, which demonstrated a satisfactory synthesis of PPVP and zircon dissolution from Egyptian zircon sand. Factors controlling parameters, such as pH values, shaking time, initial zirconium concentration, PPVP dose, nitrate ions concentration, co-ions, temperature and eluting agents, have been optimized. At 25 °C, pH 0, 20 min shaking, 0.05 mol/L zirconium ions and 0.5 mol/L nitrate ions, PPVP has an exciting preservation potential of 195 mg/g, equivalent to 390 mg/L zirconium ions. From the extraction–distribution isotherm, the practical outcomes of Langmuir’s modeling are better than the Freundlich model. With a theoretical value of 196.07 mg/g, which is more in line with the experimental results of 195 mg/g. The zirconium ions adsorption onto the PPVP composite follows the pseudo-second-order kinetics with a theoretical capacity value of 204.08 mg/g. According to thermodynamic potential, the extraction process was expected to be an exothermic, spontaneous and beneficial extraction at low temperatures. The thermodynamic parameters ΔS (−0.03 kJ/mol), ΔH (−12.22 kJ/mol) and ΔG were also considered. As the temperature grows, ∆G values increase from −2.948 kJ/mol at 298 K to −1.941 kJ/mol at 338 K. Zirconium ions may be eluted from the working loaded PPVP by 0.025M HNO3, with a 99% efficiency rate. It was found that zirconium ions revealed good separation factors towards some co-ions such as Hf4+ (28.82), Fe3+ (10.64), Ti4+ (28.82), V5+ (86.46) and U6+ (68.17). A successful alkali fusion technique with NaOH flux followed by the extraction with PPVP is used to obtain a high-purity zirconia concentrate with a zircon content of 72.77 % and a purity of 98.29%. As a result of this, the improved factors could finally be used.

Synthesis and characterization of TENORM-free nano zirconia from zircon sand

To avoid radiation exposure in the use of nano zirconia in the ceramics and dentistry industries, a Technologically Enhanced Natural Radioactive Materials (TENORM)-free nano zirconia was required. The purpose of this research was to obtain an environmentally friendly TENORM-free nano zirconia prototype. TENORM-free nano zirconia synthesis consists of processing zircon sand into sodium zirconate, leaching of sodium zirconate to form zirconyl chloride solution, separation of impurities (silica, ThO2, U3O8, etc.), crystallization of zirconyl chloride, zirconyl-oxalate sol-gel formation, and calcination. The quality test of nano zirconia products was characterized by XRD, FT-IR, SEM, and Surveymeter, while the composition test was carried out by the XRF method. The results of this research obtained an environmentally friendly TENORM-free nano zirconia prototype, that has the chemical compound of ZrO2, the crystal size was 15.09 nm, the average particle size was 91.33 nm, free of radiation exposure, and its composition includes ZrO2: 96.599%, HfO2: 2.899%, and CaO: 0.303%. This synthesis can process zircon sand containing TENORM (ThO2: 0.070% and U3O8: 0.047%) into TENORM-free nano zirconia and increase the added value by increasing the zirconia content from 40.493% to 96.599%.

Structural analysis and magnetic-microwave absorption properties of natural mineral-derived silica-coated magnetite nanocomposites

Herein, a green synthesis method to prepare silica-coated magnetite nanocomposites by employing ironstone (an Indonesian natural resource) and an industrial by-product of zircon sand purification is reported. The X-ray diffraction pattern confirmed the formation of the magnetite phase, with an increased lattice constant after the coating process. The absorbance peaks of Fourier transform infrared spectra and the clear boundary in high-resolution transmission electron micrographs suggested that no chemical reaction was involved between Fe3O4 and SiO2. Silica coating caused a decrease in magnetic saturation and initial susceptibility and an increase in the coercivity, remanence, and domain magnetic size of composites. The microwave absorption peaks for SiO2 and Fe3O4 nanoparticles were observed at approximately 10.00 and 11.00 GHz, respectively. Fe3O4/SiO2 nanocomposites exhibited both absorption peaks with improved absorption and a tunable frequency. Furthermore, the combination of Fe3O4 as a magnetic and SiO2 as a dielectric material provided an advantage in adjusting the direction of the magnetic dipole moment and electric dipole polarization for specific applications.

