Inflight dissociation of zircon in air plasma

Thermal dissociation of zircon can be conveniently carried out in a plasma reactor, which is characterized by high temperature, high energy density and high quench rate. Zirconia is recovered from this partially dissociated zircon by alkali leaching. Dissociation of zircon has been conventionally carried out in argon gas, which is expensive. The present paper reports experimental results on thermal dissociation of zircon in air plasma medium. Process simulation for 'inflight' dissociation of zircon in air plasma medium is also presented. The experimental system consists of a central hollow graphite electrode, which acts as the cathode and a graphite anode. The material to be processed is fed centrally through the cathode. The unique feature of the system is that it uses air as the working gas to generate the thermal plasma. The system has been used to study in-flight dissociation of zircon in the thermal plasma jet. Dissociation was carried out over 10-25 kW power range. Results of the study indicate that complete dissociation of zircon to ZrO2 and silica could be accomplished at 25 kW in air plasma.