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Development background of catalyst alloy powder Since the advent of synthetic diamond, the super-hard material industry has developed rapidly, which not only has driven the rapid development of related industries, but also changed people's lives. As a kind of super-hard material, synthetic diamond has high hardness and good wear resistance. It can be widely used in geology, coal field, petroleum, engineering and other drilling, cutting and processing of hard and brittle metal and non-metal materials. Grinding processing, because of its high thermal conductivity and good electrical insulation, can be used as a heat sink for semiconductor devices. It has excellent light transmission and corrosion resistance and is widely used in the electronics industry.
China has been ranked first in the world as a major producer of synthetic diamonds, and its diamond production accounts for more than 70% of world production. Due to the gradual improvement of the quality and stability of China's synthetic diamonds, the continuous reduction of costs, and the continuous expansion of the diamond products market at home and abroad, it has effectively promoted the vigorous development of the artificial diamond market. According to statistics, the annual output of synthetic diamond in China was about 2.53 billion carats (about 506 tons) in 2003, an increase of 26.5% over the 2002 output. In 2006, the annual output of synthetic diamond in China reached more than 5 billion carats (1000 tons). 2 Before the 1st century, the raw materials for the industrial production of synthetic diamond in China were mainly sheet-like catalyst alloy and flake graphite (sheet process). In the 21st century, the powder synthesis technology gradually replaced the sheet technology.
The water atomization process for the production of catalyst alloy powder project was funded by the United Nations Development Agency in 1988 (The Research and Development Project for New Technologies of Diamond Tools (CPR/85/052), and the Institute of Artificial Crystals 1996). Under the original National Building Materials Bureau (based on the research and development of scientific research projects for the production of new diamond tool binders by water atomization method, further research and development of derivative projects based on market conditions. May 2000, (Water atomization method to manufacture new types) The research and development project for diamond tool binders passed the ministerial appraisal.
In recent years, the synthetic diamond market at home and abroad has been expanding, and the use of catalytic alloy powder materials to synthesize synthetic diamond is the development direction of the diamond industry. Catalytic alloy powder materials are commonly used as catalysts to synthesize synthetic diamond. Before the 2002 diamond industry, the domestic diamond industry mainly used sheet-like catalyst alloys. The annual dosage was about 3000t. The synthetic method of synthetic diamond produced by powder method can greatly improve the yield and quality of the same volume of diamond. The material consumption is greatly reduced. The amount of catalyst alloy powder is only about 1200t. Since 2003, the synthesis of synthetic diamonds with catalyst alloy powder materials has been recognized by many domestic manufacturers. The catalyst alloy powder materials for the synthesis of high-grade synthetic diamonds have been widely applied in batches, and the demand for catalyst alloy powder materials is increasing rapidly. By the end of 2003, there were a total of 5,941 six-faceted tops and more than 100 sets of double-faced synthetic diamond equipment in China, which consumed more than 4,524 tons of catalyst. If 70% of the amount of powder catalyst was used, the amount of powdered catalyst instead of sheet-like catalyst was reduced to 1/ 3, and the development of the diamond industry, the annual demand for catalyst powder materials in the country can reach more than 1200t, and the product market prospect is very broad.
At the beginning of the development of powder catalyst synthesis technology (in the late 1990s), imported catalyst alloy powder was mainly used, the price was about 18,000 yuan per ton, the material cost was high, and the level of powder synthesis technology was still low. less. The application of domestic aerosolized catalyst alloy powder has not fundamentally solved the problem. After nearly ten years of technical research, the Institute of Artificial Crystals has greatly reduced the manufacturing cost of catalyst alloy powder and the process cost of popularization and application, from the manufacturing technology of catalytic alloy powder to the fundamental breakthrough of application technology, and promoted the synthesis of powder method in China. The rapid development of synthetic diamond technology.
Production Process of Catalyst Alloy Powder The catalyst alloy powder is a catalyst for synthesizing diamond and is the main raw material for the production of synthetic diamond. The alloy powder is mainly produced by atomization method, and there are two types of water atomization and gas atomization. We use water atomization method to manufacture catalyst alloy powder. Main equipment: Medium frequency melting furnace, high pressure water pump, vacuum drying box, screening machine, batch machine, vacuum packaging machine, etc.
Market development and application of catalyst alloy powder Synthetic synthetic diamond powder is made of graphite powder and catalyst alloy powder. The initial column preparation process is as follows: mixing one granulation one by one, one by one, one by one, vacuum Packaging, this process requires that the catalyst powder and graphite powder have low oxygen content and high purity. If the material in the powder column is insufficiently deoxidized, the diamond color is not good, the strength is low, the heat resistance is poor, and the wear resistance is poor.
The catalyst alloy powder product produced by water atomization method has a much lower cost than the aerosolized product, but its oxygen content is about 5 times higher, which is its main weakness. After atomization, it is not treated by post-treatment, water atomization. The oxygen content of the catalyst alloy powder is (2000 ~ 4000) × ppm (0.2 ~ 0.4%), the oxygen content of the aerosolized catalyst alloy powder is (200 ~ 800) ppm, the initial development of China's powder synthesis technology, the use of imports The gas atomized catalyst alloy powder is characterized by low oxygen content (about 100 ppm) after deoxidation reduction and passivation treatment, but the price is high (the unit price is 180 yuan/kg in 2002, and the transportation cost is about 200 yuan/kg). Although the catalyst powder produced by domestic aerosolization is slightly lower (about 150 yuan/kg), its oxygen content is high (about 200 ppm). In order to promote the application of low-cost water atomization catalyst alloy powder (65 yuan / kg), we have revolutionized the column-making process, deoxidation reduction of the powder column, the column cost is slightly increased, but the material cost is greatly reduced, the current column The process is as follows: the mixture is granulated one by one, the column is pressed, the vacuum is reduced, and the vacuum is packaged. The core problem solved by the current column-making process is that after the deoxidation reduction is placed on the pressure column, the water atomization catalyst alloy powder greatly reduces the cost of the powder column.
The initial column-forming process requires high purity of raw materials and low oxygen content, and it is necessary to avoid the moisture absorption of the powder material during the column making process, which is difficult to achieve in the actual production process. The use of the current process fundamentally solves the problem of oxygen content and moisture absorption, the quality and grade of diamond are greatly improved, and the more reasonable cavity structure and synthesis process improvement, the diamond yield is greatly improved. The above technical problems have been solved, and a solid technical foundation has been laid for promoting the application of water atomized catalyst alloy powder.
In recent years, the synthetic diamond market at home and abroad has been expanding. Synthetic synthetic diamond powder materials produced by water atomization have been recognized by domestic manufacturers. The demand for catalyst alloy powder materials is increasing rapidly. Beijing Sinoma Artificial Crystal Co., Ltd. has been put into the market in small batches since 2003. The annual sales volume is 30 tons, the sales income is 21,500 yuan, the sales of 270 tons in 2004, the sales income is 7.5 million yuan, the sales in 2005 is 370 tons, and the sales income is 25.2 million yuan. In 2006, it sold more than 400 tons and the sales income was 32 million yuan.
The demand for catalyst alloy powder materials is growing rapidly, and we will introduce its development and application: