The challenge is that refractory materials impose strict temperature ceilings on reactor operations. Conventional alumina-based refractory systems reach their technical limits around 1900°C. This temperature constraint directly limits process efficiency and product capability. When manufacturers want to increase flame temperature to improve yield and enable premium product grades, their refractory materials become the limiting factor.

When refractory temperature limits are exceeded, lining failure forces the entire production line offline while replacement materials are installed. But the more common reality is more subtle: manufacturers simply cannot push flame temperatures beyond what their refractory can handle, capping process efficiency and product capability at the material’s ceiling rather than the process’s potential.

We’re Your Zirconia Experts: Our specialists are here to help with material selection, custom solutions, and technical guidance for your specific applications.

Why Temperature Increases Matter Beyond Yield

The benefits of increased reactor temperatures extend past the obvious yield improvements. Fuel consumption drops (by up to 10%) as combustion efficiency increases with temperature, a meaningful reduction in operating costs for continuous processes. Higher flame temperatures also enable the production of premium carbon black grades that command better margins. These specialty products require sustained high-temperature operation, which means refractory temperature capability directly limits production capability and market access.

Reactor shell temperature presents an additional challenge when increasing flame temperatures. Current reactor designs typically operate with shell temperatures in the 220-240°C range. Higher flame temperatures increase heat loss through the reactor wall, creating a practical tradeoff between process efficiency gains and thermal management challenges.

Properly designed refractory systems can improve thermal efficiency of heating processes by as much as 50%, translating temperature control and insulation performance directly into operational economics. The refractory system must provide enough thermal insulation to manage the temperature gradient from the combustion zone to the shell while surviving the extreme conditions at the hot face.

Conventional alumina refractory materials cannot operate above 1900°C. The material reaches its performance ceiling at this temperature, particularly in the combustion zone where thermal and chemical stresses concentrate. Achieving higher reactor temperatures requires a fundamentally different refractory material.

Zirconia’s High-Temperature Performance Advantage

Zirconia refractory material solves this problem through properties that enable operation where conventional refractories fail. The material maintains structural integrity above 2000°C, providing the temperature capability needed for extreme flame operations. This isn’t a matter of zirconia degrading more slowly at extreme temperatures. It’s a matter of zirconia being able to function at temperatures where alumina-based systems cannot operate at all.

The engineered porosity in zirconia refractories creates superior thermal insulation compared to alumina systems. This controlled pore structure allows the material to maintain significantly lower thermal conductivity, up to five times better insulating value than alumina or magnesia alternatives. Better insulation reduces heat loss through the reactor wall, helping manage shell temperatures when operating at higher flame temperatures. While this doesn’t eliminate the thermal management tradeoff, it substantially improves the economics of high-temperature operation.

Chemical stability matters as much as temperature capability in carbon black reactors. The combustion atmosphere contains aggressive species that attack refractory materials, particularly at elevated temperatures. Zirconia’s chemical inertness prevents reaction with combustion gases and carbon species, eliminating a degradation pathway that limits service life in these demanding environments.

Engineering the Complete System

Successfully implementing zirconia refractories requires more than specifying different bricks. The complete solution combines engineered zirconia brick for the combustion chamber with custom castable pieces for complex geometries like the reactor cone section. This hybrid approach provides structural integrity where needed while enabling precise fitting in areas where individual brick cutting would be impractical.

The layered refractory design pairs zirconia at the hot face with alumina-based brick and castable backup materials behind it. This configuration optimizes the thermal gradient through the reactor wall, with zirconia handling extreme temperature at the combustion face while the backup insulation layers reduce heat loss and protect the reactor shell. Zircoa works with alumina refractory partner HarbisonWalker International to engineer and specify the complete system, ensuring material compatibility and thermal performance across every layer.

Installation engineering matters significantly. Unlike conventional brick that requires field cutting to fit tapered sections, engineered castable pieces with custom shapes arrive ready for installation. This reduces downtime during reactor rebuilds and ensures proper sealing between components. The custom design also accommodates thermal expansion and contraction without creating gaps that would compromise insulation performance.

Operational Reality and Performance Validation

Higher reactor flame temperatures translate directly into measurable production gains. The relationship is consistent: each 100°C increase in flame temperature yields approximately 1% improvement in carbon black output. Operating at 2150°C rather than 1900°C delivers roughly 2-3% yield improvement, which is a meaningful efficiency gain for continuous, high-volume production.

Thermal efficiency improves alongside yield. Zirconia’s engineered porosity delivers superior insulation compared to alumina systems, reducing heat loss through the reactor wall. This translates to lower fuel consumption for a given flame temperature, and more effective management of reactor shell temperature as operating temperatures increase. Better insulation means the process runs more efficiently across the entire thermal profile, not just at the hot face.

Perhaps most strategically, high-temperature capability unlocks access to premium carbon black grades. These specialty products require sustained operation at temperatures that alumina refractory systems cannot achieve. For manufacturers, this unlocks the ability to serve market segments and product specifications that were previously out of reach.

Read the full case study: See how one carbon black manufacturer achieved these results with Zircoa’s engineered refractory system in our detailed Carbon Black Reactor Case Study.

Going Beyond Carbon Black

While carbon black production provides a compelling application example, the principles extend to any high-temperature process where refractory temperature capability limits operations. Glass melting above 1900°C, quartz processing, specialty alloy production, and advanced ceramics manufacturing all face similar constraints. Process temperature determines product quality and energy efficiency, but conventional refractory materials impose technical ceilings on achievable temperatures.

Zirconia refractory material addresses this fundamental limitation by enabling operation at temperatures where conventional materials cannot function. The combination of high-temperature capability, superior thermal insulation, and chemical stability allows process engineers to optimize for performance rather than work around refractory limitations. When the refractory material can handle the temperature, the process can operate at its ideal conditions.

Facing temperature limitations in your high-temperature processes? Contact Zircoa’s refractory specialists to discuss how engineered zirconia brick and castable systems can enable higher operating temperatures and improve thermal efficiency in your specific application.

With the advanced ceramics market projected to top $17 billion by 2030, the processing standards that protect product purity are only becoming more consequential. The engineers specifying media for these applications aren’t looking for the cheapest option. They’re looking for the most defensible one.

We’re Your Zirconia Experts: Our specialists are here to help with material selection, custom solutions, and technical guidance for your specific applications.

The Issues With the Wrong Media

Most grinding media failures in high-purity applications aren’t dramatic. They’re cumulative. Steel media introduces iron contamination; lower-density alumina media chips and fractures under repeated impact, seeding the milled powder with foreign particulate. Porous media absorb slurry components and unpredictably release them. By the time contamination shows up in finished product testing, it’s already cost you a batch and the time needed for process investigation to trace it back.

The engineers who specify media for advanced ceramics processing aren’t looking for margin. They’re looking for a medium that won’t introduce variables they can’t control.

Why Zirconia Is the Right Choice

MgO PSZ addresses the contamination problem at the material level. The formulation is non-porous, which eliminates slurry absorption and cross-contamination between runs. It’s non-conductive and non-magnetic, which are critical properties for electronic ceramic applications where electromagnetic interference from media residue is a real concern. Chemical inertness means the media won’t react with processing environments, even in aggressive slurries. And at a density of approximately 5.4–5.5 g/cm³, zirconia media delivers the mass-to-size ratio that drives efficient grinding without requiring oversized media charges.

Chip resistance is the other half of the contamination equation. Media that chips or fractures during milling becomes contaminated. Zircoa’s ceramic grinding media is engineered for hardness that resists breakdown over extended service life, keeping media weight loss low and milled powder clean.

Optimized Zirconia Grinding Media Media Geometry

Zircoa manufactures ceramic grinding media as radius-end cylinders designed for vibratory, ball, and jar mills. Available in a range of sizes from 0.25″ to 1.25″, they handle the grinding of barium titanates, electronic ceramics, zircon, zirconia, and other specialty ceramics. This format provides the contact surface geometry suited to particle size reduction across a wide range of feed materials. This increased surface area leads to improved milling efficiency, such as faster grind times and consistent particle size.

All media is manufactured to order, with custom sizes available to match your specific mill configuration and target particle size.

For applications focused on dispersion rather than particle size reduction, Zircoa’s Zirbeads™ Dispersion Media is engineered specifically for high-shear mixing of paints, pigments, and high-viscosity industrial formulations. This is a related, but distinct, product optimized for different processing demands.

Four Decades of Application Engineering

Zircoa has been supplying ceramic grinding media to electronic ceramics and specialty materials processors for more than 40 years. That depth of experience informs not just the product, but the application support behind it. Zircoa’s engineering team works with customers on media sizing, mill parameter guidance, and processing best practices for specific materials. This is the kind of application partnership that matters when your grinding application has tight purity specs or unusual slurry chemistry.

Get the Right Media for Your Application

Media selection has a direct impact on product purity, process consistency, and batch yield. Zircoa’s application engineers are ready to help you identify the right grinding media configuration for your specific material and mill system. Contact the Zircoa team to discuss your grinding requirements.

