PREMIUM ALUMINA FOR CERAMIC APPLICATIONS

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PREMIUM ALUMINAFOR CERAMIC APPLICATIONS

ALUMINA FOR CERAMICSSales OfficeApplication LabPlantAlmatis – The Premium Alumina CompanyRefineryRotterdamWith more than 100 years of alumina expertise,Almatis is the world’s leader in the development, manufacture and supply of premiumalumina and alumina-based products.FrankfurtLudwigshafenBauxiteLeetsdale taAlmatis Burnside, Inc.,Burnside,Louisiana, USAAlmatis, Inc.,Bauxite,Arkansas, USACampinasAlmatis, Inc.,Dalton,Georgia, USAAlmatis, Inc.,Leetsdale,Pennsylvania, USAAlmatis, Inc.,Neville,Pennsylvania, USAAlmatis B.V.,Rotterdam,The NetherlandsAlmatis GmbH,Ludwigshafen,GermanyAlmatis AluminaPrivate Ltd.,Falta, IndiaQingdao AlmatisCo. Ltd.,Qingdao, ChinaAlmatis is both a global and fully integratedproducer, serving our customers from sixteenstrategically located sales, research and manufacturing sites. Our employees strive to exceedcustomers’ expectations through industry leading customer service, technical support andmanufacturing excellence. We implement leading technologies and continuous improvementprograms, which have established Almatisproducts as the benchmark for quality and consistency. Our commitment to strong partnershipswith our customers creates innovative solutionsthat support and enhance their growth in allregions of the world.Almatis offers the most comprehensive aluminaproduct portfolio in the industry. Our broadproduct line includes: Tabular aluminasCalcined and reactive aluminasPolishing aluminasCalcium aluminate cementsAlphabond 300Dispersing aluminasBrown sintered alumina, BSA 96Alumina and magnesia-rich spinelsCalcium hexa-aluminates, Bonite and SLA-92Across our core markets—refractories, ceramicsand polishing—we deliver one-stop shopping, always expanding our portfolio to meetcustomer and market requirements.QUICK FACTS:Global specialty alumina producer withover 100 years of expertiseMost comprehensive alumina portfolioCloser to our customers withhighest quality productsReliable and secure supply from our refineryand 9 world-class production facilitiesExcellent global and local servicewith leading-edge technical supportContinuous development of innovativesolutions and applications know-howAlmatis Limited,Iwakuni, Japan2

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSCeramics: Strong and Versatile3Technical and Advanced CeramicsSpark Plugs and InsulatorsHoneycomb and Porous SubstratesSpecialty and LCD GlassFunctional FillersInvestment CastingMetal FiltrationRegeneration BurnersAlumina is one of the most common materialsused in ceramic applications. Its strong chemicalbonds and physical stability provide superiorproperties in key application areas rangingfrom fine grained technical ceramics to wearresistant ceramics and electrical insulators.Almatis offers the broadest portfolio of specialtycalcined and tabular aluminas in the industry.Our premium aluminas are regarded for theirhighly consistent properties, ensuring efficient,defect-free ceramic manufacturing.Unground calcined aluminasCalcined aluminasAlmatis offers a variety of unground calcinedaluminas with primary crystal sizes rangingfrom 0.3 – 25µm. Our calcined alumina puritylevels range from 99.5 - 99.8%, includingnormal soda ( 0.35%), intermediate soda( 0.20%), low soda ( 0.10%) and ultra-lowsoda ( 0.05%) products.1.2CT 12001.0CL 25000.8CT 800CL 3000A 140.6A 35/A 3500HVAA2CT 19CL 44000.4CL 5000A 100.20.0Ultra-low soda calcines1P 20P 2510100PRIMARY CRYSTAL SIZE µmThe soda content of an alumina often dictatesits ability to be used in a specific application.Since residual Na2O at the particle surfacecan become soluble and change pH andrheology characteristics, some wet processesrespond better to aluminas with ultra-low sodalevels. Almatis offers a number of calcinedaluminas with a guaranteed Na2O content 0.05%, such as A 14, A 14 -325 and CT3000 LS SG. CT 3000 LS SG is our highlyreactive batch ground product that also features a low SiO2 content, which is especiallycritical for products that are subjected toharsh chemical or wear environments.Continuous ground calcinesContinuous ground calcined aluminas featurebroad particle size distributions, which are ablend of individual crystals and partial agglomerates. Almatis produces its continuousground products in highly efficient ball mill-airclassifier systems with a focus on controllingmedian particle size and 45µm residualagglomerate content.CUMULATIVE % Ceramic is a term meaning “to burn,” asin burned earth, with earthenware being oneof the first known applications. Today the term“ceramic” encompasses a much wider rangeof materials and applications.SPECIFIC SURFACE AREA (m2/g)MAJOR APPLICATIONS FORALMATIS CALCINED ANDTABULAR ALUMINAS:10Batch ground reactivesBatch ground aluminas are fully ground products often used for the manufacture of technical and advanced ceramic parts. Almatisproduces batch grounds with mono-modal(C T 3 0 0 0 S G) and bi- m odal (A 1 5 S G)distributions, which are suitable for use in avariety of processes. While many applications require the narrow particle size distribution of a mono-modal product, bi-modalproducts are used where higher green densities are needed.8Specialty tabular products64200110100PARTICLE DIAMETER µmnnCT 800 SGHVA FGnnA 2 -325 CRA 10 -325Almatis produces specialized tabular alumina fractions targeted for the investmentcasting, functional filler, ceramic roller, metalfiltration and regeneration burner markets.Some of our tabular products are availablein low iron (LI), intermediate soda (SP) andultra-low soda (XLS) versions, or as washedproducts (Tabalox). We also offer a variety ofspherical alumina balls in smooth (T162) andround (T160, FBA) versions for applicationssuch as filter beds and regeneration burners.4

