Magnesium Oxide Aggregate Purity via Chemical Precipitation
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Solution Overview
Problem
Current methods for producing high-purity magnesium oxide aggregates face challenges in achieving purity levels above 99.99% due to impurity contamination, particularly during the grinding and sintering processes, which affects their dispersibility and fluidity, and require complex and costly production facilities.
Innovation Solution
A method involving the synthesis of high-purity magnesium hydroxide using specific impurity-controlled magnesium chloride, followed by hydrothermal treatment, filtration, washing, drying, and subsequent spray drying of the magnesium oxide particles to form a redispersible aggregate with controlled pore distribution and spherical shape, achieving a purity of 99.99% or higher.
Engineering Contradictions & Design Principles
Engineering Contradiction Analysis
1Manufacturing precision
If conventional grinding and sintering processes are used to produce magnesium oxide aggregates, then production cost and facility complexity are reduced, but purity cannot exceed 99.99% due to impurity contamination
Solution Approach 1:
The patent replaces conventional mechanical grinding processes with a chemical precipitation method using magnesium chloride solution and alkaline solution. This substitution eliminates mechanical contamination from grinding mills while achieving superior purity levels (exceeding 99.99%) through controlled chemical reactions and filtration processes.
Solution Approach 2:
The patent employs a controlled chemical environment using high-purity magnesium chloride solution and regulated alkaline solutions to prevent impurity contamination. By controlling the chemical reaction conditions and using purified reagents, the process maintains an inert environment that prevents external contamination during magnesium oxide formation.
2Reliability
If conventional grinding processes are used, then facility complexity is reduced, but dispersibility and fluidity deteriorate due to impurity contamination
Solution Approach 1:
The patent replaces mechanical grinding with chemical precipitation and controlled aggregation processes. This substitution produces magnesium oxide particles with superior surface properties and controlled morphology, resulting in enhanced dispersibility and fluidity without the contamination that would degrade these properties.
Solution Approach 2:
The patent controls particle size distribution, surface area, and morphology by adjusting chemical reaction parameters such as solution concentration, temperature, pH, and addition rate. These parameter changes produce particles with optimized characteristics for dispersibility and fluidity while maintaining high purity.
3Manufacturing precision
If high-purity magnesium oxide is produced through multiple purification steps, then purity is improved, but productivity decreases due to complex processing
Solution Approach 1:
The patent performs preliminary purification by selecting high-purity magnesium chloride as the starting material and controlling the precipitation process to form pure magnesium hydroxide intermediate. This preliminary action prevents impurity formation rather than requiring extensive downstream purification, thereby maintaining high productivity.
Solution Approach 2:
The patent optimizes reaction parameters including temperature, pH, solution concentration, and addition rate to achieve rapid and complete precipitation of pure magnesium hydroxide. By controlling these parameters, the process achieves both high purity and fast reaction kinetics, eliminating the need for multiple slow purification steps.
4Ease of operation
If magnesium oxide particles are produced without aggregation, then purity is maintained, but fluidity and handling properties deteriorate
Solution Approach 1:
The patent creates controlled aggregates composed of multiple fine particles clustered together in a hierarchical structure. This segmentation approach maintains the high purity of individual particles while forming larger aggregate units that exhibit improved fluidity and handling properties, effectively combining the advantages of both fine and coarse particles.
Solution Approach 2:
The patent produces composite magnesium oxide aggregates with controlled internal structure and pore distribution. These composite structures combine pure magnesium oxide particles with specific morphology and arrangement, creating material that simultaneously achieves high purity, excellent fluidity, and desirable handling characteristics.
Applied Scientific Principles
This section explains which scientific principles are used to turn an abstract innovation direction into a practical engineering solution.
Function Achieved in This Case
The method enables the production of high-purity magnesium oxide aggregates with improved dispersibility and fluidity, maintaining high purity and preventing impurity contamination, suitable for various applications including electronic materials and plasma display panels.
Implementation Method 1
adding an alkali to the crude solution to cause precipitation of impurities contained in the crude raw material
Implementation Method 2
subjecting the alkali-containing solution to hydrothermal treatment at a temperature of 120° C. or higher to form a magnesium compound
Implementation Method 3
subjecting the dehydrated product to heating at a temperature of 1,000° C. or higher
Implementation Method 4
subjecting a slurry having dispersed therein the high-purity magnesium oxide particles to spray drying
Data Source
AI summary
The object is to provide a high-purity magnesium oxide particle aggregate that is redispersible and can be supplied with keeping high purity, and a method for producing the same.A magnesium oxide particle aggregate that is an aggregate of magnesium oxide particles, wherein the magnesium oxide particles have an average particle size of 1 μm or less, and comprises Si, Al, Ca, Fe, V, Cr, Mn, Ni, Zr, B and Zn as impurities in their respective amounts of 10 ppm by mass or less, wherein the total amount of the impurities is 100 ppm by mass or less.