Zirconia Refractory Material for Increased Carbon Black Processing Temperatures and Efficiency

For decades, non-ferrous metal extruders have faced a persistent challenge: metal extrusion dies deform under the extreme thermomechanical stresses of hot extrusion, creating dimensional inconsistencies, poor surface finish, and costly rework cycles. When a leading copper alloy tube manufacturer sought a solution that could deliver both technical performance and economic value, they turned to Zircoa’s ceramic extrusion die inserts. What began as a carefully managed transition evolved into a proven technology that has served the industry for over three decades.

The Challenge: Deformation, Inconsistency, and Rework Cycles

The manufacturer produces hot-extruded copper alloy tubes for water supply, drainage, refrigeration, and air conditioning systems. In these applications, dimensional accuracy and surface finish directly impact product quality and end-use performance. Their extrusion process operated at high temperatures with significant mechanical forces, creating conditions that pushed traditional tooling materials to their limits.

Metal extrusion dies, whether fabricated from tool steels, hot working steels, or cobalt-based alloys like Stellite, suffered from a fundamental limitation: they deformed permanently under use. The dimensional accuracy of extruded products varied along their length due to unstable ram speed and progressive die deformation caused by high thermomechanical stresses. Temperature, reduction ratio, and lubrication all influenced dimensional outcomes, but in practice, adjusting these parameters couldn’t compensate for the die’s changing geometry during operation.

The consequences compounded throughout production:

• Dimensional inconsistency – Metal dies experienced “turn-in” deformation, in which high stresses caused the inner-diameter configuration to change, making the outer diameter of extruded tubes progressively smaller. Wall thickness decreased periodically while length increased, with variations of up to 6% between extrusions.
• Poor surface finish – Even with lubricants, metal dies produced unacceptable surface quality, requiring additional processing.
• Frequent rework – Metal dies required machining after the first two to three extrusion cycles, then again after approximately thirty cycles, to restore dimensional accuracy.
• Cold drawing operations – Manufacturers had to apply calibration through cold drawing to achieve acceptable dimensional tolerances, adding process steps and costs.
• Short die life – Despite reworking, metal dies had limited service life before complete replacement was required.

The operational costs were substantial: press downtime for die rework, large die inventories to maintain production during machining cycles, machine shop labor for frequent remachining, and ultimately, shorter die replacement cycles. The manufacturer needed a solution that could withstand the extreme conditions of hot extrusion without the progressive deformation that plagued metal tooling.

The Solution: Engineered PSZ Ceramic Inserts and Process Adaptation

Zircoa proposed transitioning from metal dies to partially stabilized zirconia (PSZ) ceramic extrusion die inserts in Composition 2016. However, the solution involved more than simply replacing one material with another; it required understanding ceramic material characteristics and adapting both die design and manufacturing processes to leverage PSZ’s advantages while respecting its limitations.

The transition was framed explicitly as a “learning curve.” Ceramics behave fundamentally differently from metals, particularly regarding tensile and shear stresses. The manufacturer and Zircoa worked collaboratively to optimize die design, establish proper installation procedures, and train manufacturing personnel on ceramic-appropriate handling and press operation.

Design Engineering for Ceramic Inserts

The ceramic insert design utilized the proven geometry from existing metal dies — configurations that had been refined empirically for each specific extrusion process — but incorporated critical modifications for ceramic material requirements:

• Minimized wall thickness – Reducing ceramic insert wall thickness prevented thermal stress buildup while maintaining structural integrity.
• Adapted land length – The die land (the parallel section of the bore) was optimized for ceramic material characteristics.
• Shrink fit compensation – To account for the reduction in inner diameter caused by shrink fitting the ceramic insert into the metal holder, the ceramic bore was increased by 0.5%.
• Metal casing design – The steel die holder was engineered to support the ceramic insert while accommodating thermal expansion differences.

This hybrid design preserved the metal casing’s structural role while positioning the ceramic insert to handle the extreme temperature and wear conditions at the extrusion interface.

Material Performance Advantages

PSZ ceramic delivered several properties that metal dies couldn’t match:

• Non-wetting surface – The ceramic is not wetted by most extruded non-ferrous alloys, preventing material adhesion.
• Superior lubricity – 50% lower coefficient of friction in contact with copper compared to hot working steel, enabling extrusion even without lubricant.
• Low thermal conductivity – At 600°C, PSZ exhibits thermal conductivity of 1.9 W/mK compared to 28.8 W/mK for hot working steel, reducing heat transmission to the metal die holder and allowing it to retain hardness longer.
• Dimensional stability – No “turn-in” deformation under operational stresses, maintaining consistent bore geometry throughout die life.
• Highly polished, non-abrasive surface – Improved surface quality of extruded products.

Process Implementation

Successful ceramic insert adoption required manufacturing personnel to master several critical elements:

• Correct shrink fit procedures adapted for ceramic material
• Careful handling protocols to prevent damage from impact or thermal shock
• Appropriate press operation parameters for ceramic tooling

The manufacturer’s commitment to this learning process proved essential to realizing the technology’s full potential.

The Results: Doubled Life, Eliminated Rework, and Quantified Savings

The transition to ceramic extrusion die inserts delivered both immediate operational improvements and substantial long-term economic benefits. Die life increased by 100% compared to cobalt-based metal dies, and this calculation included the two to three reworks that metal dies underwent during their service life. Ceramic inserts required virtually no reworking.

Operational Performance Improvements

The dimensional consistency improvement was dramatic. Where metal dies produced extrusions that varied by up to 6% in length, ceramic inserts delivered extremely consistent outer diameter and extrusion length across all cycles. Surface finish improved notably as extruded tubes exhibited brighter, smoother surfaces without additional processing.

The elimination of the “turn-in” phenomenon meant that wall thickness and diameter remained stable throughout the die’s service life. Manufacturers could also increase ram speed and extrude larger billets, further improving productivity. These options weren’t viable with metal dies due to accelerated deformation.

Economic Impact

The cost analysis demonstrated clear economic advantages. Annual machine shop labor savings totaled 3,351 hours, translating to $83,780 in labor cost reduction. Additional die purchase savings of $10,000 brought the total annual savings to $93,780.

While ceramic inserts cost approximately 20% more than metal dies initially, they provided 33.4% more extrusion cycles and eliminated the machine shop rework that consumed thousands of labor hours annually. When the reject rate reduction at final inspection was factored in, additional cost savings became evident.

Long-Term Validation

The technology’s continued use across the non-ferrous extrusion industry for over three decades validates its performance. What was initially approached as a carefully managed learning curve became an established solution for manufacturers seeking to eliminate the deformation and rework cycles inherent in metal extrusion dies.

For this manufacturer, the partnership with Zircoa delivered a pathway to fundamentally improved process economics through collaborative engineering that respected both material capabilities and manufacturing realities.

Facing dimensional consistency or tooling life challenges in hot extrusion? Zircoa’s technical ceramics team can evaluate your extrusion requirements and develop ceramic insert solutions optimized for your specific process. Contact us to discuss your application.

Zirconia Refractory Material for Increased Carbon Black Processing Temperatures and Efficiency

When a global carbon black manufacturer needed to increase reactor flame temperatures from 1900°C, the limit of conventional alumina refractory linings, to improve yield, produce specialty grades, and reduce fuel consumption. The manufacturer turned to Zircoa to engineer a zirconia-based refractory system that could withstand extreme temperatures while extending equipment life — and what started as a single reactor installation evolved into a multi-year partnership advancing carbon black production technology.

The Challenge: Temperature, Life, and Installation Efficiency

The manufacturer produces carbon black through controlled pyrolysis of hydrocarbon feedstocks at extreme temperatures. Their operations depended on a direct relationship: every 100°C increase in reactor flame temperature offered the potential of 1% yield improvement, along with a roughly 10% reduction in fuel costs. Reaching 2100°C and above would also unlock the capability to produce premium carbon black grades — specialty products that demanded sustained high-temperature conditions their existing refractory system couldn’t provide.

Their alumina-based refractory linings were suitable for flame temperatures up to 1850°C – 1900°C, with an expected 12-month service life. But the economics of higher-temperature operation were compelling enough to pursue, if the engineering challenges could be solved. Increasing flame temperature to 2150°C introduced a cascade of technical problems that needed to be addressed simultaneously rather than sequentially.

First, traditional alumina refractories couldn’t maintain structural integrity above 1900°C. Thermal stress accelerated degradation dramatically, threatening to reduce reactor life to just months rather than the expected 12-month cycle. Second, higher flame temperatures risked elevating reactor skin temperature beyond the 230°C threshold required to maintain thermal efficiency. Third, the existing installation process for the reactor’s cone section required hand-cutting individual bricks on-site, extending downtime during reactor rebuilds.

The manufacturer faced a complex engineering problem:

• Achieve sustained flame temperature above 2100°C operation without sacrificing refractory life
• Maintain reactor skin temperature safely below 230°C despite the temperature increase
• Eliminate field cutting and reduce installation time during reactor rebuilds
• Deliver a solution that justifies the higher material cost through operational improvements

Without solving all of these requirements simultaneously, the efficiency gains from higher temperatures would be offset by increased refractory costs, more frequent rebuilds, and extended downtime.

The Solution: Engineered Zirconia System With Iterative Development

Zircoa began with early technical discussions to understand the reactor’s dimensional constraints and the manufacturer’s operational goals. The initial approach combined engineered zirconia brick in Composition 1651 for the combustion chamber with custom castable pieces in Composition 0872 for the cone section — the reactor’s hottest zone.

