95 sandblasted zirconia beads, with a density of over 6.0g/cm ³ and a Vickers hardness of over 1250HV, have demonstrated significant efficiency advantages in the field of industrial sandblasting. While increasing efficiency by 20% compared to traditional media sandblasting, they also achieve synchronous energy consumption reduction, becoming a core material in green manufacturing that combines performance and energy efficiency.
1 . Properties and technique parameters
|
Type |
Specification |
|
Main Composition |
ZrO2 94.5±0.2% Y2O3 5.2±0.5% |
|
Specific Density |
≥6.02 g/cm3 |
|
Bulk Density |
>3.6 g/cm3 |
|
Hardness in Mohs |
>9.0 |
|
Wear Rate(g/kg.h) |
<=0.01% |
2 . zirconia beads Specifications:
Φ0.1-0.2mm, Φ0.2-0.3mm, Φ0.3-0.4mm
Φ0.4-0.6mm, Φ0.6-0.8mm, Φ0.8-1.0mm
Φ1.6-1.8mm, Φ1.8-2.0mm, Φ2.0-2.2mm
Φ2.2-2.4mm, Φ2.4-2.6mm Φ,2.6-2.8mm
Φ4mm, Φ5mm, Φ6mm, Φ7mm, Φ8mm,
Φ9mm,Φ10mm,Φ12mm,Φ15mm,Φ17mm,
Φ20mm,Φ25mm,Φ30mm,Φ40mm,Φ45mm,Φ50mm etc.
3 . Zirconia beads Feature
1, Technical foundation and kinetic energy advantages of high-density and high hardness
Physical performance parameters
Density control: By sintering at 1750 ℃ with a ZrO ₂ content of over 95%, a dense tetragonal crystal structure is formed, with a density of 6.0-6.2 g/cm ³, which is 50% higher than that of alumina beads (3.8-4.0 g/cm ³);
Hardness advantage: With a Vickers hardness of 1250-1600HV, it can crush hard materials with a Mohs hardness below 7. The impact kinetic energy formula (E=189mv ²) shows that the kinetic energy of zirconia beads is three times higher than that of glass beads at the same velocity.
Efficiency improvement mechanism : The impact velocity of high-density beads reaches 70m/s under a pressure of 0.6MPa, which is 15% higher than traditional media, and the depth of single impact penetration increases by 20nm;
The high hardness surface reduces the energy loss caused by bead deformation, and increases the kinetic energy transfer efficiency from 60% to 85%, forming a cycle of "high-energy impact efficient crushing".
2, Dual optimization of time and energy consumption for sandblasting of kaolin
In the fine sandblasting of kaolin (paper grade/coating grade), 3-4mm zirconia beads achieve:
Comparison of process parameters
Traditional process: using 2-3mm alumina beads, sandblasting for 8 hours, energy consumption of 0.8kWh/kg;
Zirconia bead process: particle size of 3-4mm, pressure of 0.5MPa, sandblasting time shortened to 5 hours, energy consumption reduced to 0.65kWh/kg.
3, Collaborative energy consumption and equipment maintenance throughout the entire lifecycle
Indirect energy-saving with low wear and tear
The wear rate of zirconia beads is less than 0.01%/100h, which is 90% lower than that of alumina beads (0.1%/100h), resulting in:
The replacement cycle of equipment lining has been extended from 6 months to 24 months, saving 30000 yuan per maintenance and 60000 yuan per year;
Sandblasting waste has been reduced from 50 tons/year to 5 tons/year, and the cost of hazardous waste treatment has been reduced from 400000 yuan/year to 40000 yuan/year.
Recycling and energy-saving
The worn zirconia beads can be reused by sieving and grading:
When the 3-4mm bead is worn down to 2-3mm, it is transferred to the rough grinding process with a utilization rate of 95%;
Compared to traditional media with a 30% recovery rate, it reduces the annual procurement of new materials by 35 tons, equivalent to 12000 kWh of energy consumption (350 kWh/ton of energy consumption for new material production).
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