Orthophosphoric Acid & Alumina Reactions
Orthophosphoric Acid & Alumina Reactions
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products, available in the brick and specialties forms, have unusual tures, yielding crystalline AIP04. Alum-
qualities—such as high abrasion resistance, high load-bearing derived a-AI203 powders reacted slowly,
capability, and dimensional stability—that make them preferred yielding amorphous products.
materials for a number of applications. 8-10
preparation and separation, it is difficult to identify the different One problem that has been the subject of study is the premature
phases. hardening of phosphate-bonded high alumina refractory compo
Sheets et al. concluded that phosphate-bonding in high alumina
3
sitions. Lyons et al. suggest that premature hardening occurs as a
22
refractories occurs because of covalent polymerization of aluminum result of room-temperature reaction between the Al(OH) layers of 3
phosphates, which proceeds in several stages upon heating. clay minerals and H P0 to form, initially, A1(H P0 ) and, finally,
3 4 2 4 3
due to the formation of variscite (A1P0 -2H 0), whereas setting 4 2 Hall have suggested that the following reactions are responsible
24
during heating is due to the formation of an amorphous product. for the early setting of high alumina mixes:
This theory is in agreement with solubility studies in the system
AI2 O3 -P2 O5 -H2 O under the condition of excess alumina. 15-17
heating yields aluminum metaphosphate, A1(P03)3. Kopeikin et premature setting according to the following scheme:
al. and Yutina et al. maintain that the ability of mixes containing
18 19
to the formation of an amorphous phosphate. He also asserts that the presence of chemically active ions such as
Many investigators have suggested that phosphoric acid-
1 4 1 8- 1 9
Fe3+, Al3+, Ca2+, Mg2+, and β-Α1 0 play an important role in
2 3
alumina reactions lead to the formation of phases similar to those premature setting.
produced by the phosphoric acid-aluminum hydroxide reactions. Recent review papers by Cassidy and Chvatal point out that in
26 27
The usual procedure has been to assume that whatever changes real refractory systems an excess of some reactive phase such as
occur in certain aluminophosphate binders or binders with small alumina, silica, zirconia, etc., is always present. Thus bonding
additions of aluminum hydroxide will also occur in the orthophos-
14
occurs in two ways: by chemical bonding to the aggregate and by the
formation of acidic or condensed phosphates, which at certain
temperatures may decompose into polymeric phosphates which are
*Member, the American Ceramic Society. mostly amorphous. The work of O’Hara et al. shows this feature
28
Experimental
Approximately 250 g of alumina-orthophosphoric acid mixes
corresponding to the bulk compositions shown in Table I were
prepared by thoroughly mixing reagent grade orthophosphoric
acid* (85% H P04) and one of several Bayer-process calcined
3
starting materials on the reaction of orthosphoric acid with alumina tripolyphosphate A 1Η Ρ Ο ·2Η Ο, and the B-type of A1(P03)3. At
2 3 10 2
tected.
The reaction of orthophosphoric acid
with alumina, like other reactions involving
solid particles, occurs at the alumina sur
face. Thus the kinetics of the reaction is
affected by the total surface area
the irregular particles just as well as the adsorbate used in the B-A1PO after reaction for 10 days at 150°C are shown in Fig. 1(B).
4
measurement of the surface area. As can be seen, the relative yield of the acid phosphate, A1(H P04)3,
2
Figure 1 (A) shows the effect of the specific surface area of the is higher in mixes prepared with aluminas of low surface area and
Bayer-process aluminas on the fraction of alumina reacted after 10 low A1 0 :P 0 ratio. On the other hand, higher yields of aluminum
2 3 2 5
days at 150°C. As expected, the quantity of alumina reacted in orthophosphate, B-A1P04, are observed in high surface area mixes
creases with increasing surface area and increasing A1 0 :P 0 2 3 2 5 or where the A1 0 :P 0 ratio is high.
2 3 2 5
molar ratio R. The effects of the specific surface area of the alumina Figure 2 shows the combined effects of the specific surface area
Under dry conditions (such as when temperatures are above 100°C), with AA-2 yield large amounts of C-A1P04. The reaction appears
anhydrous A1P0 is likely to form.