This hybrid design delivered several advantages:

• Eliminated field cutting – Custom-engineered castable pieces with ship lap design arrived ready for installation, removing the need to hand-cut individual bricks in the tapered cone section
• Optimized thermal performance – Zirconia’s thermal shock resistance and structural integrity enabled 2150°C operation, while the engineered porosity provided insulation to maintain safe reactor skin temperatures
• Simplified installation – The ship lap design ensured structural integrity in the cone section while reducing installation time during reactor rebuilds
• Enabled temperature stratification – Proper layering with alumina backup material behind the zirconia hot face optimized the thermal gradient through the reactor wall

The first installation was completed in February 2019. The manufacturer evaluated performance across multiple criteria: refractory life at elevated temperatures, reactor skin temperature stability, yield improvements from higher flame temperature operation, and installation efficiency.

But early operation revealed a critical issue: brick failure at the 12 o’clock position with elevated skin temperature. Zircoa’s failure analysis identified eutectic formation between the zirconia and alumina layers; this phenomenon is where materials react at elevated temperatures to form a lower-melting-point compound that compromises structural integrity.

This discovery triggered a collaborative engineering response. Zircoa and their alumina-backup materials supply partner, HarbissonWalker International, worked together to redesign the material stackup, eliminating the conditions that enabled eutectic formation. The refined design was validated in the second installation, completed in August 2023, incorporating the lessons learned from the first reactor’s performance and failure analysis.

As part of an ongoing performance optimization effort, the team has developed a modified brick design to be featured in the next installation. This enhancement will better accommodate thermal expansion and contraction during dynamic heat-up and cool-down cycles, improving the overall structural stability of the refractory system.

The Results: Doubled Life and an Expanding Partnership

The engineered zirconia refractory system delivered the performance the manufacturer needed. The second installation achieved close to 24 months of operation, doubling the 12-month life expectancy of the previous alumina system while running at the higher 2,100°C flame temperatures required for yield optimization and premium product manufacturing.

Beyond extending refractory life, the solution addressed the manufacturer’s complete set of operational requirements. Reactor skin temperatures remained safely below 230°C despite the elevated flame temperature. The custom castable pieces with ship lap design eliminated field cutting, reducing installation time during reactor rebuilds. The yield increase and fuel consumption reduction justified the higher material cost, delivering improved economics along with extended equipment life.

The success of the 2019 and 2023 installations established an ongoing partnership. The manufacturer has committed to additional reactor linings, including at least one installation in 2026 and three more reactor rebuilds planned for 2027. The collaboration now extends beyond material supply to include co-development work on further product improvements, continued flame temperature increases, and enhanced stability of both brick and castable components.

What began as a single reactor installation to solve a temperature and life limitation has evolved into a multi-year partnership driving continuous improvement in carbon black production efficiency. For the manufacturer, the relationship delivered validated materials that enabled their operational goals. For Zircoa, it demonstrated the value of collaborative engineering that goes beyond material supply to solve complex application challenges through iterative design and failure analysis.

Facing temperature or refractory life limitations in high-temperature processes? Zircoa’s engineering team can develop custom refractory linings and other solutions for demanding industrial applications. Contact us to discuss your specific requirements.

Melting platinum and its alloys isn’t a job for just any crucible. With melting points pushing past 2,000°C, and the added complexity of corrosive slags, aggressive thermal cycling, and the highest demands on melt purity, platinum group metal (PGM) processing demands ceramic materials engineered specifically for the task.

That’s exactly the challenge explored in Zircoa’s latest publication. Ronny Simon, Jake Mochoskay, and Tobias Schmidt recently co-authored a feature article for the American Ceramic Society Bulletin titled “Zirconia Crucibles: Enabling Reliable Melting of Platinum Group Metals.” The piece digs into why zirconia crucibles have become the go-to solution for PGM processing, and how composition selection makes all the difference.

The article breaks down four distinct zirconia crucible compositions Zircoa has developed, each engineered for specific operating conditions. From magnesia-stabilized zirconia handling continuous loads at 1,800°C and beyond to yttria-stabilized formulations capable of operating at 2,300°C for the most demanding platinum-rhodium alloys, the piece illustrates how Zircoa’s depth of materials engineering translates directly into application performance.

The authors also address one of the more nuanced challenges in zirconia crucible use: managing phase transitions. Zirconia passes through monoclinic, tetragonal, and cubic phases as temperatures change, and those transitions come with volume changes of approximately 3–5% that can cause cracking if thermal cycling isn’t designed carefully. The article includes thermal expansion data for each composition and specific temperature guidance — practical information that engineers can actually use.

PGM recycling adds another layer to the discussion. Since these metals are rare and expensive, the recycling process is economically critical—and it’s chemically punishing for crucibles. The ability of zirconia to resist glassy siliceous slags while maintaining surface smoothness that minimizes contamination makes it particularly well-suited for this work. The article also highlights Zircoa’s zirconia-based backup insulating materials, which provide approximately five times the insulating value of alumina or magnesia backups — extending crucible life and improving thermal efficiency in induction furnace installations.

Read the full article in the March 2026 issue of the American Ceramic Society Bulletin, or download the PDF directly from Zircoa’s website.

If you’re working through a similar challenge, whether in PGM processing or another high-temperature application, we’d like to hear about it.

Zirconia Refractory Material for Increased Carbon Black Processing Temperatures and Efficiency

When a South American nuclear power plant operator needed nuclear reactor refractory materials capable of withstanding the most extreme conditions imaginable — molten core material at temperatures exceeding 2300°C — they turned to Zircoa for a solution that would help secure a 20-year operating license renewal for their facility.

The Challenge: Meeting IAEA Standards for Severe Accident Protection

The nuclear power plant operator was pursuing a 20-year operating license renewal for one of their generating facilities as part of their commitment to long-term plant safety and modernization.

Meeting the International Atomic Energy Agency (IAEA) Safety Aspects of Long-Term Operation standards required the operator to enhance protective structures throughout the facility. One critical requirement involved creating a sacrificial barrier system in the reactor sump — a containment area designed to capture and contain debris in the event of a severe accident.

In the unlikely event of a core meltdown, the reactor would produce corium: an extremely hot mixture of molten nuclear fuel, fission products, control rods, and structural materials from the reactor core. This molten material can reach temperatures between 2300°C and 2500°C and remains dangerously hot for extended periods. The operator needed a barrier system capable of protecting the reactor sump from this corium for up to 36 hours, allowing time for other critical safety protocols to be executed.

To be effective, the barrier system had to address a set of extraordinary anticipated design criteria, including the need to:

• Provide sustained thermal resistance against corium — routinely estimated at 2300-2500°C — to help delay melt progression for an extended period (targeted at up to 36 hours)
• Demonstrate high resilience and structural stability when subjected to extreme water quenching and high-pressure steam
• Achieve exceptionally low porosity to resist melt penetration and corium ingress
• Provide predictable, reliable performance as a single-use sacrificial structure

Without a solution that met these demands, the operator faced serious consequences: failure to meet IAEA safety standards, inability to obtain operating license renewal, potential catastrophic damage to critical mechanical equipment, and significantly reduced safety margins for the facility.

The Solution: Engineered Zirconia Refractory System with Validated Performance

Zircoa began working with the operator’s engineering team in early technical discussions to understand the exposure scenarios and performance expectations for the barrier system. The collaborative process involved evaluating suitable zirconia compositions, considering various brick geometries including layered and interlocking designs, and reviewing critical properties like porosity, density, and thermal-mechanical behavior.

Based on these discussions, Zircoa recommended a refractory system based on magnesia partially stabilized zirconia (MgO-PSZ). The solution consisted of custom-geometry refractory bricks in Composition 3004 paired with a compatible zirconia mortar in Composition 1640.

This refractory system offered several critical advantages:

• Exceptional resistance to molten metallic and oxidic materials – MgO-PSZ composition provides superior chemical inertness and erosion resistance against both metallic and oxidic phases of corium
• High mechanical integrity at extreme temperatures – Maintains structural stability even under exposure to 2300-2500°C conditions
• Predictable performance after water or steam exposure – Reliable behavior across the range of environmental conditions in a reactor containment scenario
• Reduced risk of system failure under severe conditions – Custom geometries and engineered mortar joints prevent melt penetration or corium ingress

Before committing to full-scale supply, the operator required thorough validation. In 2023, Zircoa supplied sample bricks and mortar for comprehensive testing. The operator’s evaluation process examined:

• Thermal stability under extreme temperature conditions
• Ablation and melt resistance when exposed to corium-simulating materials
• Mechanical strength under load, or Refractoriness Under Load (RUL)
• Behavior and thermal shock resistance during water quenching
• Mortar compatibility and joint performance

The 2023 testing program validated the material performance across all critical criteria. The samples demonstrated the thermal stability, melt resistance, and mechanical properties required for this mission-critical application. Based on these successful test results, the operator approved Zircoa’s refractory system for full-scale supply.

