Zirconium Silicate Micro Milling Media

Zircosil is the registered name of Jyoti Ceramic Industries Pvt. Ltd. for their proprietary formulated Zirconium Silicate composite, specially developed for upper medium density (4.4 g/cm3) ceramic micro milling beads used for wet milling/dispersion of formulation

Looking at the market needs for medium density, long-lasting, cost-effective ceramic milling beads, we started an extensive research to develop suitable ceramic milling beads to the specific segment of customers who have bead mills but not suitable to carry the load of Zirconox high density (6.2 g/cm3) beads. We finally developed Zircosil ceramic micro milling beads

Generally, for dispersion or particle size reduction of substances, ceramic-glass beads are used world over in bead mills, pearl mills or in agitating attritor mills

img

Zircosil beads can conveniently replace glass and most of ceramic beads due to it's superior features and cost economics. Zircosil beads are most ideally suited for dispersion and micro fine milling of low and medium viscous. Agro chemicals : Fungicides, Herbicides pesticides. Dyestuff : Textile dyes, Textile Inks. Cosmetics. Food Stuff. Inks : Printing inks, Inkjet - Magnetic inks, Tattoo inks. Minerals : Calcium Carbonate, Talc. Oxides : Titanium Dioxide. Paints & Varnishes : Auto & allied paints, Decorative & Marine paints. Pharmaceuticals.

Zircosil beads are also used for shot peening treatment on metal surfaces, metal polishing, contact eye lenses polishing and a host of many other applications.

PHYSICAL PROPERTIES
Colour Light Grey
Surface Finish Glossy, Satin Smooth
Density 4.4 ±0.05 g/cm3
Bulk Density 2.70 ±0.05 kg/ltr
Porosity Nil
Water absorption Nil
Hardness on Moh’s scale 9
Hardness on Vicker’s scale (Hv5) 1100-1150
Crushing strength (Ø 1.5mm bead) 72.5 kgf
Bead Sphericity 90% ≥ 0.95
% Cumulative Weight loss / HR. (wear test conducted with water)
After 24 hrs. 0.0063
After 96 hrs. 0.00582
CHEMICAL PROPERTIES
ZrO2 60%
SiO2 30%
Others 10%

Versatile Industrial Applications

Benefits Of Using Zircosil

Zircosil beads, are of upper medium density (4.4 g/cm3) tough and sapphire hard (9 Moh’s scale), ideally suited for speedy dispersion / milling of hard and soft substances in high-low speed, horizontal and vertical type bead mills, sand mills, atrritor, turbo and pearl mills.

  • Zircosil beads being of low co-efficient of friction, having glossy satin smooth surface and are most gentle to expensive mill parts.
  • Zircosil beads are free from pin holes or cracks, bead fused with other bead resulting in reduced downtime, and greater process safety. During change of formulation process cleaning and washing of beads is faster & less cumbersome.
  • Zircosil micro beads have dense homogeneous internal microstructure, due to this property beads maintain satin smooth surface finish and do not crack or shatter easily. As the hours of milling progress, the wear rate of Zircosil micro bead reduces further and the surface finish of beads appears more glossy.

Zircosil ceramic beads are

Non-contaminative Non-toxic Non-radioactive
Non-magnetic Chemically inert Resistant to all acids and alkalis except hydrofluoric acid.

Certificate

Fraunhofer Institute, Freising, Germany has approved Zircosil ceramic micro milling beads for milling of food in accordance with the regulations of the European Community.

Guidelines for Using Zircosil Micro milling Beads

  • To avoid fracture, shearing of beads or flattened plate shape beads, ensure that the gap between the mill chamber walls and the bottom of mill vessel to the agitating stator arm must be maintained minimum 3 to 5 times larger than the largest bead size.
  • To avoid passage of beads in the slurry, ensure that the size of strainer aperture is min. 2 times smaller than the average size of beads.
  • Before charging the mill with Zircosil beads, it is strongly recommended to thoroughly check inner condition of the mill chamber. It should be free from any cavities or worn out parts. Capacity and volume of the bead mill chamber to assess the right quantity of Zircosil beads required for the mill (i.e. 60 to 85% volume of mill X packing density of Zircosil beads = Quantity).