Structural, physical and mechanical properties of zirconia-polymorph/alumina composites

The effect of zirconia polymorphs on the structural, physical, and mechanical properties of zirconia composites reinforced with various contents alumina was studied. The zirconia polymorphs exhibited amorphous (aZ) and tetragonal (tZ) phases, which were obtained by processing natural zircon sand, and the alumina (A) was a commercial product. The mixture of zirconia and alumina was mechanically activated and sintered at 1400 °C for 3 h. The elemental analysis and phase analysis of the purified zirconia powder was performed via X-ray fluorescence spectroscopy (XRF), and X-ray diffraction (XRD). Characterization of the composites included diameter shrinkage, density, and Vickers hardness. The atomic diffusivity in the interfacial region between each element was also observed based on the EDX line analysis. The results show that the amorphous zirconia powder contained 81.1% Zr with Si and Ti being dominant impurities. However, the identified phases were amorphous and tetragonal for zirconia raw powder respectively. Further analysis of the composite phase exhibited new phases such as zircon, monoclinic zirconia, and mullite. The aZ/A 90:10 sample had the largest shrinkage in pellet diameter, apparent density, and Vickers hardness, at 20.8%, 4.40 g/cm3, and 6.07 GPa, respectively.

Life cycle assessment comparison between zircon and alumina sand applied to ceramic tiles

The goal of the study is to assess and compare the use of opacifier (whitener) materials zircon sand and alumina applied in ceramic tiles production. This study provides a comparison using a cradle-to-gate life cycle assessment (LCA) approach, giving an overview of the differences from an environmental perspective between these materials in body mixtures to obtain tiles with a high degree of whiteness. This ISO compliant study is backed by an independent critical review panel and presents the first European-representative LCA comparison between zircon and alumina, using primary data from industry. A super white (with CIELab coordinate L*>85) ceramic tile can be produced using zircon or alumina as opacifier, with different mixtures. For zircon data, a previous ISO reviewed LCA and its associated paper has been used. This data comes from Zircon Industry Association members. For alumina, the eco-profile of alumina and bauxite developed by the European Aluminium has been used and is available in the “Environmental Profile Report for the European Aluminium Industry”. This study considers the use phase of the compared materials as whiteners. Milling phase data was collected from specific producers and tile mixture preparation data was taken from wider industrial bodies. Sensitivity and scenario analysis were used to understand the main differences between mixtures and influences between materials. Comparing the use of zircon sand with alumina in different ceramic mixtures, the primary result is that tiles using zircon had lower environmental burdens for almost all the analysed impact potentials. The alumina mixtures investigated show about 20% higher Global Warming Potential (GWP), Eutrophication Potential (EP), Acidification Potential (AP), Photochemical Ozone Creation Potential (POCP), Abiotic Depletion Element and Fossil Potential (ADPe/f) and Primary Energy Demand (PED). The Ozone Depletion Potential (ODP) is the only potential impact that is similar for zircon mixtures and alumina mixtures. The milling process is not negligible for all the impact categories considered in this study. The results of the study show that main differences between zircon and alumina mixtures are closely tied to the environmental performance of regional grid electricity generation. This study quantifies and compares the environmental impacts associated with the production of super-white ceramic tile mixture with two different whiteners: zircon and alumina. With this study, ceramic tile producers are given a tool to guide their choices in opacifier material selection, using a rational, scientific and peer-reviewed methodology, ensuring objective comparison between two materials.

