TECHNOPLAN FABRITECHNIK GMBH & CO. KG GERMANY.
Jyoti Ceramic is the proud manufacturer of Zirconox milling media, exporting 70% of it’s production to 55 countries globaly for over three decades. Zirconox milling media has proved to be the most efficient, cost effective milling media in varied industries.
Zirconox was formulated in early 1990's from micro fine monoclinic zirconia powder stabilized with rare earth Cerium Oxide transformed to tetragonal polycrystals.
Due to its unique features Zirconox has become synonymous with milling beads and today is considered as the wonder ceramic milling beads.
Physical Propertise | |
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Colour | Golden brown |
Surface Finish | Glossy, Satin Smooth |
Density | 6.20 ±0.05 g/cm3 |
Bulk Density | 3.85 ±0.15 kg/ltr |
Porosity | Nil |
Water absorption | Nil |
Hardness on Moh’s scale | 9 |
Hardness on Vicker’s scale (Hv5) | 1250-1300 |
Crushing strength (Ø 1.5mm bead) | 215 kgf |
Bead Sphericity 90% | ≥ 0.95 |
% Cumulative weight loss / HR(wear test conducted with water) | |
After 24 hrs. | 0.0015 |
After 96 hrs | 0.0010 |
Chemical Propertise | |
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ZrO2 | 83% |
CeO2 | 17% |
Non-contaminative | Non-toxic | Non-radioactive |
Non-magnetic | Chemically inert | Resistant to all acids and alkalis except hydrofluoric acid |
Zirconox micro beads are being used in varied industries for micro fine milling & dispersion of :
Agro chemicals : Fungicides, Herbicides , Pesticides.
Adhesive, Sealants & Glues.
Ceramic : Ceramic Inks, Engobes, Glazes, Frits, Enamels, Pigments.
Cosmetics. Dyestuff : Textile dyes, Textile Inks.
Electronic materials : Lithium Iron Phosphate battery.
Food Stuff.
Inks : Printing inks, Inkjet - Magnetic inks, Tattoo inks.
Minerals : Calcium Carbonate.
Metal : Gold, Silver, Platinum.
Oxides : Titanium Dioxide, Zirconium Oxide.
Paints & Varnishes : Auto & allied paints, Decorative & Marine paints.
Pharmaceuticals. Zirconox beads are also used for shot peening treatment on metal surfaces, metal polishing, contact eye lenses polishing and a host of many other applications.
TECHNOPLAN FABRITECHNIK GMBH & CO. KG GERMANY.
Practical Wear test with Zirconox - milling media (1.7-2.4 mm) In comparison to actually used glass beads.
In reference to the graph
Initially the cost of Zirconox may be higher by about 17 times than the glass beads
In the course of usage of the mill for about 18 month, it is realized that the amount spent on both types of micro media is the same.
At the end of 24 months it is observed that the cost of glass beads is higher by about 40% than Zirconox.
Comments:
The above trend is mainly due to exorbitantly high wear of glass beads in comparison to Zirconox beads. Figures from the graph indicate that the glass beads wear is about 300 times more than that of Zirconox.
Fraunhofer Institute, Freising, Germany has approved Zirconox micro media for milling of food stuff in accordance with the regulations of the European Community.
National Radiological Protection Board (NRPB), Great Britain has confirmed that the radio activity of Zirconox is within the regulations established by the European Community.
Media Type | % Cumulative weight Loss / Hr | |
---|---|---|
After 24 Hrs. | After 96 Hrs. | |
Zirconia Ce stabilized Zirconox (India) | 0.0015 | 0.0010 |
Zirconia YTZ stabilized (China) | 0.00213 | 0.00175 |
Zirconia Ce stabilized (USA) | 0.00233 | 0.00418 |
Zirconia MgO stabilized (USA) | 0.0236 | 0.0273 |
Zirconia Ce stabilized (France) | 0.00329 | 0.00309 |
Glass Beads (China) | 0.2724 | 0.298 |
Characteristics | Units | Ce stabilized zirconia (INDIA) |
Yttria stabilized zirconia (CHINA) |
Ce stabilized zirconia Beads (USA) |
MgO stabilized zirconia Beads (USA) |
Ce stabilized zirconia (FRANCE) |
Glass Beads (CHINA) |
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Colour Shade | - | Golden Brown | White | Brown | Golden Yellow | Black | Transparent |
Density | g/cm3 | ≥ 6.20 | 6.0 | 6.17 | 5.73 | 6.2 | 2.24 |
Bulk Density | kg/ltr | 3.85 ± 0.15 | 3.81 | 3.60 | 3.59 | 3.81 | 1.55 |
Porosity | % | 0.00 | 0.00 | 0.00 | 0.00 | 0.00 | 0.00 |
Water Absorption | % | 0.00 | 0.00 | 0.00 | 0.00 | 0.00 | 0.00 |
Hardness on | Moh’s scale | 9 | 9 | 9 | 8 | 9 | 5.5 |
Hardness on Vicker’s Scale | Hv5 | 1310 | 1350 | 1150-1200 | 900-950 | 1250 | 500-550 |
Average Bead size taken for crushing strength | mm | Ø 1.496 | Ø 1.615 | Ø 1.44 | Ø 1.55 | Ø 1.52 | Ø 1.66 |
Crushing Load | Kgf | 215.50 | 233.82 | 200.00 | 81.00 | 159.57 | 45.00 |
Sphericity for 90% of the beads | - | >0.96 | 0.98 | 0.90 | >0.95 | 0.96 | 0.95 |
% Cumulative Weight Loss Per Hour of Wear Test (Wear Test conducted with Water) | After 24 Hrs. | 0.0015 | 0.00213 | 0.00233 | 0.0236 | 0.00329 | 0.2724 |
After 96 Hrs. | 0.0010 | 0.00175 | 0.00418 | 0.0273 | 0.00309 | 0.2982 | |
Surface Condition of Beads observed after 96 Hrs. of Wear Test in water | - | Glossy Satin smooth surface, free from pin holes & no broken beads | Glossy Satin smooth surface, few beads with pin holes & few broken beads observed | Satin smooth few beads with pin holes & few broken beads observed | Satin smooth surface, few broken beads observed | Dull surface finish observed | Dull surface finish observed |
The density of Zirconox beads is > 6.20 g/cm3 which is about 3 times greater than the glass beads, 1.6 times > than Zirconium Silicate beads and 1.1 times than the MgO PSZ beads.
