Zirconium Carbonate from Zirconium Oxide Ore Residue (Cap: 17 MT/Day)

ZIRCONIUM CARBONATE FROM ZIRCONIUM OXIDE ORE RESIDUE (CAP: 17 MT/DAY)

[EIRI/EDPR/4507] J.C.: 2723XL

Zirconium dioxide (ZrO2), sometimes known as zirconia (not to be confused with zircon), is a white crystalline oxide of zirconium. Its most naturally occurring form, with a monoclinic crystalline structure, is the mineral baddeleyite. A dopant stabilized cubic structured zirconia, cubic zirconia, is synthesized in various colours for use as a gemstone and a diamond simulant.

Zirconia is chemically unreactive. It is slowly attacked by concentrated hydrofluoric acid and sulfuric acid. When heated with carbon, it converts to zirconium carbide. When heated with carbon in the presence of chlorine, it converts to zirconium (IV) chloride. This conversion is the basis for the purification of zirconium metal and is analogous to the Kroll process.

Zirconium dioxide is one of the most studied ceramic materials. ZrO2 adopts a monoclinic crystal structure at room temperature and transitions to tetragonal and cubic at higher temperatures. The change of volume caused by the structure transitions from tetragonal to monoclinic to cubic induces large stresses, causing it to crack upon cooling from high temperatures. When the zirconia is blended with some other oxides, the tetragonal and/or cubic phases are stabilized. Effective dopants include magnesium oxide (MgO), yttrium oxide (Y2O3, yttria), calcium oxide (CaO), and cerium (III) oxide (Ce2O3).

Zirconia is often more useful in its phase 'stabilized' state. Upon heating, zirconia undergoes disruptive phase changes. By adding small percentages of yttria, these phase changes are eliminated, and the resulting material has superior thermal, mechanical, and electrical properties. 

In some cases, the tetragonal phase can be metastable. If sufficient quantities of the metastable tetragonal phase is present, then an applied stress, magnified by the stress concentration at a crack tip, can cause the tetragonal phase to convert to monoclinic, with the associated volume expansion. This phase transformation can then put the crack into compression, retarding its growth, and enhancing the fracture toughness. This mechanism, known as transformation toughening, significantly extends the reliability and lifetime of products made with stabilized zirconia.

The ZrO2 band gap is dependent on the phase (cubic, tetragonal, monoclinic, or amorphous) and preparation methods, with typical estimates from 5–7 eV.

A special case of zirconia is that of tetragonal zirconia polycrystal, or TZP, which is indicative of polycrystalline zirconia composed of only the metastable tetragonal phase.

Zirconium Basic Carbonate

CAS Number: 57219-64-4

Chemical Formula: Zr(CO3)2.H2O

Applications: Zirconium basic carbonate is supplied in a high purity grade for use in catalysis and also a reactive grade for use in the production of paint driers.

Zirconium basic carbonate is perhaps the most important zirconium chemical as it is often the pre-cursor material for many zirconium products.

COST ESTIMATION

Plant Capacity            17 MT/Day  

Land & Building (6000 sq.mt.)    Rs. 2.29 Cr    

Plant & Machinery                    Rs. 3.70 Cr 

Working Capital for 1 Month    Rs. 11.64 Cr 

Total Capital Investment          Rs. 17.95 Cr 

Rate of Return                          43%

Break Even Point                      38%

CONTENTS

INTRODUCTION

ZIRCONIUM BASIC CARBONATE

PROPERTIES OF ZIRCONIUM BASIC CARBONATE

ZIRCONIUM BASIC CARBONATE

ZIRCONIUM CARBONATE TYPICAL PROPERTIES

ZIRCONIUM CARBONATE PACKAGING AND SHIPPING

ZIRCONIUM CARBONATE STORAGE

USES OF ZIRCONIUM CARBONATE

RAW MATERIALS

ZIRCONIUM OXIDE

ZIRCONIUM OXIDE PROPERTIES (THEORETICAL)

ZIRCONIUM OXIDE HEALTH & SAFETY INFORMATION

PHYSICAL PROPERTIES

PROPERTIES OF ZIRCONIUM OXIDE

MARKET OVERVIEW OF ZIRCONIUM

MAJOR PLAYERS IN THE ZIRCONIUM MARKET ARE:

PRESENT MANUFACTURERS OF ZIRCONIUM CARBONATE

MANUFACTURING PROCESS OF ZIRCONIUM CARBONATE

METHOD OF PREPARING HIGH PURITY BASIC ZIRCONIUM CARBONATE

THE FOLLOWING ILLUSTRATION SHOWS THE PRESENT PROCESS:

ILLUSTRATION 1

ILLUSTRATION 2

ILLUSTRATION 3

MATERIAL SAFETY DATA SHEET ZIRCONIUM CARBONATE

CHEMICAL FORMULA:

PHYSICAL AND CHEMICAL PROPERTIES

PROPERTIES OF MATERIALS THAT MAY INITIATE OR CONTRIBUTE TO FIRE 

INTENSITY

NON-FLAMMABLES THAT COULD CONTRIBUTE UNUSUAL HAZARDS TO A FIRE

ADDRESSES OF PLANT & MACHINERY SUPPLIERS

APPENDIX – A:

01. PLANT ECONOMICS

02. LAND & BUILDING

03. PLANT AND MACHINERY

04. OTHER FIXED ASSESTS

05. FIXED CAPITAL

06. RAW MATERIAL

07. SALARY AND WAGES

08. UTILITIES AND OVERHEADS

09. TOTAL WORKING CAPITAL

10. TOTAL CAPITAL INVESTMENT

11. COST OF PRODUCTION

12. TURN OVER/ANNUM

13. BREAK EVEN POINT

14. RESOURCES FOR FINANCE

15. INSTALMENT PAYABLE IN 5 YEARS

16. DEPRECIATION CHART FOR 5 YEARS

17. PROFIT ANALYSIS FOR 5 YEARS

18. PROJECTED BALANCE SHEET FOR (5 YEARS)