4
to follow a different path because of the high reactivity of metastable
The effect of temperature on isolated aluminum phosphates γ-Α1 03, which is present in large proportions in AA-2 and absent
2
not reversible upon cooling, and the TG plot (Fig. 5) does not
indicate major change within that region. The DTA curve obtained
from a mechanical mixture of A1 0 and A1(P0 ) in a 1:1 molar 2 3 3 3
ness and Hot-face Temperatures in EAF Sidewalls,” Proc. Electr. Furn. Conf., 31,
activity, it is expected that the ribbon test will be used to further the 214-18 (1973).
basic understanding of thermal shock mechanisms for a wide range 5J. H. Ainsworth and R. H. Herron, “High Temperature Fracture Energy of
Institute (TRI), Pittsburgh, Pa., for their ongoing support of this lia, ASR 31, Method 24; U.S., Bethlehem Steel procedure (modified). U
Diagram for the System Α120.}-Ρ20-,-Η20 at 60°," Bull. Soc. Chim. Fr., 1960, pp.
from Bayer aluminas. This difference is believed to be due to the 851-56.
differences in crystallinity, particle size, impurity levels, and possi 18 V. A. Kopeikin, A. I. Kudryashova, L. N. Kuz’minskaya, I. L. Rashkovan, and I.
bly to milling. V. Tananaev, “Formation of the Amorphous Phase during Cementation of Materials
with Aluminophosphate Binder,"Izv. Akad. NaukSSSR, Neorg. Mater., 3[4] 737-39
5) Compositions containing large quantities of γ-Α1 0 are very 2 3 (1967).
19A. S. Yutina, Z. D. Zhukova, and S. V. Lysak, “Reaction of Phosphoric Acid
reactive and yield crystalline C-A1P04. Compositions made with
with Some Forms of Alumina,” ibid., 2 [11] 2020-28 (1966).
the less reactive high purity α:-Α1 0 yield amorphous products if
2 3 20A. Boulle and F. B. D’Yvoire, “Thermal Evolution of Aluminum Phosphates of
the alumina is present in large quantities. the Group P20.-,/Al203 = 3,” Compt. Rend., 245, 531-34 (1957).
21R. N. Rickies, “The Effect of Heat on Inorganic Cements,” J. Appl. Chem.
F. J. Gonzalez wishes to thank Resco Products, Inc., for their Stabilization: II,” Natl. Acad. Sci.—Natl. Res. Council, Publ. No. 964, 5-24(1962).
23 J. E. Lyon, T. U. Fox, and J. W. Lyons, “An Inhibited Phosphoric Acid for Use in
financial support in the form of a fellowship. High-Alumina Refractories,” Am. Ceram. Soc. Bull., 45 [7] 661-65 (1966).
24E. Eti and W. B. Hall, “Control of Premature Hardening in Phosphate-Bonded
References High-Alumina Refracoty Compositions,” ibid., 50 [7] 604-606 (1971).
1 W. D. Kingery, “Fundamental Study of Phosphate Bonding in Refractories: I,"J. 251. D. Prendergast, “Premature Set of Phosphate-Bonded Refractory Mixes,”
Am. Ceram. Soc., 33 [8] 239-41 (1950). presented at the Fall Meeting of the Refractories Division of the American Ceramic
2S. L. Golynko-Vol’fson and L. G. Sudakas, “Some Principles of the Appearance of Society and NICE, Bedford, Pa., October 9, 1976; for abstract see ibid., 55 [8] 740
Binding Properties in Phosphate Systems, "J. Appl. Chem. USSR (Engl. Transl.), 38 (1976).
26 J. E. Cassidy, “A Review of Phosphate-Bonded Refractories,” in High Tempera
[7] 1441-45 (1965).
3H. D. Sheets, J. J. Bulloff, and W. H. Duckworth, “Phosphate Bonding of ture Chemistry of Inorganic and Ceramic Materials, ” Spec. Publ. No. 30. Edited by F.
