Method for manufacture of sintered alumina from ammonium aluminum carbonate hydroxide

Claim 1

A method for the manufacture at low temperatures, of a compactly sintered high-purity alumina having a bulk density greater than 3.8 g/cc, which comprises: adding to a solution of ammonium hydrogen carbonate having a concentration of from 40 g/1. to 270 g/1. a solution of at least one aluminum salt selected from the group consisting of aluminum chloride, aluminum nitrate, aluminum sulfate, ammonium aluminum sulfate and basic salts thereof having a concentration of from 5 g/1. to 150g/1. computed as aluminum oxide, the amount added being not less than 0.07 and not more than 0.75 of the equivalent weight computed as A1/NH 4 , the rate of addition of said solution being from 0.03 1./hr. to 1.8 1/hr. per 1000 cc of said solution of ammonium hydrogen carbonate and the resulting addition reaction being conducted at a temperature of from 30° to 35° C. and a pH of from 7.5 to 9.0, allowing the resultant solution to stand to permit growth of crystals of ammonium aluminum carbonate hydroxide, filtering said solution containing grown crystals of ammonium aluminum carbonate hydroxide to obtain crystals of ammonium aluminum carbonate hydroxide, drying the crystals, subjecting the dried crystals of ammonium aluminum carbonate hydroxide to thermal decomposition at temperatures in the range of from 1,250° to 1,300° C. to afford α-alumina capable of being readily sintered, adding to said α-alumina an organic binder, molding the resultant mixture under pressure and sintering the molded mixture at temperatures in the range of from 1600° to 1700° C. to obtain a compactly sintered high-purity alumina having a bulk density greater than 3.8 g/cc.

Claim 2

A method for the manufacture at low temperatures, of a compactly sintered high-purity alumina having a bulk density greater than 3.8 g/cc, which comprises: adding to a solution of ammonium hydrogen carbonate having a concentration of from 40 g/1. to 270 g/1. a solution of at least one aluminum salt selected from the group consisting of aluminum chloride, aluminum nitrate, aluminum sulfate, ammonium aluminum sulfate and basic salts thereof having a concentration of from 5 g/1. to 150g/1. computed as aluminum oxide, the amount added being not less than 0.07 and not more than 0.75 of the equivalent weight computed as A1/NH 4 , the rate of addition of said solution being from 0.03 1./hr. to 1.8 1/hr. per 1000 cc of said solution of ammonium hydrogen carbonate and the resulting addition reaction being conducted at a temperature of from 30° to 35° C. and a pH of from 7.5 to 9.0, allowing the resultant solution to stand to permit growth of crystals of ammonium aluminum carbonate hydroxide, filtering said solution containing grown crystals of ammonium aluminum carbonate hydroxide to obtain crystals of ammonium aluminum carbonate hydroxide, drying the crystals, subjecting the dried crystals of ammonium aluminum carbonate hydroxide to thermal decomposition at temperatures in the range of from 1,250° to 1,300° C. to afford α-alumina capable of being readily sintered, adding to said α-alumina an organic binder, molding the resultant mixture under pressure and sintering the molded mixture at temperatures in the range of from 1600° to 1700° C. to obtain a compactly sintered high-purity alumina having a bulk density greater than 3.8 g/cc.