The Results: Validated Materials Supporting Nuclear Modernization

Following the successful 2023 testing program, Zircoa supplied the complete refractory system for the facility’s modernization in 2025. The validated materials provided the operator with confidence in the barrier’s performance characteristics, supporting their efforts to meet IAEA safety standards and proceed with the operating license renewal process.

The thorough testing and validation approach — from 2023 sample evaluation through 2025 full-scale supply — demonstrated Zircoa’s understanding of the rigorous requirements in nuclear safety applications. The project required more than just supplying materials; it demanded collaborative engineering to refine barrier structure concepts, careful consideration of installation guidance, including mortar use and joint design, and the ability to deliver custom geometries that met exact specifications.

For the operator, the partnership delivered validated materials that met the most stringent safety requirements for severe accident mitigation. The successful completion of this project also positioned Zircoa as a capable supplier for nuclear-sector applications, demonstrating expertise in advanced zirconia ceramics for mission-critical environments where performance margins are extremely tight.

This project represents the type of application where material failure is not an option. By providing nuclear reactor refractory materials that passed rigorous validation testing and met IAEA safety standards, Zircoa supported the operator’s commitment to long-term operational safety and facility modernization.

Facing extreme thermal or chemical challenges in critical applications? Zircoa delivers engineered zirconia refractory solutions for the most demanding environments. Reach out to explore how we can support your project.

Zirconia Refractory Material for Increased Carbon Black Processing Temperatures and Efficiency

Advanced ceramics manufacturers have long faced a fundamental tension: the applications demanding the highest material performance often require the most complex component geometries. Yet traditional manufacturing methods have consistently struggled to deliver both simultaneously. Zircoa addressed this by formulating a dedicated CIM feedstock built around its proprietary Composition 1876, transferring the distinctive mechanical and microstructural attributes of that established MgO-PSZ grade into a fully injection-moldable system.

The Challenge: Performance Without Compromise on Geometry

Ceramic Injection Molding (CIM) is a proven process for producing complex-shaped ceramic components at scale. The process follows a defined sequence: Ceramic powder is compounded with an organic binder to create a flowable feedstock, which is then injection-molded to form a near-net-shape green part. The binder is subsequently removed through debinding, the most process-sensitive step in CIM, where incompatibilities between powder and binder can cause irreversible cracking, warping, or density gradients, making feedstock formulation a critical engineering decision in its own right. The component is then sintered to full density. The result is the ability to produce intricate geometries that conventional press-and-sinter methods cannot achieve efficiently or economically, including undercuts, complex internal channels, and fine features.

For manufacturers producing wear parts, fluid control components, sensors, and other high-performance technical ceramics, CIM offered a compelling path to more complex designs and higher production volumes. But a critical gap persisted: none of the commercially available CIM feedstocks offered the specific performance profile that Zircoa’s established MgO-PSZ compositions were known for.

Magnesia partially stabilized zirconia (MgO-PSZ) is prized for its combination of high wear resistance, fracture toughness, corrosion resistance, and thermal stability. Manufacturers specifying Zircoa’s MgO-PSZ for its proven performance were effectively constrained to press-and-sinter routes, limiting achievable geometry and increasing per-part costs for complex or low-volume series.

The consequences of this gap were real:

• Inability to manufacture intricate near-net-shape components with this high-performance zirconia
• Higher per-part costs for complex or low-volume production series
• Lost opportunities for performance improvements in wear-, temperature-, and corrosion-critical environments
• Barriers to adopting advanced zirconia materials in geometrically demanding new applications

Zircoa recognized that their established Composition 1876 MgO-PSZ powder, already proven across demanding applications including wear parts and ceramic grinding media, had the right material properties to fill this gap if it could be successfully adapted for CIM processing.

The Solution: Proven Material, New Manufacturing Pathway

Zircoa GmbH’s development team identified both the market need and the technical pathway: adapt Composition 1876’s established powder characteristics to a proven CIM binder system, creating a zirconia feedstock that brings MgO-PSZ performance into injection molding workflows without sacrificing material integrity.

To accomplish this, Zircoa partnered with INMATEC Technologies GmbH, a specialist in ceramic and metal injection molding feedstock development. The collaboration centered on adapting Composition 1876 with INMATEC’s INMAFEED thermoplastic binder system, an industry-standard binder already well-regarded for its injection behavior and environmentally friendly debinding process.

The resulting feedstock, Zircoa Composition 1876 INMAFEED, delivered several critical advantages:

• Preserves established MgO-PSZ material performance — CIM-processed components deliver the same wear, corrosion, mechanical, and fracture resistance as conventional press-and-sinter parts
• Enables complex geometries — Injection molding unlocks intricate shapes, fine features, and near-net-shape designs beyond the reach of press-and-sinter
• Compatible with industry-standard processing — Globally adopted across CIM environments, the INMAFEED binder system integrates seamlessly into existing production workflows
• Supports environmentally responsible manufacturing — Designed around a clean debinding process, the INMAFEED binder system minimizes waste and promotes more sustainable production
• Expands application reach — Zircoa’s proven MgO-PSZ performance becomes accessible across a wider range of geometries and manufacturing workflows

The development process involved rigorous evaluation of mechanical, thermal, and chemical resistance benchmarks to confirm that the zirconia CIM feedstock matched the performance characteristics of Zircoa’s established press-and-sinter route. The successful validation confirmed that the feedstock’s material properties were fully transferable to the CIM process; this was a non-negotiable requirement for customers whose applications depend on predictable, certified material behavior.

The feedstock was featured in PIM International, the leading global specialist magazine for powder injection molding — an industry recognition of its significance to the CIM materials landscape.

The Results: A New Market Entry and Expanded Design Freedom for Customers

The development and release of Composition 1876 INMAFEED in October 2022 marked Zircoa’s entry into the ceramic injection molding market. The move strategically extended Zircoa’s advanced zirconia materials into a new and growing segment of technical ceramics manufacturing.

For Zircoa customers, the feedstock removed a longstanding barrier: the need to compromise between material performance and geometric complexity. Engineers designing wear components, fluid control parts, sensors, and other demanding applications can now specify Zircoa’s proven MgO-PSZ performance profile while taking full advantage of CIM’s design flexibility and production scalability.

The feedstock is available for sampling, allowing customers to evaluate material performance in their specific applications and processing environments before committing to full production runs. Zircoa’s engineering team supports customers through feedstock evaluation and application development, drawing on decades of zirconia materials expertise.

Looking ahead, Zircoa has identified additional zirconia compositions as candidates for future CIM feedstock development, signaling a long-term commitment to expanding the role of advanced zirconia ceramics in injection molding applications. What began as a single product development project has opened a broader strategic pathway. With each new feedstock development, Zircoa’s full range of advanced zirconia materials moves closer to the design and production workflows of the global technical ceramics industry.

Ready to bring Zircoa’s MgO-PSZ performance into your CIM workflow? Whether you’re evaluating feedstock compatibility or developing a new component, Zircoa’s engineering team brings decades of zirconia materials expertise to your application. Contact us to get started.

A Grain monoclinic zirconia powder exists because Zircoa took a different manufacturing approach entirely. Rather than precipitation chemistry or fusion, Zircoa synthesizes A Grain from zircon sand using a proprietary solid-state reaction process. This process produces something neither conventional method can deliver: consistently distributed spheroidal particles with remarkably low surface area. The result is a powder with properties that solve problems instead of creating them.

We’re Your Zirconia Experts: Our specialists are here to help with material selection, custom solutions, and technical guidance for your specific applications.

The Spheroidal Advantage

Particle shape matters more than most spec sheets acknowledge. A Grain’s spheroidal particles aren’t just aesthetically different from the agglomerated structures of precipitated zirconia or the angular shards of fused material; they fundamentally change how the powder behaves in processing. Research across multiple industries demonstrates that particle morphology directly impacts material properties, including flowability, packing density, and dispersibility. These effects become especially pronounced at the micron scale, where A Grain operates.

The spheroidal geometry enables exceptional dispersibility and flow. Where angular particles interlock and agglomerated powders resist breakdown, A Grain’s smooth spheres flow freely and distribute uniformly in various media. This translates directly to higher solids loading — 80-90% in typical spray drying applications compared to 50-70% for precipitated powders and 65-75% for fused alternatives. Higher solids loading means fewer processing steps, lower drying costs, and more throughput from existing equipment.

The surface area tells the other half of the story. A Grain’s 1 m²/g surface area sits dramatically below the high surface area typical of precipitated zirconia. A lower surface area means reduced reactivity during processing, lower binder demand in formulations, and superior flow characteristics that simplify handling. The 2 µm mean particle size provides consistency without requiring the intensive milling that fused zirconia demands.

Together, these properties create a material that simply processes better. Parts made with A Grain exhibit lower shrinkage during firing, improving dimensional control and reducing rejection rates. The powder disperses easily across different systems without specialized equipment or complex processing protocols. For manufacturers optimizing costs while maintaining quality, these aren’t minor conveniences but meaningful operational advantages.

Monoclinic Zirconia Powder Applications Where Properties Matter

A Grain’s unique characteristics make it the material of choice for applications where powder behavior directly impacts product performance or manufacturing economics.