Effect of Elevated Temperature on the Properties of Self‐Compacting Mortar Containing Nanomaterials and Zircon Sand

The present research work tries to assess the performance of a self‐compacting mortar containing zircon sand as a substitute for river aggregate in combination with nanoalumina and nanosilica as cement replacements. The fresh state results, as observed through the mini slump cone and mini V funnel, showed positive effects of zircon sand on workability attainment. The EFNARC limits of workability were even satisfied at high substitution levels of the nanoparticle due to the contribution of zircon sand. The mechanical properties, durability, and microstructure of the mortar were evaluated by conducting experiments at room temperature and then at 200°C, 400°C, 600°C, and 800°C. Results show that there was a significant improvement in the thermal stability of the RPC mixes due to the synergistic effect of nanomaterials and zircon sand addition. The addition of nanomaterials and zircon sand accelerated the microstructural buildup and durability at elevated temperatures. The findings thus suggest a novel and effective approach to using zircon sand as a potential alternative to quartz sand in RPC in combination with nanomaterials to produce temperature‐resistant concrete structures.

PHASE ANALYSIS AND PHYSICAL PROPERTIES OF B2O3-ADDED ZIRCON CERAMICS SINTERED AT 1300 °C

This study was aimed to know the effect of B2O3(boria) addition on the phase composition and physical properties of zircon ceramics.The raw zircon powder used in the study was a purified natural zircon sand from Kereng Pangi, Central Kalimantan, Indonesia. The zircon ceramics were prepared by a solid state reaction method with variation of B2O3 addition of 3 wt%, 6 wt% and 9 wt% and sintered at 1300 °C for 5h. The phase composition, density and microstructure were characterized using X-ray diffraction (XRD), densimeter and Scanning Electron Microscope (SEM), respectively. Vickers Hardness measurement was perfomed at the polished surface of the ceramics. Results showed that all samples contained pure zircon phase, i.e. there was no effect of B2O3 addition on the phase composition. In general, the density and hardness increased with increasing B2O3 addition, but addition up to 9 wt% is not optimum to achieve ultra-dense zircon ceramics. Furthermore, the SEM image also showed no significant difference in average grain size. The crystallite size has grown nearly eight times (325 nm) of its original powder. The Vickers hardness of the ceramics is not significantly influenced by the addition of boria. It appears that the boria failure to increase densification also results in the extent of contact between grains which then produces relatively large zircon grains.

Effect of zircon addition on the sintering of chromite-based ladle filler sands

ABSTRACT To check the application possibility of zircon grains for high Mn-high Al steel grades, laboratory experiments are carried out to investigate the sintering behaviors of the mixed filler sands of chromite and zircon grains. It is found that the mixed filler sands have a good sintering performance without the impact of liquid steel, and the sintering is continuously accelerated with the increase of zircon addition. During sintering, the zircon grains will decompose into zirconia and SiO2, and react with chromite grains to generate a liquid phase. Liquid steel enhances the sintering of the filler sands significantly, and the Mn and Al contents in steel play an important role. In case of high Mn-high Al steel grades, the effect of Mn on the sintering is more remarkable than that of Al, and the mixed filler sands are seriously sintered. Zircon sand grains are not suitable for high Mn-high Al steel grades.

Synthesis, characterization, and evaluation of ZrSiO4/Fe2O3 adsorbent for methylene blue removal in aqueous solutions

Methylene blue dyes are widely used in textile, batik, plastic, paper, and many other industries. The remain of methylene blue dyes in the textile waste is hazardous for health and the environment. Therefore, it takes effort to deal with it. One of the efforts is the process of adsorption using adsorbents. In this study, the adsorbent ZrSiO4/Fe2O3 was synthesized using the coprecipitation method using NaOH as precipitant. Either ZrSiO4 or Fe2O3 was synthesized from Indonesia mineral local zircon sand and jarosites, respectively. The composites of ZrSiO4/Fe2O3 were prepared in %mole variation, which is 75:25; 50:50; and 25:75. All obtained composites were then characterized using X-Ray Diffraction (XRD). The XRD analysis showed that the crystal structure formed was tetragonal for ZrSiO4 and hexagonal for Fe2O3 (also known as α-Fe2O3). Evaluation toward isotherm adsorption and kinetic adsorption showed that the adsorption of MB using ZrSiO4/Fe2O3 follows the Langmuir isotherm model and pseudo-second-order model, respectively.