As Zirconox beads possess higher density as compared to any other ceramic micro milling beads, it can generate considerable heat during milling process, which may affect physical properties of ingredients being milled. Therefore, it is strongly recommended to provide suitable cooling system to the mill chamber, to monitor dissipation of heat generated during the milling process
Due to higher density of Zirconox milling beads, it is strongly recommended
Chemical Medium | Concentration | % Weight Loss per hour |
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Acetic Acid (CH3COOH) | 50% | 0.00 |
Chromic Acid (H2CrO4) | 25% | 0.00 |
Formic Acid (CH2O2) | 25% | 0.00 |
Hydrochloric Acid (HCI) | 18% | 0.00 |
Hydrofluoric Acid (HF) | 24% | 0.01 |
Nitric Acid (HNO3) | 35% | 0.00 |
Perchloric Acid ( HClO4) | 25% | 0.00 |
Phosphoric Acid (H3PO4) | 25% | 0.00 |
Sulphuric Acid (H2SO4) | 50% | 0.00 |
Saturated Sodium Hydroxide Acid (NaOH) | 50% | 0.00 |
With the exception of Hydrofluoric acid Zirconox beads did not lose it’s gloss or colour
Dia (mm) | kg/ltr |
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Ø 0.40 - 0.70 mm | 3.75 ± 0.05 kg/ltr |
Ø 0.70 - 1.20 mm | 3.75 ± 0.05 kg/ltr |
Ø 1.20 - 1.70 mm | 3.85 ± 0.05 kg/ltr |
Ø 1.70 - 2.40 mm | 3.85 ± 0.05 kg/ltr |
Ø 2.40 - 2.80 mm | 3.95 ± 0.05 kg/ltr |
Ø 2.80 - 3.30 mm | 3.95 ± 0.05 kg/ltr |
Broad Fraction Size | ||
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Ø 0.4 - 0.7 mm | Ø 0.7 - 1.2 mm | |
Ø 1.2 - 1.7 mm | Ø 1.7 - 2.4 mm | |
Ø 2.4 - 2.8 mm | Ø 2.8 - 3.3 mm |
* We also offer custom fraction size beads, if found feasible for production.
