Experimental synthesis of granulated zirconia powders by spray dryer

• We examine change in zeta potential with pH.
• Increase in binder ratio increases granulation %.
• Increase in binder ratio increases granule size.
• Monoclinic zirconia is partially stabilised with 9 mol% MgO.
• The source of MgO as a stabilising agent is dead burnt magnesia.

In this paper, the effect of processing factors on granulation of monoclinic zirconia powders by spray drying was investigated. Grain size and morphology of the raw materials were characterized with laser particle sizer and scanning electron microscope. The preparation conditions of suspension before spray drying were investigated by measuring zeta potential. As a result binder ratio and pump rate (of spray dryer) were found affecting the structure and flow properties of granules. Granulation and the size of granules increased with increasing binder ratio and pump rate. The flow properties and compressibility of resulting powder in granule form were identified by Carr’s index, Hausner Ratio, Angle of Repose. Morphology of granules were characterised by SEM. Good flow properties were achieved when the pump rate was 50% and binder ratio was 5% (by weight).