Automotive oxygen sensors depend on zirconia’s ionic conductivity properties, but sensor manufacturers need powder that disperses uniformly and fires to precise dimensions. A Grain’s spheroidal particles and consistent particle size distribution enable the tight tolerances these sensors require. Similarly, zirconium metal production for automotive airbag initiators leverages A Grain’s high purity and processing characteristics to produce the reactive metal powders that enable critical safety systems.

Display glass manufacturers face a different challenge. They need a zirconia filler that toughens glass without introducing processing complications or contamination. A Grain’s low surface area and superior dispersibility allow uniform distribution throughout glass melts, while the spheroidal shape reduces abrasive wear on processing equipment. The result is tougher, more durable display glass produced more efficiently.

The chlor-alkali industry represents another domain where A Grain solves a specific materials problem. As manufacturers transition away from asbestos-based materials, they need alternatives that provide similar performance without health and safety risks. A Grain’s chemical inertness, thermal stability, and processing characteristics make it an effective non-asbestos material for chlor-alkali processes, supporting both performance and safety objectives.

Electronic ceramics manufacturing, catalyst support production, ceramic colorants, and refractory feedstock applications all leverage different aspects of A Grain’s property set. Some applications prioritize the high solids loading for processing efficiency. Others value dimensional stability or the consistent particle characteristics. The common thread is that A Grain’s distinctive properties enable either better products or better economics compared to conventional powder alternatives.

Beyond Standard Specifications

What makes A Grain genuinely one-of-a-kind isn’t just the current standard specification. It’s Zircoa’s ability to customize the powder’s chemical and physical properties for specific applications. The baseline 99.6% ZrO₂ purity with controlled trace elements represents a starting point, not a limitation.

Engineers working on novel applications or facing unique processing constraints can work with Zircoa’s materials team to modify properties while maintaining the core advantages of the spheroidal particle shape and solid-state synthesis approach. This customization capability matters particularly for R&D teams developing new products or manufacturers looking to optimize existing formulations. Rather than forcing an application to work around powder limitations, the powder itself can be engineered to support the application requirements.

Standard packaging in 500-pound (~ 226.8 kg) drums with plastic bag liners and typical lot sizes of 12,000 pounds (~ 5,443 kg) reflect Zircoa’s focus on commercial-scale manufacturing. This isn’t a laboratory curiosity or a specialty material produced in small batches. A Grain supports volume production across multiple industries, backed by quality control systems that ensure batch-to-batch consistency for critical applications.

Powder Selection as Process Optimization

Selecting zirconia powder shouldn’t require compromising between purity, particle characteristics, and processing economics. The limitations of precipitated and fused zirconia aren’t universal constraints; they’re artifacts of specific manufacturing approaches. When engineers understand that spheroidal monoclinic zirconia powder with low surface area exists as a third option, powder selection becomes about matching material properties to application requirements rather than working around inherent limitations.

A Grain represents Zircoa’s recognition that many applications benefit more from superior dispersibility and processing characteristics than from the specific advantages that precipitated or fused powders offer. For sensors, glass manufacturing, electronic ceramics, and dozens of other applications, the spheroidal advantage translates directly to better products or lower costs. That’s the value proposition of a truly one-of-a-kind manufacturing process.

Looking to optimize your zirconia powder processing or explore alternatives to precipitated and fused powders? Contact Zircoa’s materials specialists to discuss how A Grain’s unique spheroidal particles and low surface area can improve your specific application’s performance and economics.

Zirconia Refractory Material for Increased Carbon Black Processing Temperatures and Efficiency

When a leading specialty alloy manufacturer faced contamination issues threatening critical aerospace qualifications, they needed more than just a supplier. They needed a problem-solving partner who could respond with urgency and precision.

The Challenge: Contamination Threatening Aerospace Qualification

A specialty alloy manufacturer operates a powder production facility specializing in metal powders for hot isostatic pressing, additive manufacturing, and coating applications. These materials require absolute cleanliness and consistency.

The facility operates an ALD Vacuum Induction Melting Inert Gas Atomizer (VIGA) to produce these critical metal powders. In gas atomization, molten metal streams through zirconia atomization nozzles, where high-pressure inert gas breaks it into fine powder particles. The bore diameter and surface quality of these atomization nozzles directly impact powder particle size distribution and cleanliness. When supplying aerospace engine components, these factors are non-negotiable.

The manufacturer faced a significant problem with their existing nozzle supplier. The OEM manufacturer supplied zirconia atomization nozzles with machined bores to achieve tight tolerances. While this machining delivered dimensional precision, it created an unintended consequence: the machining process left microscopic zirconia particles that contaminated the metal powder during atomization.

For aerospace-grade metal powders destined for critical rotating components in aircraft engines, contamination from refractory was unacceptable. The manufacturer was pursuing qualification to supply metal powders to a global aerospace engine manufacturer, and the contamination from machined nozzle bores was causing them to fail qualification requirements. The situation was urgent. Without resolving this issue, the manufacturer faced:

• Failure to meet qualification requirements for key aerospace accounts
• Loss of competitive position against other powder metal producers
• Continued contamination of aerospace-grade powders
• Violation of customer requirements (machined bores were technically not allowed)

The manufacturer needed a supplier who could provide contamination-free atomization nozzles with the necessary tolerances, performance characteristics, and most importantly, speed.

The Solution: As-Pressed Bores and Rapid Response

Zircoa was already supplying atomization nozzles to another facility within the manufacturer’s operations, establishing a foundation of technical knowledge and trust. When the powder operations team reached out with their urgent contamination challenge, Zircoa moved quickly to evaluate the requirements and develop a solution.

The technical review process identified the core issue: eliminating the need for bore machining while maintaining the tight tolerances required for consistent powder production. Zircoa proposed supplying atomization nozzles in magnesia partially stabilized zirconia with as-pressed bores, meaning the critical bore dimension would be formed during the pressing process rather than machined afterward.

This approach offered several critical advantages:

• Eliminated contamination source entirely – No bore machining meant no zirconia particles to shed into the powder stream
• Achieved necessary bore tolerances – Precision pressing and tooling design delivered the tight tolerances required for consistent powder production
• Provided balanced thermal and mechanical properties – The zirconia composition offered the strength and wear resistance needed for demanding atomizer conditions
• Enabled rapid trial production – Domestic manufacturing capabilities allowed Zircoa to meet urgent qualification deadlines

Zircoa structured a trial schedule to meet the manufacturer’s qualification deadlines, supplying trial nozzles with urgency. The manufacturer evaluated the trial results across multiple criteria:

• Elimination of contamination from the press-and-sinter bore
• Consistency and repeatability of bore size tolerances
• Quality of the powder produced (size, shape, and surface finish)
• Mechanical and thermal performance of the zirconia material in the atomization system

The trials confirmed that Zircoa’s as-pressed nozzles delivered contamination-free operation while maintaining the powder quality characteristics needed. The material proved compatible with the ALD system, and the bore tolerances remained consistent across production runs.

The Results: Qualification Achieved and Partnership Established

With Zircoa’s contamination-free zirconia atomization nozzles, the manufacturer successfully met the qualification requirements for their key aerospace accounts, enabling them to supply metal powders for critical aircraft engine components. The as-pressed bore solution eliminated the contamination risk that had threatened this qualification, giving them confidence in their powder cleanliness.

Beyond solving the immediate contamination problem, Zircoa’s solution delivered operational improvements. Domestic supply of consumable nozzles improved lead times compared to international OEM sources. Zircoa’s commitment to maintaining safety stock and responsive customer support gave the manufacturer greater supply chain confidence. The rapid trial response demonstrated Zircoa’s capability to quickly react and provide customized solutions in highly technical atomization applications.

The project established an ongoing supply relationship, with Zircoa continuing to provide atomization nozzles that meet the manufacturer’s quality, lead-time, and responsiveness requirements. For the customer, the partnership meant more than just solving a contamination problem; it meant gaining a supplier who understood the urgency of aerospace qualifications and could deliver engineered solutions under pressure.

Facing contamination challenges in your powder metallurgy operations? Zircoa’s engineering team can evaluate your atomization requirements and develop customized zirconia solutions. Contact us to discuss your application.

Understanding zirconia begins with recognizing what sets it apart from alternatives like alumina, magnesia, or silica-based refractories. The material’s unique crystalline structure can be manipulated through partial or full stabilization with compounds like magnesia, calcia, or yttria. This engineering flexibility allows manufacturers to dial in specific properties for demanding applications, from investment casting crucibles to precision grinding media.

We’re Your Zirconia Experts: Our specialists are here to help with material selection, custom solutions, and technical guidance for your specific applications.

The Core Benefits of Zirconia

Zirconia’s performance advantages derive from fundamental material properties that solve real industrial challenges. The material excels in four critical areas where conventional refractories and ceramics struggle.

Thermal shock resistance defines zirconia’s reputation in high-cycling applications. Unlike materials that crack when subjected to rapid temperature changes, zirconia maintains structural integrity through thermal cycles from room temperature to more than 1500°C in as little as 30 seconds. This property proves essential in investment casting operations where crucibles undergo repeated heating and cooling cycles, and in steel continuous casting where components face constant thermal stress.

Chemical inertness at extreme temperatures makes zirconia the go-to material for molten metal contact. The material resists corrosive attack from aggressive alloys, caustic slags, acids, and harsh atmospheres that would degrade standard refractories. Investment foundries melting superalloys, precious metal refiners processing platinum group metals, and glass manufacturers working with corrosive melts all rely on zirconia’s chemical stability.

Transformation toughening represents zirconia’s most elegant property. When subjected to fracture stress, the material undergoes a crystalline phase change that causes the stressed area to expand, effectively closing cracks before they propagate. This self-healing mechanism prevents catastrophic failure in components facing mechanical stress, thermal shock, or impact loading.

Superior thermal insulation delivers measurable energy savings. Zirconia provides up to five times the insulating value of alumina or magnesia backup materials, reducing heat loss through furnace walls and maintaining tighter temperature control. For operations running continuous high-temperature processes, this translates directly to reduced operating costs and improved thermal efficiency.

Zirconia Applications Across Critical Industries

Zirconia solutions address specific challenges in industries where material failure creates significant operational and safety risks.

Investment casting operations serving aerospace and industrial gas turbine manufacturers depend on zirconia crucibles for melting cobalt and nickel-based superalloys. These crucibles must deliver clean melts free from contamination while withstanding temperatures exceeding 1650°C and the corrosive nature of reactive alloys. Zirconia’s low wettability prevents alloy contamination while multi-use capability reduces operational costs compared to disposable crucible systems.

Steel production facilities use zirconia components throughout continuous casting systems. Tundish metering nozzles manufactured from various zirconia compositions enable casting times ranging from 8-12 hours up to 24+ hours depending on steel grade and operational requirements. Slide gate plate inserts provide the erosion resistance needed for challenging steel grades while reducing overall steelmaking costs through extended service life.

Glass manufacturing above 1900°C requires materials that maintain dimensional stability while resisting both thermal shock and chemical attack from molten glass. Zirconia brick, custom shapes, and castable materials create furnace linings that outperform traditional refractories, particularly in crown and superstructure applications where temperatures and corrosive atmospheres are most severe.

Precious metals processing demands materials that won’t introduce contamination during melting and refining operations. Zirconia crucibles engineered specifically for platinum group metals combine inertness to the melt with high-temperature capability, enabling clean processing of gold, silver, platinum, palladium, and other valuable metals.

Technical ceramics applications leverage fine-grain, fully-densified zirconia for grinding media, dispersion beads, extrusion dies, and wear-resistant components. The material’s exceptional hardness, wear resistance, and chemical stability enable processing operations that would quickly degrade alternative materials.

Tailored Solutions for Extreme Conditions

What distinguishes zirconia from commodity refractories is its engineerable nature. Manufacturers like Zircoa don’t simply supply standard products — they develop specific compositions optimized for individual applications. Partial stabilization with magnesia suits molten metal environments subject to extreme wear, while calcia stabilization performs better in continuous high-temperature cycling without metal contact.

The material takes three primary forms to address different operational needs. Coarse-grain specialty refractories engineered with controlled porosity balance thermal shock resistance with erosion resistance for furnace linings and metal contact applications. Dense technical ceramics manufactured from fine-grain compositions deliver impervious, wear-resistant surfaces for milling, grinding, and precision component applications. Granular products, including Zircoa’s proprietary A Grain zirconia powder, provide either raw materials for custom solutions or superior thermal insulation when used as backup material behind primary refractories.

Go Beyond Standard Materials With Zircoa

Industries facing extreme operating conditions can’t afford material failures that cause costly downtime, compromised product quality, or safety incidents. Zirconia bridges the gap between what standard materials can withstand and what advanced industrial processes demand, and Zircoa is proud to leverage our long-standing expertise with zirconia to find solutions for our customers.

The material’s seven decades of proven performance across diverse applications reflect both its technical capabilities and the specialized expertise required to properly specify, manufacture, and apply zirconia solutions. As industrial processes continue pushing temperature, purity, and efficiency boundaries, engineered zirconia compositions provide the foundation for reliable operations in conditions where failure isn’t an option.

Ready to solve your toughest high-temperature material challenges? Contact the Zircoa team to discuss how our specialty zirconium oxide solutions can deliver the thermal stability, chemical resistance, and operational reliability your specific application demands.

The Zircoa Supply Chain Code of Conduct will guide the way our supply chain partners play an active role in helping us achieve our goals.

Scope:

Zircoa requires all our directors, officers, and employees along with those working on our behalf to comply with all laws and to act ethically and with integrity. Our intent as a supply chain team is to only work with companies who understand and share our commitment to the principles outlined below.

Working together we will build a sustainable business relationship that will enable us all to be successful. We require our supply chain partners to adhere to these principles and to reflect these same principles upon their suppliers.

Policy Requirements:

Health, Safety, Security, Environment and Assurance (HSSEA)

Supply chain partners must:

• Comply with all applicable HSSEA laws, regulations, and industry requirements.
• Manage their operations so any potential negative impact to the environment or community is prevented or minimized where unavoidable.
• Provide a safe and healthy work environment for their employees and must provide adequate training, work procedures, and appropriate personal protective equipment.
• Provide a workplace that has suitable temperature, ventilation, lighting, and washing and sanitation areas appropriate for both genders.
• Where accommodation / housing is provided they must be safe, sanitary and meet the basic needs of the workers with regard to space, temperature, lighting, ventilation, food, water, privacy, affordability, and they must meet or exceed host country housing standards.
• Establish and maintain a management program that drives continual improvement in HSSEA performance and transparent reporting regarding health and safety incidents.

Ethics and legal requirements

Supply chain partners must:

• Disclose in advance any relationship with a Zircoa director, officer, employee, or person working with Zircoa that represents or might appear to represent a conflict of interest.
• Comply with all applicable anti-trust, competition laws and the anti-corruption laws including the UK Bribery Act 2010, the Criminal Finances Act 2017, the US Foreign Corrupt Practices Act and any similar local laws. Partners must also have in place adequate policies and procedures designed to effectively prevent bribery, corruption, and facilitation of tax fraud. The highest standards of integrity are expected in all transactions.
• Keep complete, accurate, and reliable records of all matters related to their business with Zircoa and provide copies of relevant records on request.
• Protect Zircoa’s confidential information and personal data and prevent its disclosure, theft, damage or unauthorized use.
• Notify Zircoa without undue delay after becoming aware of a personal data breach under the General Data Protection Regulation or other applicable local legislation.

Supply chain partners must not:

• Develop any relationship with a Zircoa director, officer, employee, or those working for Zircoa, whether financial or otherwise, which might conflict, or appear to conflict, with such person’s obligation to act in the best interest of Zircoa.
• Encourage or allow others to engage in any form of bribery, including the small payments often known as facilitation payments intended to improperly influence someone.
• Engage in tax evasion or facilitate the evasion of tax by any other party.
• Offer any incentive to any Zircoa director, officer, employee, or such person’s family or friends in order to obtain, retain, or influence Zircoa business.

Human rights and labor standards

Supply chain partners must:

• Comply with all applicable labor laws.
• Set working hours, wages, and overtime pay in compliance with all applicable laws. Workers shall be paid at least the legal minimum wage or a wage that meets local industry standards, whichever is greater. All wages and benefits should be paid in a regular, timely manner in accordance with law.
• Ensure all workers are provided with recruitment agreements and employment contracts in writing as required by applicable laws, in a language understood by them.
• Ensure the work relationship between their workers and their suppliers is freely chosen and free from threats and that all workers are free to have time off, or to leave their employment or work after giving reasonable notice in compliance with all applicable laws.
• Workers always have access to passports and personal documentation. Workers shall also have freedom of movement out with normal working hours, unless there are legitimate security or health and safety reasons that threaten the safety or the wellbeing of the worker.
• Comply with all applicable laws regarding harassment and abuse of employees.
• Employ workers based on their ability to perform the job, not based on their personal characteristics or beliefs (including race, color, gender, ethnicity, nationality, religion, sexual orientation, age, disability, maternity or marital status).
• Respect freedom of association and the right to collective bargaining. Where the right to freedom of association and collective bargaining is restricted under law, the employer must not hinder the development of parallel means for independent and free association and bargaining.
• Have adequate policies and reliable systems in place to prevent the use of illegally or unethically sourced materials, policies and systems to prevent improper procurement of conflict minerals also known as tantalum, tin, tungsten, and gold.
• Supply chain partners must make every reasonable effort to ensure that their sources are conflict free and be able to provide adequate verification if requested.
• Use recruiters that uphold and respect the standards contained in this Supply Chain Code and reflect best practices for recruiting in respect of human rights and labor standards.

Supply chain partners must not:

• Use any force, bonded, involuntary prison, or child labor.
• Subject their employees to psychological, verbal, sexual, or physical harassment or any other form of abuse.
• Use misleading or fraudulent practices during the recruitment of employees or offering of employment, such as failing to disclose or misrepresenting key terms and conditions of employment, including wages and benefits, the location of work, the living conditions, housing and associated costs, and any significant cost to be charged to the employee, and if applicable, the hazardous nature of the work.
• Use recruiters that do not comply with local labor laws.
• Charge employees for recruitment fees.
• Improperly retain workers’ identification documentation.

Compliance

Zircoa reserves the right to assess and monitor suppliers’ compliance with this Supply Chain Code of Conduct.

