Make Zirconium And Its Products
Zirconium, a remarkable metal known for its exceptional properties, undergoes a detailed and sophisticated process to transform from
raw materials into the diverse range of high-quality products that contribute to various industries.
The process typically begins with the extraction of zirconium-containing minerals, and zircon is a primary source. The sand and gravel that contain zircon are typically collected from coastal waters by a floating dredge, a large steam shovel fitted on
a floating barge. After the shovel has scooped up the gravel and sand, they are purified by means of spiral concentrators, and then unwanted material is removed by magnetic and electrostatic separators.
End-product manufacturers of zircon further refine the nearly pure zircon into zirconium by using chlorine to purify the metal and then sintering(heating) it until it becomes sufficiently workable for industrial use. Less-pure zircon is made into zirconia, an oxide of zirconium, by fusing the zircon with coke, iron borings, and lime until the silica is reduced to silicon that alloys with the iron.
Following the production of zirconium metal, it is further processed into various forms such as bars, sheets, powders, and alloys. Each form undergoes specific manufacturing processes tailored to its intended application.
Zirconium Bar
Melting and Casting: The zirconium metal produced from reduction undergoes a melting process. The molten zirconium is then cast into ingots or molds to form solid bars.
Hot Working: The cast zirconium bars may undergo hot working processes such as extrusion or forging to achieve the desired shape and dimensions.
Heat Treatment: Heat treatment is applied to optimize the microstructure and mechanical properties of the zirconium bars. This step ensures enhanced strength and other desired characteristics.
Surface Finishing: Zirconium bars may undergo surface finishing processes, such as polishing or machining, to meet specific surface requirements.
Zirconium Sheet
Rolling: Zirconium sheets are typically produced through rolling processes. The zirconium metal is passed through rolling mills to reduce thickness and achieve the desired sheet dimensions.
Annealing: Annealing processes may be applied to relieve stress and enhance the material's ductility. This step ensures the zirconium sheets maintain their integrity during further processing.
Cutting and Shearing: The rolled and annealed zirconium sheets are cut and sheared to the required size and shape.
Surface Treatment: Surface treatment methods, such as pickling or passivation, may be employed to enhance the corrosion resistance of zirconium sheets.
Zirconium Powder
Hydriding/Dehydriding Process: Zirconium sponge is subjected to a hydriding process, where it absorbs hydrogen, causing it to become brittle.The hydrided zirconium is then mechanically processed to create fine zirconium powder. Dehydriding follows to remove the absorbed hydrogen.
Sizing and Classification: The zirconium powder is sized and classified to achieve the desired particle size distribution.
Quality Control: Rigorous quality control measures, including testing for particle size and purity, ensure the zirconium powder meets specified standards.
Zirconium Alloys
Alloying Process: Additional alloying elements, such as niobium or tin, are introduced during the melting process. This step forms zirconium alloys with specific properties tailored to the intended application.
Casting or Forming: The molten zirconium alloy is cast into the desired shape or formed through processes like extrusion or forging.
Heat Treatment: Zirconium alloys undergo heat treatment to refine their microstructure and enhance mechanical properties.
Final Inspection: Zirconium alloys undergo a final inspection to ensure they meet stringent quality standards before being prepared for distribution.
