US 12,031,089 B2
Ceramic foundry media and related methods
Steven C. Howe, Richmond, TX (US); Chad Cannan, Lancaster, NY (US); and Todd Roper, Katy, TX (US)
Assigned to CARBO CERAMICS INC., Houston, TX (US)
Filed by CARBO CERAMICS INC., Houston, TX (US)
Filed on May 25, 2021, as Appl. No. 17/329,292.
Application 17/329,292 is a continuation of application No. 16/005,006, filed on Jun. 11, 2018, granted, now 11,015,112.
Application 16/005,006 is a continuation of application No. 14/813,452, filed on Jul. 30, 2015, granted, now 9,994,764, issued on Jun. 12, 2018.
Claims priority of provisional application 62/031,564, filed on Jul. 31, 2014.
Prior Publication US 2021/0284900 A1, Sep. 16, 2021
Int. Cl. C09K 8/80 (2006.01); C09K 8/524 (2006.01); C09K 8/528 (2006.01)
CPC C09K 8/80 (2013.01) [C09K 8/524 (2013.01); C09K 8/528 (2013.01); C09K 2208/10 (2013.01); C09K 2208/12 (2013.01); C09K 2208/20 (2013.01); C09K 2208/22 (2013.01); C09K 2208/32 (2013.01)] 20 Claims
OG exemplary drawing
 
1. A method, comprising:
providing a slurry of ceramic raw material, the slurry comprising a polysaccharide, a dispersant, and a pH-adjusting agent, wherein the slurry has a solids content from about 25 wt % to about 75 wt %; wherein the slurry has a viscosity of less than 150 cP and a pH of about 9 to about 10.5;
flowing the slurry through a nozzle while vibrating the slurry to form droplets in a surrounding gas to form droplets having a substantially spherical shape, wherein the slurry of ceramic raw material flows through the nozzle at a rate of about 1 to about 15 kg/(mm2×hr);
gelling the droplets upon contact with a liquid to provide gelled droplets, wherein the liquid comprises a coagulation agent;
transferring the gelled droplets from the liquid;
drying the gelled droplets to form green pellets;
sintering the green pellets in a selected temperature range to form sintered pellets;
introducing the sintered pellets to a mixing vessel, the mixing vessel comprising a chemical treatment agent solution; and
introducing microwave energy to the mixing vessel comprising the sintered pellets and the chemical treatment agent solution.