Supply chain partners must:

• Comply with the most demanding requirements, whether they are relevant applicable local and national laws and regulations, or the principles set out in this Supply Chain Code of Conduct, in the provision of materials or services to Zircoa.
• Implement systems and controls to ensure compliance with applicable laws and regulations and the principles set out in this Supply Chain Code of Conduct, including policies, training, monitoring, and auditing mechanisms designed to provide ongoing improvement and assurance of its effectiveness.
• Apply these or similar principles to the supply chain they work with in providing materials and services to Zircoa.
• Notify Zircoa of any alleged potential, suspected or actual breach of the law or the Supply Chain Code of Conduct.
• Provide a process for employees to report, without fear of retaliation, activity inconsistent with the content of this Supply Chain Code of Conduct – with reference to ethical business conduct, and human and labor rights.

Note: This Supply Chain Code of Conduct contains general requirements applicable to all Zircoa’s supply chain partners. Supply chain contracts may contain more specific provisions addressing some of the same issues. To the extent there is inconsistency between this Supply Chain Code of Conduct and any other provision of a particular contract, supply chain partners must comply with whichever provision is stricter. As a general matter, Zircoa expects supply chain partners to act not just in accordance with the specific provisions of this Supply Chain Code of Conduct, but also in accordance with its spirit.

Tim Leitzel
President

• A. Prompt acceptance of this order by signing and returning the acknowledgement copy hereof is requested but, in any event, any delivery hereunder shall constitute an acceptance hereof and of all its terms.B. This order is a final, complete and exclusive statement of the agreement between the parties and may not be modified, supplemented, explained or waived by parol evidence, Seller’s acknowledgements, a course of dealing, or in any other way except in writing signed by an authorized representative of Buyer. Any references in this order to seller’s proposal or quotation are only to describe the materials or work covered hereby and do not constitute as acceptance of any terms set forth therein.

  C. This order and the language herein shall be construed and enforced under the Uniform Commercial Code as in effect in the State of Ohio on the date hereof.

2. Performance by Seller

• A. Time is of the essence for this order and it is essential it be performed and filled on the specified date(s) and that the work progress in a timely fashion.
• B. Seller warrants that material and work furnished hereunder shall be of the highest grade and quality unless otherwise specified and shall meet all standards of the Occupational Safety and Health Act of 1970 (OSHA) and all applicable state and local safety and health requirements. At Buyer’s option any part of the material or work not complying with the requirements hereof, expressed or implied, may be returned, at Seller’s risk and expense including transportation both ways, for prompt correction of defects. Payment by Buyer shall not constitute acceptance or waive any rights of Buyer hereunder.C. This order is issued to Seller in reliance on Seller’s personal performance and Seller may not assign this order or the partial payment of any sums due hereunder or subcontract any substantial part of the performance or work other than for standard commercial supplies.

  D. Seller warrants that it shall comply with all applicable Federal, State and Local laws including the Fair Labor Standards Act of 1938, Executive Order 11246, Title VII of the Civil Rights Act of 1964, Section 503 of the Rehabilitation Act of 1973, Section 402 of the Vietnam Era Veterans Readjustment Assistance Act of 1974 and the Americans with Disabilities Act of 1990, including amendments and regulations issued pursuant thereto and this order hereby incorporates by reference all provisions required by said laws and regulations to be included herein.

  E. Seller agrees to exculpate, defend, indemnify and hold harmless the Buyer and its customers from and against all claims, liabilities, lawsuits, expenses (including attorney’s fees and other defense costs) and penalties, including those based on Buyer’s or its customer’s negligence, which arise, directly, out of any of the following (I) personal injury or death or property damage or destruction arising out of alleged defects in material, workmanship or design of the material or work furnished hereunder: (ii) violations of OSHA, state or local safety or health requirements arising out of the use or resale of material or work furnished hereunder, (iii) personal injuries or death of Seller’s agents, employees or subcontractor’s personnel and damage to or destruction of Seller’s or its subcontractor’s property; and (iv) the infringement by material or work furnished hereunder of any United States or foreign patent or trademark.

3. Certain Charges 0r Expenses Negated

• Unless otherwise specifically provided here (i) no charges for transportation, packing, crating, cartage, storage or containers shall be allowed, (ii) Seller shall pay and the price includes all applicable sales and similar type taxes which are not imposed by law on the Buyer and (iii) any information or data disclosed or furnished to Buyer by Seller hereunder shall be deemed sold as part of the price hereof, non-proprietary and free of all restrictions whatsoever.

4. Buyer’s Property

• A. Buyer retains title to all drawings, specifications and technical data furnished to Seller for use with this order and the same shall be treated as Buyer’s confidential information, shall be used by Seller only to complete this order and shall be returned upon completion or termination of this order, along with all copies or reproductions thereof, provided copies or reproductions shall be made only with Buyer’s written consent.
• B. All materials, including tools, special dies and patterns furnished or specifically paid for by the Buyer, shall be the property of the Buyer, shall be returned to Buyer when no longer required hereunder, shall be used only to complete this order and shall be segregated and clearly identified as property of the Buyer. Seller assumes all risk and liability for loss or damage thereto, except for normal wear, and agrees to permit inspection and supply detailed statements of inventory upon request of Buyer.

5. Changes

• Buyer may at any time by written notice make changes within the general scope of this order. If any such change affects the time for or cost of performance, an equitable adjustment shall be made in the delivery schedule, purchase price, or both by agreement of the parties. All claims by Seller for adjustment under this clause must be asserted in writing and in full within (30) days from the date of notification of the change or shall be waived. Nothing herein shall excuse Seller from proceeding with the order as changed. No extras shall be allowed except pursuant to written changes and this clause.

6. Termination

• A. Buyer may at any time terminate this order, in whole or in part, by written notice, whereupon Seller shall terminate work pursuant to the terms of such notice. Seller shall promptly advise Buyer of the quantities of applicable work and material on hand or purchased prior to termination and the most favorable disposition that Seller can make thereof. Seller shall comply with Buyer’s instructions regarding disposition of such work and material. All claims by Seller based on such termination must be asserted, in writing and in full, within ninety (90 days from the date of notification of the termination, or shall be waived. Buyer shall pay Seller the purchase order price of finished work and the cost to Seller (excluding profit or losses) of work in process and raw material; less however, (I) the agreed value of any items used or sold by Seller with Buyer’s consent, and (ii) the reasonable value or cost (whichever is higher) of any defective, damaged or destroyed work or material and any items sold or used by Seller without Buyer’’ consent. Buyer will make no payments for finished work in process or raw material fabricated or procured by Seller unnecessarily in advance or in excess of Buyer’’ delivery requirements. The payment provided under this clause shall constitute Buyer’s only liability in the event this order is terminated as provided herein. The foregoing provisions of this clause shall not apply to any termination by Buyer for default of Seller or under the following provisions of this clause unless a court shall find such termination by Buyer to be improper.
• B. To the extent this order covers items normally carried in inventory by Seller (as distinguished from items specially made to Buyer’s specifications), Buyer shall have no liability for any termination of this order, in whole or in part, prior to actual shipment and for any termination, within ten (10) days after receipt by Buyer its liability shall be limited to returning said items and reimbursing Seller for direct costs of handling and transportation.
• C. Buyer shall not be liable for failure to take delivery of material of work or render any other performance in the event for fire, accidents, labor difficulties, governmental actions, third party failures or any other conditions beyond Buyer’s reasonable control render it commercially impractical for Buyer to do so.

7. Government Contracts

• If this order is for material or work under a government contract or subcontract, all contract provisions applicable hereto and required by law, order regulations or Buyer’s government contract or subcontract are hereby incorporated herein by reference as fully as if set forth herein in full. Where necessary to make the context of such provisions or clauses applicable to this order, the term “Contractor”, “Contract”, and “Government” or “Contracting Officer” (or terms of similar import) shall mean respectively Seller, this order, and Buyer.

8. Notice

• Zircoa inc. values highly the confidence and good will of its customers and suppliers. We offer our products only on their merit, and we expect our customers to judge and purchase our products and services solely on the basis of quality, price, delivery and service. Likewise, Zircoa Inc. buys only on merit, and we judge and purchase solely on the basis of quality, price, delivery and service. Zircoa Inc. corporate policy applies in all relationships with our customers and suppliers.

We reserve the right to increase the sale price and amend the terms and conditions of sale for the goods covered hereby at any time prior to the expected shipment date, unless Buyer has requested a later shipment date, then such right is reserved to that date, provided that written notice of such price increase is sent to Buyer at least 30 days prior to shipment. Buyer shall be deemed to have accepted the increase unless at least 5 working days prior to the date of expected shipment (or Buyer’s requested shipment date, if later) Buyer cancels the order or furnishes evidence to us that Buyer is able to purchase from another Seller, goods of similar quality, in similar quantities and under like terms and conditions, at a lower delivered price than our price as increased, in which case we may elect to meet such price or cancel the order.

We reserve the right to over or under ship quantities of made-to-order goods by up to 10% of the order quantity or 5 pieces, whichever is greater, unless otherwise noted on the face of the SOA.