Narrow Fraction Size | |
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Ø 0.05 - 0.1 mm | Ø 0.1 - 0.2 mm |
Ø 0.2 - 0.4 mm | Ø 0.4 - 0.6 mm |
Ø 0.6 - 0.8 mm | Ø 0.8 - 1.0 mm |
Ø 1.0 - 1.2 mm | Ø 1.2 - 1.4 mm |
Ø 1.4 - 1.6 mm | Ø 1.4 - 1.7 mm |
Ø 1.6 - 2.0 mm | Ø 1.7 - 2.0 mm |
Ø 2.0 - 2.4 mm | Ø 3.5 - 4.0 mm |
Type of Media Load | Bead Charge |
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Closed Horizontal | 75% - 85% of Volume |
Closed Vertical | 70% - 80% of Volume |
Open Vertical | 60% - 70% of Volume |
E.g. : Bead mill net volume capacity is 50 ltr. Charging with Ø 1.2- 1.7 mm bead. For vertical closed type mill it works out to = 35 ltr (70% of mill vol.) x 3.85 kg/ltr (Bulk Density of Zirconox beads) that is 135 kg. of Zirconox micro beads charge required for a 50 ltr capacity closed vertical mill.Considering Bead Ø 1.2 - 1.7 mm & bead charge of 75-85% of volume of grinding chamber for closed horizontal mill, 70-80% of volume for closed vertical mill & 60-70% of volume for open vertical mill. |
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Volume of Gridning Chamber (ltr) | Qty. of Zirconox Micro Beads (kgs) | ||
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Closed Horizontal Mill | Closed Vertical Mill | Open Vertical Mill | |
8.0 | 23 - 26 | 22 – 25 | 18 - 22 |
15.0 | 43 - 49 | 40 – 46 | 35 – 40 |
30.0 | 87 - 98 | 81 - 92 | 69 – 81 |
45.0 | 130 - 147 | 121 - 139 | 104 – 121 |
60.0 | 173 - 196 | 162 - 185 | 139 – 162 |
115.0 | 332 - 376 | 310 - 354 | 266 - 310 |
225.0 | 650 - 736 | 606 - 693 | 520 - 606 |
Mill Type | Horizontal Lab Bead Mill |
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Model | LME - 1 |
Mill Capacity | 0.61 Ltr |
Ceramic Media (Qty.) | 2.35 kgs. |
Make | NETZSCH, Germany |
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Mill Container | Polyurethane |
Mill Agitator Speed | 3000 RPM |
Media (Milled with) (Qty.) | Water |
High Speed Bead Mill for Wear Test
After milling for 24 & 96 hours at 3000 RPM (10.0 m/s), beads were collected, washed and dried thoroughly, weighed on sensitive electronic balance (Resolution : 100 mg) & the percentage weight loss was calculated as.
Where
P = Percentage Weight Loss
W1 = Initial Weight of Beads
W2 = Final Weight of Beads
The weight loss of Zirconox micro beads was found insignificant as well as caused lowest wear on mill contact parts. The percentage cumulative weight loss of Zirconox beads was observed to be 0.0015% per hour in the 24 hour test. The percentage cumulative weight loss came down to 0.0010% per hour in the 96 hour test.
Zirconox macro milling media are manufactured from micro fine Zirconia powder stabilized with rare earth Cerium Oxide, transformed to tetragonal polycrystals. Zirconox macro media have a density of 6.1 g/cm3, are tough sapphire hard and have a glossy, satin smooth surface finish. After Tungsten Carbide, Zirconox macro milling media are considered to have the highest density among the ceramic materials and the lowest in coefficient of friction. Due to its unique features, Zirconox milling media mills hard and soft high viscous substances faster and produces insignificant contamination from its wear.
Zirconox macro milling media are ideal for particle size reduction, dispersion of hard and soft substances in Attritor mills, Jar mills, lab scale and bulk production Ball mills and Vibro Energy Mills.
For Jar mills, satellite type or iso pressed dia 12.5, 15 & 20 mm balls are ideal, for ball mills dia 20 to 30 mm iso pressed balls are recommended. For Vibro energy mills 6, 10, 12.5, 15 mm dia radius corner / radius end cylinders are recommended.
For low and medium speed attritor mills 6, 8 and 10 mm dia satellite type balls are recommended. Smaller the size of milling media, larger the number of contact points, resulting in reduced milling time. Zirconox macro milling media lasts longer due to its dense, homogeneous internal micro structure, higher toughness and micro fine grain size. Zirconox media are very gentle on mill contact parts.
Zirconox Macro Media Are Available in Following Sizes | ||
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Type of Zirconox Macro Milling Media | Available Sizes (In mm) | Shapes |
Uniaxial pressed sphere with ridge / band at centre | Dia 6, 8, 10, 12.5 | |
Iso pressed sphere with ring at top | Dia 16, 21, 26, 31 | |
Radius end Cylinder (REC) | Dia 6, 8, 10, 12.5 | |
Radius end Corner Cylinder (RCC) | Dia 6, 8, 10, 12.5, 15, 20, 25 |
Physical Properties | |
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Colour | Golden brown |
Surface Finish | Glossy, Satin Smooth |
Density | 6.10 ±0.05 g/cm3 |
Bulk Density | 3.95 ±0.05 kg/ltr |
Water absorption | Nil |
Hardness on Moh’s scale | 9 |
Hardness on Vicker’s scale (Hv5) | 1200 - 1300 |
Flexural strength at Room Temp | 490 MPa |
Chemical Properties | |
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ZrO2 | 83% |
CeO2 | 17% |
Zirconox macro milling media are excellent for milling and dispersion of high viscous formulations, wet and dry grinding of hard and soft substances, such as auto and allied paints, printing inks, colors, pigments, chemicals, Calcium Carbonate, minerals, enamels, glazes, frits, graphite, advanced ceramic materials, dielectric and piezoelectric formulations, cosmetics, batteries, pharmaceuticals, food and a host of many other applications requiring contamination free, speedy micro fine milling or dispersion of formulations.
Satellite type or ISO Pressed dia. 12.5, 15 & 20 mm balls are ideal.
Dia. 6, 8, 10, 12.5, 15 mm radius corner / radius end cylinder are recommended.
Satellite type dia. 6, 8 and 10 mm balls are recommended.
Iso Pressed dia. 20 to 30 mm balls are
recommended