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[Chemical Knowledge]：Manufacturing method and process flow of zirconia

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Zirconia (ZrO2) is an important inorganic non-metallic material with excellent physical and chemical properties, such as high temperature stability, corrosion resistance, high hardness, high refractive index and so on. Therefore, zirconia has a wide range of applications in the field of chemical production raw materials, such as ceramics, catalysts, sensors, biological materials, etc. This article will introduce the manufacturing method of zirconia.

1. Feedstock Preparation

The first step in manufacturing zirconia is to prepare the feedstock. Zircon (ZrSiO4) is usually used as a raw material because it contains an abundant zirconium element. The zircon is first crushed, ground into a powder, and then chemically treated to remove impurities.

2. chemical synthesis

1. alkali fusion method
alkali fusion method is a commonly used zirconia manufacturing method. In this method, zircon is mixed with sodium hydroxide or potassium hydroxide and subjected to a melting reaction at a high temperature. Zirconium silicate in zircon is decomposed by alkali to produce sodium or potassium zirconate and silicate slag. The zirconate is then dissolved in water to give a sodium or potassium zirconate solution, which is then precipitated by adding an acid.

2. Sol-Gel Method
The sol-gel method is a method of producing zirconia by a solution chemical reaction. In this method, a solution of a zirconium salt is mixed with a hydrolyzing agent such as aqueous ammonia or acetic acid, and the zirconium salt is hydrolyzed to form a zirconium sol. Then, the sol is converted into a gel by heating, drying and baking, and finally a zirconia powder is obtained.

3. Physical Processing

1. Ball Milling
Ball milling is a method of preparing zirconia by mechanochemical action. In this method, zirconia coarse powder is put into a ball mill together with grinding balls, and the particle size of the zirconia powder is reduced and the specific surface area is increased by long-term grinding and impact.

2. Vapor Deposition Method The
vapor deposition method is a method of preparing a zirconia thin film by a vapor phase reaction. In this method, a zirconium element-containing gas is introduced into a reaction chamber using a technique such as metal organic chemical vapor deposition (MOCVD) or physical vapor deposition (PVD) to form a zirconium oxide thin film on a substrate by reactive deposition.

4. post-treatment

After manufacturing zirconia, post-treatment is usually required to improve its performance and meet the needs of different applications. For example, high temperature sintering may be performed to improve the density and mechanical properties of the zirconia; surface coatings may be performed to improve its corrosion resistance or biocompatibility; and doping may be performed to adjust its electrical or optical properties.

In short, there are various manufacturing methods for zirconia, which can be selected according to different raw materials and process conditions. Different manufacturing methods will have an important impact on the performance of zirconia, so it is necessary to select the appropriate manufacturing method according to the specific needs in actual production.

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