Claims
- 1. Ceramic media comprising:
40-65% by weight SiO2; 10-45% by weight Al2O3; less than 0.25% by weight of alkali metal, expressed as the oxide; less than 31% by weight alkaline earth metals, expressed as the oxide; and wherein the media has a ratio of cordierite: crystalline silica phase of less than 1.2, as determined by X-ray diffraction analysis.
- 2. Ceramic media according to claim 1, wherein ratio of cordierite: silica phases is less than 1.0.
- 3. Ceramic media according to claim 2, wherein ratio of cordierite: silica phases is less than 0.9.
- 4. Ceramic media according to claim 1, wherein the ceramic media has a water absorption value of from 7-15%.
- 5. Ceramic media according to claim 4, wherein the ceramic media has a water absorption value of from 8-10%.
- 6. Ceramic media according to claim 1, wherein the ceramic media has an open porosity of from 10-30%.
- 7. Ceramic media according to claim 6, wherein the ceramic media has an open porosity of from 15-20%.
- 8. Ceramic media according to claim 1, wherein the alkali metal, measured as the oxide, is less than 0.1% by weight.
- 9. Ceramic media according to claim 1, wherein the alkaline earth metal, measured as the oxide, comprises: 0.1-4% by weight CaO; and 0.7-27% by weight MgO.
- 10. Ceramic media according to claim 1, wherein the alkaline earth metal, measured as the oxide, comprises at least 13% by weight MgO.
- 11. Ceramic media according to claim 1, wherein the alkaline earth metal, measured as the oxide, comprises at least 15% by weight MgO.
- 12. Ceramic media according to claim 1, wherein the media comprises less than 40% cordierite phase, as measured by X-ray diffraction.
- 13. Ceramic media according to claim 1, wherein the silica phase comprises at least one of free silica, cristobalite and quartz silica.
- 14. Ceramic media comprising:
40-65% by weight SiO2; 10-45% by weight Al2O3; less than 0.25% by weight of alkali metal, expressed as the oxide; less than 31% by weight alkaline earth metals, expressed as the oxide; and wherein less than about 40% by weight of the media is in the form of cordierite, as measured by X-ray diffraction.
- 15. A process for the production of ceramic media which comprises:
forming a mixture comprising 10 to 98%, by weight of a clay having an alumina content of at least 36% by weight; from 2 to 90% by weight of a talc containing at least 95% by weight of magnesium silicate as determined by X-ray diffraction analysis; and from 0 to 10% by weight of a dolomitic limestone containing 60 to 90% by weight of calcium carbonate and 10% to 40% by weight of magnesium carbonate and less than 10% of non-carbonate impurities, the mixture containing less than 0.25% by weight of alkali metals, measured as the corresponding alkali metal oxides in the product remaining after firing; adding water in an amount sufficient to make a shapeable product; shaping the product to a desired shape; and d) calcining the shaped product at a temperature of from 1100° C. to 1400° C. for sufficient time to form ceramic media having a ratio of cordierite:crystalline silica phase of less than 1.2.
- 16. A process according to claim 15, in which the clay is a ball clay.
- 17. A process according to claim 15, in which the clay component is a powder with particle sizes such that at least 95% by weight are smaller than 10 micrometers.
- 18. A process according to claim 15, in which the talc is in the form of a powder with particles sizes such that at least 95% by weight are 200 mesh or finer.
- 19. A process according to claim 15, in which the dolomitic limestone is a powder with particles sizes in which at least 95% by weight are 325 mesh, or smaller.
- 20. A process according to claim 15, in which the calcining temperature is less than 1300° C.
- 21. A process according to claim 15, in which the calcining temperature is about 1250° C.
- 22. A process according to claim 15, in which the ceramic media has a water absorption value of between 7% and 15%.
- 23. A process according to claim 15, in which the product is shaped into the form of random dumped packing elements.
- 24. A process according to claim 15, in which the product is formed into monolith structures.
- 25. A process according to claim 15, in which the product is formed into bed support structures.
- 26. A process according to claim 15 in which the product is shaped using an extrusion process.
- 27. A process according to claim 15 in which the product is shaped using a pressing process.
- 28. A process according to claim 15, in which the ratio of cordierite crystalline silica phase is less than 0.8.
Parent Case Info
[0001] This application claims the benefit, as a continuation-in-part, of U.S. application Ser. No. 09/849,647, filed May 4, 2001, which is incorporated herein in its entirety, by reference.
Continuation in Parts (1)
|
Number |
Date |
Country |
Parent |
09849647 |
May 2001 |
US |
Child |
10460940 |
Jun 2003 |
US |