A Novel Process for Production of High Purity Zirconium Oxy Chloride from Zircon Sand for Bio-Inert Ceramics

A Novel Process for Production of High Purity Zirconium Oxy Chloride from Zircon Sand for Bio-Inert Ceramics

THE EFFECT OF PH AND CALCINATION TEMPERATURE ON THE ZrO2 PHASE FORMATION FROM NATURAL ZIRCON SAND OF KERENG PANGI

In this research ZrO2 has been synthesized from Kereng Pangi zircon sand in Central Kalimantan through alkali fusion-coprecipitation method. Firstly, zircon sand (ZrSiO4) was purified to reduce impurities by magnetic separation, cleaned using an ultrasonic cleaner, soaked/leached with HCl 2 M for 12 hours and leached with HCl at 60 ºC for 3 hours. Secondly, alkali fusion was done with KOH as an alkali. This product was then washed by water and dried before leached with HCl 30% at 90 ºC for 30 minutes to precipitate and seperate Silica from Zircon. ZrO2 filtrate (ZrOCl2) precipitated with NH4OH at pH 4, pH 7, and pH 10 forms Zr(OH)4 gel. Zr(OH)4 gel was dried and characterized by DTA-TGA, which was then followed by calcination based on DTA TGA results at temperature ranges of 550 ºC - 700 ºC to produce ZrO2. XRD results show that single tetragonal phase of ZrO2 is formed in all variations of pH precipitation and calcination temperature. An analysis using MAUD software show that crystal size reduces as the increase in precipitation of pH. The crystal size results are 110 nm, 66 nm and 48 nm at pH 4, pH 7 dan pH 10 at 700 ºC, respectively. Moreover, XRF results show that ZrO2 with purity is at around 95.8 % at pH 4 and 96.3 % at pH 7 and pH 10.

Force-displacement analysis of PMMA/zircon composites using dynamic mechanical analyzer (DMA)

In the study, poly(methyl methacrylate) (PMMA)/zircon (ZrSiO4) composites were successfully prepared using the liquid method at different compositions of 1, 2.5, and 5 wt% of zircon. The zircon filler was processed from a natural, local zircon sand and was processed via a top-down method using wet ball-milling for 5 and 15 h as well as annealing at temperature of 200 °C for 1 h. The force-displacement curves of the composites have been acquired using a DMA (dynamic mechanical analyzer) technique in tensile mode. XRD (x-ray diffraction) data of the composites were collected and analyzed in order to examine the present phases and used as the evidence of the formation of the composites. Furthermore, MAUD software was used to estimate the crystallite size of the filler. Results indicated that zircon crystallite size for 15 h wet ball-milling was smaller than that of 5 h. Furthermore, the maximum DMA force (also representing stress) for the composite with smaller filler was generally higher than that of 5 h, ca. by 2.5 times. In addition, in general, the composites exhibited an increasing slope of force-displacement curve with increasing amount of filler.

PREPARATION OF FLUORIDE ADSORBENT FROM ZIRCON SAND USING MECHANOCHEMICAL TREATMENT, AND ITS APPLICATION FOR FLUORIDE REMOVAL

Removal of low-concentration fluoride in natural water is an important issue all over the world. Japan is a volcanic country with many hot springs, and the removal of low-concentration fluoride from hot spring drainage is desired. In this study, we attempted to prepare a novel adsorbent with high selective removal ability of fluoride from zircon sand using mechanochemical treatment, and applied it for removing fluoride from hot spring water. Mechanochemical treatment of zircon sand was carried out using a planetary ball mill, and fluoride removal of the product was examined using fluoride aqueous solution and hot spring water. The hot spring water is collected from one of the hot spring in Japan, and a typical sulfuric acid hot spring water pH 2 including high contents of SO42-(12000 mg L-1) and Cl- (5000 mg L-1) with 11 - 15 mg L-1 of fluoride ion. Regardless of ball sizes, with increasing the mechanochemical treatment time to 10 min, the removal ability of the product for fluoride increases, and then be almost constant. With decreasing pH of the solution to 2, the adsorption amount increases, and then be almost constant. With increasing the temperature of the solution, the adsorption amount decreases, while the rate of adsorption increases and the amount increases. The adsorption isotherm at pH 2 follows much better Langmuir model than Freundlich model, and the calculated maximum adsorption amount is 0.11 mmol g-1. Fluoride can be adsorbed selectively from hot spring water below Japanese effluent standard for fluoride (8.0 mg L-1).