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSDIFFERENTIAL %Higher Purity Ceramics10Technology continues to evolve and providethe world with a faster, smarter and greenerlifestyle. Computer interfaces, smart devicesand touchscreens are examples of technologymade possible through advances in physicalmaterials, such as alumina. Though alumina isgenerally regarded for its refractory and insulating qualities, it has also been at the forefront ofmaterials innovation for decades.864200110100PARTICLE DIAMETER µmnnnCT 3000 LS SGA 152 SGA 14 -325Alumina is a critical material for the manufactureand processing of modern technologies suchas silicon wafer chips, solar panels, batteries,LED lighting, electronics, LCD and cover glass,jet engines, synthetic polymers and refined metalalloys, as well as the products that insulate andUNGROUNDProduct Properties5Almatis aluminas for higher purity ceramicsfeature low and ultra-low Na2O levels and havetypical purity levels of 99.8% or higher. Theseproducts are often the major or only powdercomponent used in a particular formulation.Applications include technical and electronicceramics, wear ceramics for harsh chemicalenvironments, high performance spark plugsand catalyst supports.CONTINUOUS GROUNDBATCH GROUNDCT 1200CL 2500CL 3000A 14CL 3000 FGA 14 -325CT 3000 LS SGA 152 SGCT 1200 .020.010.030.020.030.03Surface Area[m2/g]Primary Crystal / Ground D50 [µm]AI2O3Na2OSiO2dissipate heat generated from these applications. While not often recognized, alumina hasplayed a silent but key role in enabling thedevelopment of critical materials for emergingtechnologies.6

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSCUMULATIVE %Technical Ceramics10Technical and advanced ceramics succeedwhere other materials fail, such as with corrosiveenvironments, extreme temperatures, highwear rates, large stresses or high electricalcurrents. Alumina provides a specific set ofproperties that allow technical ceramics to succeed, including a high melting temperature,physical stability, hardness, wear resistance,heat resistance, corrosion resistance, thermalconductivity and mechanical strength.864200110100PARTICLE DIAMETER µmnnnCT 800HVAnnCL 5000A 10A2These characteristics make alumina an excellentchoice for a wide variety of applications. Some ofthe most common applications are componentsused in automotive, electronics, energy, environmental, household, industrial and medical devices.Product PropertiesThe primary crystal size, specific surface areaand morphology of our unground aluminas aretightly controlled to provide a consistent andeasy to process alumina in wet or dry systems.CT 800HVAA 35A2CL 5000A .010.010.020.020.04Surface Area[m2/g]Primary Crystal Size [µm]AI2O3Na2OSiO2Almatis unground calcined aluminas for technicalceramics need to be processed further and areoften spray dried prior to use in a particularapplication. Choosing an unground productallows the user to control the particle size distribution and simultaneously blend other batchcomponents.Primary crystal size determined by planetary grind.SEM: Almatis CT 800 unground78

ALUMINA FOR CERAMICSDIFFERENTIAL %Technical Ceramics10864200110100PARTICLE DIAMETER µmnnnCT 3000 SGA 152 SGnnTechnical and advanced ceramic componentshave functional and supporting roles within theirapplications to provide a safe operating environment. The alumina components are mainlyinternal to equipment such as protective coatings,liners and seals for high temperature, wear or corrosive environments. Other alumina products suchas spacers, feedthroughs, tubes, rings and mountsoffer electrical or thermal resistance. Regardlessof whether the end-use application is industrial,commercial, medical, analytical or household,alumina-based products are critical for reliableoperation.HVA FGAlmatis batch ground products are ideal for usersthat do not have internal grinding capability orwould prefer an already ground product. Theyhave been successfully used in many productionprocesses, including tape casting, slip casting,injection molding, roll compaction, uniaxial andisostatic pressing, and extrusion.A 2 -325 CRA 15 SGCONTINUOUS GROUNDProduct PropertiesBATCH GROUNDCT 800 SGHVA FGA 2 -325 CRCT 3000 SGA 16 SGA 152 SGCT 1200 SGA 15 SGCT 530 SGSurface Area[m /g]1.10.70.77.58.84.33.14.95.1Ground D50[µm]3.24.85.00.40.41.21.31.71.62Green Density[g/cm ] 2.23Fired Density[g/cm3] 3.91Pressing PressureTemperature / 1hr390 Mpa1540 CShrinkage[%]17.1AI2O3[%]Temperature / 1hr9Almatis batch and continuous ground calcinedaluminas for technical ceramics are well suited forvarious formulations, whether as the only component in an all-alumina body, major component ina high-alumina body or as filler in a low-aluminamatrix.99.799.799.62.2134.5 Mpa3.901540 C17.52.3434.5 Mpa3.861620 C15.32.3890 Mpa3.921670 C15.62.5534.5 Mpa3.861670 C12.82.6090 Mpa3.901670 C13.21540 C1540 C1620 C1670 C1670 C1670 .030.030.0410

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSReady-to-Press PowderSpray dried powders are turnkey materialsmainly used in isostatic and uniaxial pressing applications. While many manufacturersprefer to formulate their own pressing powder, others prefer the efficiency of procuringa ready-to-press product. Common applications for spray dried powders are for theproduction of semiconductor manufacturingsupports, technical ceramics, wear parts,and household and medical devices.Product PropertiesCT 3000 SDP: Spray dried powder granule11Surface AreaGround D50Granule D50 (Sieve)[m2/g]Green Density (90MPa)Fired Density (1600 C/1hr)Shrinkage (1600 C/1hr)AI2O3Na2OSiO2Almatis spray dried powders are producedfrom thermally reactive aluminas CT 3000 SGand CT 3000 LS SG. The granule distribution,binder formulation and chemical purity provide an easy-to-press powder capable ofachieving high fired density and strength.These properties combine to ensure its use ina wide variety of applications, particularly forsemiconductor manufacturing and technicalceramics.CT 3000 SDPCT 3000 LS 20.02

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSCUMULATIVE %Electronic Substrates10Electronic substrates are the base supportsfor production of electronic circuits used incomputer chips, multi-chip modules, circuitboards and disk drives. Ceramic substratesare often tape cast or roll compacted intothick- or thin-film flexible sheets. The sheets arecut to size and are then available for avariety of processing steps such as beingpunched, filled and laminated, scribed andco-fired. Once fired, the co-fired package orsintered substrate may also have subsequentprocessing steps such as laser machining, lapping, polishing, etching or plating.864200110100PARTICLE DIAMETER µmnnCL 2500CL 3000nnCL 4400Mechanical strength, hardness and overallintegrity are improved when alumina is addedA 10to formulations, as are thermal and electricalproperties such as expansion coefficient,conductivity, dielectric constant and resistivity.Almatis offers unground and continuous groundcalcined aluminas for thick-, mid- and thin-filmelectronic substrates. We offer unground products for users that want to wet or dry processthe alumina to achieve a desired particle sizedistribution, and continuous ground productsfor users that prefer to blend rather than grindthe components. Our aluminas also feature lowimpurity levels, specifically low Na2O content,for improved processing and final substrateproperties.UNGROUNDProduct PropertiesSurface Area[m /g]Primary Crystal / Ground D50 [µm]CL 3000CONTINUOUS GROUNDCL 4400A 10CL 2500 SGCL 3000 FGCL 4400 FGA 10 .020.042AI2O3Na2OSiO2CL 2500Primary crystal size determined by planetary grind.1314

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSCUMULATIVE %Spark Plugs10Spark plugs are a critical part of ignition systemsin internal combustion engines and industrial applications. As the voltage differential betweenthe electrodes exceeds the dielectric breakdownvoltage of the gases in the chamber, the gasesionize and a spark is generated. The sparkignites the fuel/air mixture and typically facilitates a thermomechanical energy conversion.864200110100PARTICLE DIAMETER µmnnA 10CL 5000nnCL 3000CT 800Alumina is used in the insulator, which insulatesthe central electrode and must have a high dielectric strength. As ignition technology evolveswith a focus on energy efficiency, the spark plugis being subjected to higher voltages while thegeometry is becoming increasingly elongated.These increased demands require a more robustinsulator with thinner walls and higher dielectricstrengths.Product PropertiesSurface AreaPrimary Crystal SizeGreen DensityAI2O3Na2OSiO2SEM: Almatis CL 3000 unground15[m /g]2Almatis calcined aluminas for spark plug applications include coarse, medium and fine crystalline products with intermediate and low Na2Olevels. These products are easily processed inwet or dry grinding systems and provide tightshrinkage characteristics for the insulator body.From standard bodies to high performanceinsulators, Almatis aluminas have consistently metthe ever-tightening industry requirements of thinner walls and higher dielectric strengths for over50 years.CT 1200CL 2500CT 800CL 3000CT 700CL 5000A .010.010.010.010.010.020.04Unground particle size distributions determined by planetary grind.16