Zircosil Beads Are Available In Following Fraction Sizes

Broad Fraction Size
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
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 1.6 - 2.0 mm Ø 2.0 - 2.4 mm

Chemical Resistance Data Of Zircosil Micro Beads At 25°C Test Time 24hrs

Chemical Medium Concentration % Weight Loss per hour
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% 0.12
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 Zircosil beads maintain their integrit

Zircosil Beads Bulk
Density

Dia (mm) kg/ltr
Ø 0.40 - 0.70 mm 2.70 ± 0.05 kg/ltr
Ø 0.70 - 1.20 mm 2.70 ± 0.05 kg/ltr
Ø 1.20 - 1.70 mm 2.70 ± 0.05 kg/ltr
Ø 1.70 - 2.40 mm 2.75 ± 0.05 kg/ltr
Ø 2.40 - 2.80 mm 2.75 ± 0.05 kg/ltr
Ø 2.80 - 3.30 mm 2.75 ± 0.05 kg/ltr

Zircosil Bead Charge Weight Suggested For Different Capacity Mills

Considering beads 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.

Volume of Gridning Chamber (ltr) Qty. of ZIRCOSIL Micro Beads (kgs)
Closed Horizontal Mill Closed Vertical Mill Open Vertical Mill
8.0 16-18 15-17 13-15
15.0 30-34 28-32 24-28
30.0 61-69 57-65 49-57
45.0 85-91 85-97 73-85
60.0 121-138 113-130 97-113
115.0 233-264 217-248 186-217
225.0 456-516 425-486 365-425

Details Of Bead Mill Used For Conducting The Wear Test

Mill Type Horizontal Lab Bead Mill
Model LME - 1
Mill Capacity 0.61 Ltr
Ceramic Media (Qty.) 1.65 kg.
Make NETZSCH, Germany
Mill Container Polyurethane
Mill Agitator Speed 3000 RPM
Media (Milled with) Water

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.

formula

P = Percentage Weight Loss
W1 = Initial Weight of Beads
W2 = Final Weight of Beads

The weight loss of Zircosil micro beads was found insignificant as well as caused lowest wear on mill contact parts. The percentage cumulative weight loss of Zircosil beads was observed to be 0.0063% per hour in the 24 hour test. The percentage cumulative weight loss came down to 0.00582% per hour in the 96 hour test.

High Speed Bead Mill for Wear Test

Comparative Typical Property And Wear Rate Chart

Characteristics Units ZIRCONIUM SILICATE BEADS GLASS BEADS
JYOTI (INDIA) FRANCE CHINA ISRAEL GERMANY
Colour Shade - Light Grey Off White White White Off White Transparent
Density g/cm3 ≥ 4.4 3.84 3.75 4.08 4.13 2.25
Bulk Density kg/ltr 2.70±0.05 2.44 2.38 2.47 2.46 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 9.00 7.50 7.50 8.50 8.0 5.5
Hardness on Vicker’s Scale Hv5 1100-1150 690 650 962 1080 500-550
Avg. Bead size taken for crushing strength mm Ø 1.50 Ø 1.49 Ø 1.51 Ø 1.50 Ø 1.40 Ø 1.66
Crushing Load Kgf 72.50 47.30 51.00 70.22 58.21 45.00
Sphericity for 90% of the beads - ≥ 0.95 > 0.9 > 0.9 > 0.9 > 0.9 > 0.95
% Cumulative Weight Loss Per Hour of Wear Test (Wear Test conducted with Water) After 24 Hrs. 0.0063 0.0255 0.032 0.0191 0.0206 0.2724
After 96 Hrs. 0.00582 0.041 0.056 0.034 0.0128 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 & broken beads observed Glossy Satin smooth surface with Pin holes & bead fused with other bead observed Dull surface finish beads with Pin holes observed -- Dull surface finish observed

Graphical Representation Of Wear Test Results

Media Type % Cumulative Weight
Loss / Hr
After 24 Hrs. After 96 Hrs.
Zirconium Silicate Zircosil Beads (Jyoti) 0.00630.00582
Zirconium SilicateBeads (France) 0.0255 0.041
Zirconium Silicate Beads (China) 0.032 0.056
Zirconium Silicate Beads (Israel) 0.0191 0.034
Zirconium Silicate Beads (Germany) 0.02059 0.0128
Glass Beads (China) 0.2724 0.2982

Download PDF

Zircosil Brochure
images
Download Now