Effect of Reinforcement, Load and sliding distance on Al-4.5%wt Copper Matrix Hybrid Composites

Aluminum is prospectively a significant material for tribological appliances for the reason that of its less density and superior thermal conductivity. However, aluminium by itself displays deprived tribological properties. Hence, the investigation of the tribological performance of aluminium based composite materials is flattering increasingly significant. Hence in the present research tribological behavior of Al-4.5%wt copper reinforced with varying percentage of zircon sand (2% -8% in increments of 2 %) with and without 2%wt graphite of hybrid composite samples prepared by friction stir casting technique.. To know the allocation of particles and bonding flanked by reinforcement with matrix, microstructure of the composites and base alloy were premeditated by means of “Optical and Scanning Electron Microscopy”. The wear loss was computed employing pin on disc apparatus at room temp underneath dry sliding state. The investigation reveals that the wear rate of Al-4.5%wtCu alloy effected by composition, load and speed.

Investigations on microstructure and tensile properties of as-cast ZA-27 metal matrix composite reinforced with zircon sand

Zinc-Aluminum alloys are employed as a bearing material in various machinery. In the present work zircon sand microparticles of size, 100 µm are dispersed in ZA-27 alloy with weight fractions of 1.5 wt%, 3.0 wt%, 4.5 wt%, and 6.0 wt% to synthesize ZA-27 metal matrix composites by stir casting. Microstructure studies using, SEM/EDAX conducted to determine the morphology of the particles and the ZA-27composites. Physical properties like density and porosity of the zircon sand microparticulate reinforced ZA-27 are evaluated and their effect on strength and ductility of the composites are evaluated using the tensile test. dispersion of zircon sand is seen in the SEM micrographs and EDAX confirms the same. The results obtained revealed an increase in tensile strength and yield strength at 3.0 wt%, 4.5 wt and 6.0 wt% at the cost of a reduction in percentage elongation when compared to ZA-27 alloy. The tensile behavior of ZA-27 composites is found to be affected by the dispersion of reinforcement in the matrix arising due to dislocation density.

Preparation of Fe-Cu-Based Friction Material and its Adoption in Automobile Mechanical Mechanism

To prepare a kind of Fe-Cu-based friction material with good friction performance and wear resistance, and apply it to the brake structure of automobile machinery, the powder metallurgy method is used to prepare the friction materials in the standard with 4% Ni, 4% Mo and 2% Sn as the auxiliary material, SiC, Al2O3, and zircon sand as the basic friction material, 8% graphite and 3% MoS2 as the lubricating component. Meanwhile, 50% Fe and 20% Cu is used for the preparation of friction materials. The friction and wear resistance can be increased by increasing the carbon fiber content of 0-8% concentration of the material. The results show that the friction coefficient of the Fe-Cu-based friction material is relatively gentle after the addition of 2% carbon fiber, and the compactness peaks, reaching 93.3%. Its shear strength and impact strength peak, which are 37.42Mpa and 6.7J/cm2 respectively. 4% carbon fiber material with a hardness of 120.2 HV is the hardest one, followed by 2% carbon fiber material with a hardness of 118.1 HV. Added with 2% carbon fiber, the abrasion amount of the friction-based material is 0.0027 g at room temperature and-0.0008 g at 400°C after 60 minutes respectively. With all indicators considered, the result shows that the friction performance and wear resistance of Fe-Cu-based friction materials can be increased by adding 2% carbon fiber during the preparation of basic friction materials.