ALUMINA FOR CERAMICSDIFFERENTIAL %Honeycomb Ceramics10Emissions control solutions are critical for reduction of greenhouse gases and particulates fromsources such as mobile vehicles and stationarypower plants. Global energy consumption isexpected to rise over 50% in the next 30 yearsand the number of vehicles on the roadwayswill soon exceed 90 million. While these numbers are only expected to increase, particularlyin developing areas, environmental regulationsare getting tighter.864200110100PARTICLE DIAMETER µmnnnA 1000 SGA 3000 FLnnHVA FGA 2 -325 CRA 10 -325Honeycomb ceramics are substrates thatsupport an active catalyst in emission controlapplications. Substrate consistency is necessaryfor the coating process, both to ensure adequate emissions regulation and becauseof the high value associated with the preciousmetals being used.Almatis aluminas for honeycomb ceramicapplications include batch and continuousground products. Our fine crystalline aluminasare ground in batch ball mills to provide a narrow particle size distribution for use as the finescomponent of a mix or as a standalone component in a high performance product.Our coarse crystalline aluminas are continuousground to provide a broad distribution and airclassified to minimize the 45µm agglomerates. The strict controls we place on our processensure a consistent product for making reproducible, high-quality substrates.CONTINUOUS GROUNDProduct PropertiesSurface Area[m2/g]Ground D50[µm]Wet Mesh 45µm [%]SEM: Almatis HVA FG17AI2O3Na2OSiO2BATCH GROUNDCT 800 SGHVA FGA 2 -325 CRA 10 -325CT 3000 SGA 1000 SG1.00.70.70.57.58.2A 3000 0.080.080.070.07[%]0.020.020.020.040.030.030.0218

ALUMINA FOR CERAMICSDIFFERENTIAL %Wear Parts10Wear parts are necessary to maintain highthroughput manufacturing, such as processingpulp into paper or thread into fabric. The sheervolume and rates associated with theseindustries necessitate a minimal amount ofoperational downtime and therefore a certainlongevity or lifetime in the supporting components. To ensure component longevity, ceramicwear parts are often incorporated into theseoperations, replacing similar metal or polymerbased parts.864200110100Alumina wear parts are commonly used inpulp and paper, textile, industrial grinding,food, pharmaceutical and medical industries.Parts such as wear liners, valves, plungers, tools,blades, cones, nozzles, tips, seals, bearings,PARTICLE DIAMETER µmnnCT 3000 SGCT 800 FGnnHVA FGA 2 -325 CRUNGROUNDProduct Properties19Almatis calcined aluminas for wear parts areavailable as unground, continuous ground andbatch ground products. The product choice isdependent on processing capability, desiredalumina content in the formulation and the enduse application. Lower alumina formulationstypically use coarse crystalline, normal andintermediate soda products, such as A 2 andCT 800, or their continuous ground equivalents. As the alumina content in the formulationincreases, the product choice usually transitionsto an intermediate or low soda product suchCL 2500 or CT 3000 SG.CONTINUOUS GROUNDBATCH GROUNDCL 2500CT 800WRAA2CT 800 FGA 2 -325 CRCT 3000 SGA 1000 rface Area[m2/g]Primary Crystal / Ground D50 [µm]Wet Mesh 45μm[%]AI2O3Na2Otubes and rods are all made from alumina inorder to survive particularly harsh manufacturingconditions.20

ALUMINA FOR CERAMICSALUMINA FOR CERAMICSDIFFERENTIAL %High Voltage Insulators10Electrical insulators play a substantial role inelectrical power distribution. Insulator postsprovide non-conductive supports that ensuresafe and reliable suspension of high voltagepower lines. The insulators must also be ableto withstand demanding mechanical, electricaland environmental conditions.864200110100PARTICLE DIAMETER µmnnnA 2 -325 CRHVA FGA 35 -325 CRAlumina is used in high voltage insulators toincrease dielectric and mechanical properties.Coarse crystalline, unground and continuousground aluminas are recommended in order tomaximize these important proper

Global specialty alumina producer with over 100 years of expertise . Almatis offers the broadest portfolio of specialty calcined and tabular aluminas in the industry. Our premium aluminas are regarded for their . high performance spark plugs and catalyst supports. Higher Purity Ceramics

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