Refractory Compositions,” Refract. J., 34 [9] 402-406 (1958). P. Glasser and P. E. Potter. Chemical Society, London, 1976.
4K. Fisher, “Chemical Bonds for Refractory Materials,” Proc. Br. Ceram. Soc., 27T. Chvatal, “The Position of Refractory Phosphate Bonding Today,"Sprechsaal
12, 51-64 (1969). Keram., Glas, Baustoffe, 108 [19-20] 576, 578, 580, 582-89 (1975).
50. W. Florke, “The Structure of A1P0 28M. J. O'Hara, J. J. Duga, and H. D. Sheets, Jr., “Studies in Phosphate Bonding,”
4 and Si02”; pp. 13-27 in Science of
Ceramics, Vol. 3. Edited by G. H. Stewart, Academic Press, New York, 1967. Am. Ceram. Soc. Bull., 51 [7] 590-95 (1972).
6F. A. Hummel, “Properties of Some Substances Isostructural with Silica, "J. Am. 29G. D. Salmanov andG. N. Aleksandrova, “Highly Refractory Concrete Based on
Ceram. Soc., 32 [10] 320-26 (1949). an Aluminophosphate Binder,” Izv. Akad. NaukSSSR, Neorg. Mater., 5 [1] 148-51
7W. R. Beck, “Crystallographic Inversions of the Aluminum Orthophosphate (1969).
30A. A. Chistayakova, V. A. Sivkina, V. I. Sadkov, and A. P. Khashkovskaya,
Polymorphs and Their Relation to Those of Silica,” ibid., [4] 147-51.
8W. H. Gitzen, L. D. Hart, and G. MacZura, “Phosphate-Bonded Alumina Casta “Effect of Corundum on the Phase Composition of Products of Heating in the Al20;r
bles: Some Properties and Applications,” Am. Ceram. Soc. Bull., 35 [6] 217-23 P20.-,-H20 System,” ibid., [10] 1738-41.
31F. J. Gonzalez, “Phosphate Bonding in High-Alumina Refractories”; Ph.D.
(1956).
9R. E. Fisher, “Hot Strength of Phosphate-Bonded Refractory Plastics,” ibid., 56 Thesis, Pennsylvania State University, University Park, 1980.
32M. Tsuhako, T. Matsuo, I. Motooka, and M. Kobayashi, “Formation of
[7] 637-39 (1977).
I0K. A. Baab and J. M. Blackwood, “Volume Stability of Phosphate-Bonded Aluminum Phosphates at Low Temperatures, "Chem. Lett., 1978, No. 7, pp. 777-80.
33J. R. Lehr, A. W. Frazier, and J. P. Smith, “Precipitated Impurities in Wet-
High-Alumina Brick,” ibid., 50 [7] 607-10 (1971).
'' F. d’Yvoire, “Aluminum andTrivalent Iron Phosphates: I, "Bull. Soc. Chim. hr., Process Phosphoric Acid," J. Agric. Food Chem., 14 [1] 27-33 (1966).
34National Bureau of Standards Mono. 24, Sec. 2, 1960.
1961, pp. 1762-76; “II,” ibid., pp. 2277-82; “III,” ibid., pp. 2283-90; “IV,”
35O. W. Florke, “Crystallization and Polymorphs of A1P0
ibid., 1962, pp. 1224-36; “V,” ibid., pp. 1237-43; “VI,” ibid., pp. 1243-46. 4 and AlP04-Si02 Mixed
12P. H. Hsu, “Interaction Between Aluminum and Phosphate in Aqueous Solu Crystals,” Z. Kristallogr., 125, 134-46 (1967).
36D. Lewis and M. W. Lindley, “Enhanced Activity and the Characterization of
tion, ” Advan. Chem. Ser., 1968, No. 73, 115-27.
,3M. Tsuhako, K. Hasegawa, T. Matsuo, I. Motooka, andM. Kobayashi, “Studies Ball-Milled Alumina," J. Am. Ceram. Soc., 49 [1] 49-50 (1966). H