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J. Korean Ceram. Soc. > Volume 61(5); 2024 > Article
Journal of the Korean Ceramic Society 2024;61(5): 872-889.
doi: https://doi.org/10.1007/s43207-024-00406-9
Processing of millimeter-sized spherical ZrO2 granules through sodium alginate cross-linking and an assessment of their resultant properties
Maria Dolores Sosa Lucio1,2, Eun-Ji Oh1, Jang-Hoon Ha1 , Jongman Lee1,2, Hong-Joo Lee1, Seung Hwa Jung3, Jun Young Shin3, In-Hyuck Song1,2
1Ceramic Materials Division, Korea Institute of Materials Science (KIMS), 797 Changwon-daero, Seongsan-gu, Changwon-si, Gyeongsangnam-do 51508, Republic of Korea
2Department of Advanced Materials Engineering, University of Science and Technology (UST), 217 Gajeong-ro, Yuseong-gu, Daejeon 34113, Republic of Korea
3R&D Center, Cenotec Co., LTD., 1256-40, Hamma-Dearo, Gaya-Eup, Haman-gun, Gyeongsangnam-do 52035, Republic of Korea
Correspondence  Jang-Hoon Ha ,Email: hjhoon@kims.re.kr
Received: November 16, 2023; Revised: March 31, 2024   Accepted: May 13, 2024.  Published online: May 23, 2024.
ABSTRACT
ZrO2–based porous and dense engineering ceramics exhibit a wide range of applications due to their remarkable features. Specifically, applications related to catalytic supports, inert matrix fuel pellets, and structural materials (milling media) require the preparation of millimeter-sized ZrO2-based spherical granules with high sphericity. This ensures easy handling and recovery, improved mass transfer, uniform packing density, and efficient designs of processes. However, commonly applied granulation methods involve the use of toxic and corrosive reagents and severe processing conditions, which can impede safe industrial manufacturing. The present study investigates the processing of millimeter-sized spherical ZrO2 granules based on ZrO2 as a raw material in the form of a solid network and with sodium alginate cross-linked through ion exchange as a patterned structure. The results suggest that optimized spherical ZrO2 granules, with high sphericity processed between 1000 and 1200 °C, exhibit characteristics preferable for catalytic supports, including good structural stability and hierarchical meso/macro porosity. Furthermore, spherical ZrO2 granules processed between 1400 and 1500 °C displayed low residual porosity and a refined microstructure, resulting in high compressive strength, comparable to ZrO2 granules potentially suitable for structural applications such as milling media and inert matrix fuels.
Key words: ZrO2 granules  · Sodium alginate  · Cross-linking  · Sphericity  · Porosity  · Compressive strength
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