Method for producing solid ceramic particles using a spray drying process

Abstract

Methods for producing solid, substantially round, spherical and sintered particles from a slurry of a calcined, uncalcined or partially calcined raw material having an alumina content of greater than about 40 weight percent. The slurry is processed with spray drying methods into solid, substantially round, spherical and sintered particles having an average particle size greater than about 200 microns, a bulk density of greater than about 1.40 g/cc, and an apparent specific gravity of greater than about 2.60.

1 . A method for producing solid sintered ceramic particles that are substantially round and spherical comprising:
 preparing a slurry having a solids content of greater than about 50% by weight, and comprising water and a ceramic starting material, which ceramic starting material has an alumina content of greater than about 40 weight percent;   feeding the slurry to an atomizer operably connected to a dryer;   operating the atomizer to atomize the slurry into droplets;   operating the dryer to provide an air inlet temperature in a range of from about 100° C. to about 500° C.;   forming solid substantially round and spherical particles by allowing the droplets to pass through the dryer and exit through a discharge of the dryer;   sintering at least a portion of the particles discharged from the dryer at a temperature of from about 1000° C. to about 1600° C. for a time at peak temperature of from about 20 to about 45 minutes, wherein sintered, solid, substantially round and spherical particles are formed having an average particle size of greater than about 200 microns, an average bulk density of greater than about 1.40 g/cc, and an average apparent specific gravity of greater than about 2.60.   
   
   
       2 . The method of  claim 1  wherein the air inlet temperature is in a range selected from the group consisting of from about 100° C. to about 200° C., from about 200° C. to about 300° C., from about 300° C. to about 400° C., and from about 400° C. to about 500° C. 
   
   
       3 . The method of  claim 1  wherein the air inlet temperature is in a range selected from the group consisting of from about 150° C. to about 200° C. and from about 200° C. to about 250° C. 
   
   
       4 . The method of  claim 1  further comprising:
 adding a binder to the slurry before feeding the slurry to the atomizer, wherein the binder is added to the slurry in an amount of less than about 0.5 weight percent, by weight of the ceramic starting material.   
   
   
       5 . The method of  claim 1  further comprising:
 adding a binder to the slurry before feeding the slurry to the atomizer, wherein the binder is added to the slurry in an amount of less than about 1.0 weight percent, by weight of the ceramic starting material.   
   
   
       6 . The method of  claim 1  further comprising:
 adding a dispersant to the slurry before feeding the slurry to the atomizer, wherein the dispersant is added to the slurry in an amount of less than about 0.3% weight percent.   
   
   
       7 . The method of  claim 1  further comprising:
 adding a dispersant to the slurry before feeding the slurry to the atomizer, wherein the dispersant is added to the slurry in an amount of less than about 0.5% weight percent.   
   
   
       8 . The method of  claim 1  further comprising:
 adding a dispersant to the slurry before feeding the slurry to the atomizer, wherein the dispersant is added to the slurry in an amount of less than about 1.0% weight percent.   
   
   
       9 . The method of  claim 1  wherein the ceramic starting material is selected from the group consisting of calcined material, uncalcined material, partially calcined material, and mixtures thereof. 
   
   
       10 . The method of  claim 1  wherein the ceramic starting material is selected from the group consisting of kaolin clay, bauxitic kaolin and bauxite. 
   
   
       11 . The method of  claim 1  wherein the atomizer is selected from the group consisting of rotary wheel atomizers, pressure nozzle atomizers and dual fluid nozzle atomizers. 
   
   
       12 . A method for producing solid sintered ceramic particles that are substantially round and spherical comprising:
 preparing a slurry having a solids content of greater than about 50% by weight, and comprising water and a ceramic starting material, which ceramic starting material has an alumina content of greater than about 40 weight percent;   feeding the slurry to an atomizer operably connected to a dryer;   feeding drying air into the dryer;   operating the atomizer to atomize the slurry into droplets;   forming solid substantially round and spherical particles by allowing the droplets to pass through the dryer; and   controlling at least one of the solids content of the slurry, the temperature of the drying air entering the dryer, and the feed rate of the drying air entering the dryer so as to produce solid substantially round and spherical particles, that when sintered at a temperature of from about 1000° C. to about 1600° C. for a time at peak temperature of from about 20 to about 45 minutes, have an average particle size of greater than about 200 microns, an average bulk density of greater than about 1.40 g/cc, and an average apparent specific gravity of greater than about 2.60.   
   
   
       13 . The method of  claim 12  further comprising:
 adding at least one additive selected from the group consisting of dispersants and binders to the slurry; and   controlling the amount of the selected additive so as to produce the sintered, solid substantially round and spherical particles having an average particle size of greater than about 200 microns, an average bulk density of greater than about 1.40 g/cc, and an average apparent specific gravity of greater than about 2.60.   
   
   
       14 . The method of  claim 13  wherein the selected additive is a dispersant selected from the group consisting of colloids, polyelectrolytes, tetra sodium pyrophosphate, tetra potassium pyrophosphate, polyphosphate, ammonium citrate, ferric ammonium citrate and sodium hexametaphosphate. 
   
   
       15 . The method of  claim 13  wherein the selected additive is a binder selected from the group consisting of polyvinyl alcohol, polyvinyl acetate, methylcellulose, dextrin and molasses. 
   
   
       16 . The method of  claim 12  further comprising:
 adjusting a dimension of the dryer so as to adjust at least one of the average particle size, bulk density and apparent specific gravity of the solid substantially round and spherical particles.   
   
   
       17 . The method of  claim 16  wherein the height of the dryer is increased so as to increase the average particle size of the solid substantially round and spherical particles. 
   
   
       18 . Particles that:
 are solid;   are substantially round and spherical;   have an average size of greater than about 200 microns;   have an average bulk density of greater than about 1.40 g/cc; and   have an average apparent specific gravity of greater than about 2.60, wherein the particles are formed by:   preparing a slurry having a solids content of greater than about 50% by weight, and comprising water and a ceramic starting material having an alumina content of greater than about 40 weight percent;   feeding the slurry to an atomizer operably connected to a dryer;   operating the atomizer to atomize the slurry into droplets;   operating the dryer to provide a flow of air into the dryer at an air inlet temperature in a range of from about 100° C. to about 500° C.;   forming solid substantially round and spherical particles by allowing the droplets to pass through the dryer and exit through a discharge of the dryer; and   sintering at least a portion of the particles discharged from the dryer at a temperature of from about 1000° C. to about 1600° C. for a time at peak temperature of from about 20 to about 45 minutes.