Microstructure, Dislocation Density and Thermal Expansion Behavior Using Thermo Elastic Models of Zircon Sand Reinforced as Cast ZA-27 Composites

In the present work stir casting route is used to fabricate the ZA27 Metal matrix composites containing 3 wt%, 6 wt%, 9 wt%, and 12 wt%. Zircon sand particulates of size 100 mesh. Microstructure studies using Optical Microscopy, SEM-EDAX are carried out to ascertain the distribution and morphology of particulates in the composites. Effect of zircon sand as reinforcement on bulk density, porosity, of the fabricated composites is studied. SEM studies are carried out to understand the behavior of as-cast ZA27 alloy reinforced with zircon sand. The dislocation density of the fabricated composite affects the strength of the composites and depends on the strain due to thermal mismatch and is found to increase with increase in weight% of zircon sand. However, it does not consider casting defects of voids/clustering observed in micrographs of the fabricated composite. Porosity in composites does not have influence on Coefficient of thermal expansion (CTE) of the ZA27 composites studied using thermoelastic models like Kerner and turner model and rule of mixtures of composite.

Silica-free zirconia from zircon mineral by thermal plasma processing

ABSTRACT Experimental and thermodynamic studies on thermal plasma processing of zircon-carbon mixtures are reported in this paper. Plasma processing of zircon-carbon mixtures to convert the silicate mineral to zirconium dioxide with concurrent removal of silica was studied. Zircon sand was mixed with carbon powder and processed in a specially designed nontransferred arc plasma reactor operated using air as plasma medium. Addition of carbon to zircon facilitated in situ reduction of silica to SiO gas, which escaped with the exhaust gas. More than 96% product purity could be obtained by in-flight removal of silica by processing zircon mixed with sufficient amount of carbon at 25 kW input power. Microstructure analysis showed that in-flight removal of silica facilitated the hexagonal growth pattern and irregularly shaped bulk zirconia crystal structures of monoclinic zirconia. Thermodynamic analysis of in-situ removal of silica by carbo-thermal reduction showed that the amount of carbon had a significant effect. The studies showed that controlled addition of carbon could lower the reaction temperature by more than 500 K and facilitated in situ removal of silica. The studies are technologically relevant and offer useful guidance for making the plasma process economically viable.

Sulfuric Acid Leaching of Heavy Rare Earth Elements (HREEs) from Indonesian Zircon Tailing

Solid pollution has been an issue in mineral processing for decade. One of these pollutants is zircon sand mining waste (zircon tailing). Due to the concentration of rare earth minerals in zircon tailing and the increasing demand of REE in advanced technologies, studying zircon tailing as a potential source of REE had become an interest for us. Our experiments consisted of mineral characterization and an alkaline fusion process, followed by a leaching process. The characterization process was carried out to obtain actual information from zircon tailing samples. This process showed total rare earth elements (REEs) content of 58.62%, at 9%, 1%, 1.2%, 1.7%, and 1.5% for Y, Gd, Er, Dy, and Yb, respectively. A sieving process was carried out since it was known that most heavy rare earth elements (HREEs) content occurs at a larger size. The alkaline fusion process was applied with an intent to break the phosphate bonds present in the REE-carrying minerals (xenotime and monazite) and convert phosphate bonds to hydroxide bonds in rare earth metals. During the alkaline fusion process, as much as 75%, 66.45%, and 60% of the phosphate, silica, and zirconium, respectively, were reduced. The leaching process was carried out in a flat-bottom three-neck flask. The optimum point of leaching experiments occurs at 0.5 M H

Influence of background characteristics on the optimal sample filling height in gamma-ray spectrometry

The minimum detectable activity (MDA) for gamma spectrometric measurements was studied as a function of filling height for two detectors having different background characteristics and for two sample matrices: a water sample with a low content of natural radionuclides, and zircon sand, with high activities of uranium and thorium. The zircon sand is also a material in which the self-attenuation of low-energy gamma photons will be high. The results show that for the water sample it is always favourable to completely fill the sample container. However, due to the inherent content of naturally occurring radionuclides in the zircon sand the MDA may not necessarily improve with the filling height, since an increased amount of sample will increase the background in the spectrum as well.