All prices are in U.S. Dollars, FCA Free Carrier, Incoterms® 2010 (ICC Pub. No. 715E). Any taxes relating to the sale of products (such as sales, use, VAT, GST) are NOT included in prices and, as needed, will be invoiced separately for payment by Buyer. If it is agreed that Buyer will designate the freight forwarder, Incoterms® 2010 FCA Solon, Ohio USA, shall be applied. We will ship products according to our standard practices. Special packing or shipping instructions must be agreed upon, and all related charges will be billed separately to Buyer. Title to the products will pass to Buyer only when the purchase order and all related expenses have been paid in full

Shipping dates are approximate and acceptance of the goods by Buyer shall constitute a waiver of all claims due to delay in delivery; and failure to make any one or more shipments when due if caused by any one or more but not limited to any of the following: fire, storms, floods, strikes, lockouts, accidents, war, riots, or civil commotions, inability to obtain shipment space or raw material, government regulations, or any other cause or contingency beyond our reasonable control (whether or not of the same kind of nature as the causes or contingencies above enumerated) shall not subject us to any liability. No claim relating to quantity, weight, condition, loss or damage to the goods made by Buyer will be accepted by us after thirty (30) days from the arrival of such goods at Buyer’s location.

For a period of one (1) year from the date of shipment, we warrant our goods to meet our published specifications and to be free from defects in materials and workmanship as defined in the specifications or, if not so defined, normally supplied by us for the goods. We make no guarantee of the results to be obtained from the use of our goods.

Provided a claim under the above express warranty is made within one (1) year from the date of shipment of the goods for which the claim is made, and provided the failure to conform to the above warranty is shown to our satisfaction, we will repair or replace such goods, FOB Solon, Ohio, USA Incoterms® 2010. All goods not manufactured by us shall carry only the warranty and remedy provided by the manufacturer thereof.

We warrant freedom from patent infringement only on those goods comprising our regular line of goods and only when used for normal purposes in the form in which sold by us. We make no warranty with respect to patents covering composite structures or systems into which such items may be incorporated by Buyer. Buyer assumes all liability for and will hold us, our employees and agents, harmless from any and all patent liability in connection with any goods manufactured to Buyer’s designs or specifications or specifically designed by us or our suppliers to meet Buyer’s requirements.

Our liability for claims of breach of warranty, whether based on warranty, contract, tort, negligence, strict liability, indemnification, or otherwise, shall be limited to replacement of the goods, or issuing a credit or refund up to the full purchase price of the goods affected, as decided in our sole discretion. Our selection of one of these alternatives shall be Buyer’s exclusive remedy. WE SHALL NOT BE LIABLE FOR ANY INDIRECT, INCIDENTAL, CONSEQUENTIAL, SPECIAL, PUNITIVE, OR EXEMPLARY DAMAGES OF ANY KIND, WHETHER BASED ON WARRANTY, CONTRACT, TORT, NEGLIGENCE, STRICT LIABILITY, INDEMNIFICATION, OR OTHERWISE, INCLUDING, BUT NOT LIMITED TO, LOSS OF PROFITS OR REVENUE OR BUYER’S LOSS OF PRODUCTION, COSTS OF SUBSTITUTE PRODUCTS, DELAYS, BUSINESS INTERRUPTIONS, CLAIMS BROUGHT AGAINST BUYER BY THIRD PARTIES, OR LOSS OF OR DAMAGE TO PROPERTY OR EQUIPMENT OTHER THAN THE DELIVERED GOODS, EVEN IF WE HAVE BEEN ADVISED IN ADVANCE OF THE POSSIBILITY OF SUCH LOSSES OR DAMAGES.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE AND OF ALL OTHER OBLIGATIONS OR LIABILITIES THAT WE MAY HAVE AND WE DO NOT ASSUME OR AUTHORIZE ANY OTHER PARTY TO ASSUME FOR US ANY OTHER LIABILITY IN CONNECTION WITH THE SALE OF GOODS WE MANUFACTURE.

Buyer assumes all risks, liabilities arising from unloading, discharge, storage, handling, and use of the goods, including use of such goods alone or in combination with other substances and equipment. Buyer assumes full responsibility for compliance with Governmental laws, rules and regulations governing unloading, discharge, storage, handling and use of the goods.

Charges included for tools in “Engineering and Set Up Charges” herein are based on the manufacture of products in quantity as specified in Buyer’s order. Unless changes are made in design, specifications, and the like, these charges will be made on the first order only. We retain title to all tools and will keep them in repair and make necessary replacements without additional charge. Tools may be scrapped three (3) years from the date of last order unless special arrangements are made.

Our obligations under these Terms are subject to the applicable laws and regulations of the United States of America and the European Union, including any U.S. economic sanctions policy promulgated by Executive Order, the interpretation of the applicability of which shall be in our sole discretion.

Buyer warrants and represents that it is familiar and will comply with the requirements of the U.S. Foreign Corrupt Practices Act, the UK Bribery Act, the OECD Antibribery Convention, and similar national laws that may apply to Buyer or our sale of the goods to Buyer.  Buyer further warrants and represents that it is familiar and will comply with U.S. laws, regulations, and executive orders, including but not limited to the Export Administration Regulations, the antiboycott and embargo regulations (including the avoidance of transactions with any party listed on the “Denied Persons List”, the “Denied Parties List” and the “Specially Designated Nationals” list maintained by the Department of Commerce and the Department of the Treasury, Office of Foreign Assets Control), and the International Traffic in Arms Regulations. Buyer agrees to indemnify and hold us harmless from and against claims, fines, penalties, settlements, assessments, damages, costs and expenses (including attorney fees) that may be incurred due to Buyer’s failure to comply with such laws and regulations.  Buyer will cooperate with us in obtaining appropriate export licenses for the goods and will submit all documents we request for that purpose.  If Buyer exports the goods, Buyer assumes responsibility for obtaining any required export and import authorizations and will not export the goods or any technical data in violation of applicable export laws, regulations, or orders, including diversion or transshipment of the goods.  Buyer agrees to include these requirements in any contracts for the resale of the goods.

Without regard to any conflict of law rules, these Terms shall be governed by, and construed according to the laws of the State of Ohio, including its statutes of limitations, and the United Nations Convention on Contracts for the International Sales of Goods, when applicable to Buyer’s purchase of the goods.  Any controversy or claim arising out of or relating to these Terms shall be resolved by final and binding arbitration in accordance with the International Arbitration Rules of the International Centre for Dispute Resolution.  The seat of the arbitration shall be Cleveland, Ohio, USA and the arbitration shall be held before a single arbitrator who is a national and active member of a bar of the U.S. Buyer agrees to waive any sovereign immunity claims or defenses.  All arbitration proceedings shall be conducted in English and all monetary awards shall be made in U.S. Dollars.

We reserve the right to increase the sale price and/or amend the terms and conditions of sale for the goods covered hereby at any time prior to the expected shipment date, unless Buyer has requested a later shipment date, then such right is reserved to that date, provided that written notice of such price increase is sent to Buyer at least 30 days prior to shipment. Buyer shall be deemed to have accepted the increase unless at least 5 working days prior to the date of expected shipment (or Buyer’s requested shipment date, if later) Buyer cancels the order or furnishes evidence to us that Buyer is able to purchase from another Seller, goods of similar quality, in similar quantities and under like terms and conditions, at a lower delivered price than our price as increased, in which case we may elect to meet such price or cancel the order.

We reserve the right to over or under ship quantities of made-to-order goods by up to 10% of the order quantity or 5 pieces, whichever is greater, unless otherwise noted on the face of the SOA.

Unless otherwise specifically stated on the face of the SOA, title and possession of all goods shall pass to Buyer upon delivery to the carrier at the point of shipment. We, therefore, do not assume any liability for loss or damage to the goods after the shipment is delivered to the carrier.

Shipping dates are approximate and acceptance of the goods by Buyer shall constitute a waiver of all claims due to delay in delivery; and failure to make any one or more shipments when due if caused by any one or more but not limited to any of the following: fire, storms, floods, strikes, lockouts, accidents, war, riots, or civil commotions, inability to obtain shipment space or raw material, government regulations, or any other cause or contingency beyond our reasonable control (whether or not of the same kind of nature as the causes or contingencies above enumerated) shall not subject us to any liability. No claim relating to quantity, weight, condition, loss or damage to the goods made by the Buyer will be accepted by us after thirty (30) days from the arrival of such goods at the Buyer’s location.

We warrant our goods to meet our published specifications and to be free from defects in materials and workmanship as defined in the specifications or, if not so defined, normally supplied by us for the goods. We make no guarantee of the results to be obtained from the use of our goods.

Provided a claim under the above express warranty is made within one (1) year from the date of shipment of the goods for which the claim is made, and provided the failure to conform to the above warranty is shown to our satisfaction, we will repair or replace such goods, F.O.B. our plant. All goods not manufactured by us shall carry only the warranty and remedy provided by the manufacturer thereof.

Our liability under this contract or otherwise shall be limited to replacement of, or refund of, and amount not to exceed the purchase price attributable to, the goods as to which such claim is made. Our selection of one of these alternatives shall be Buyer’s exclusive remedy. IN NO CASE WILL WE BE LIABLE FOR CONSEQUENTIAL INCIDENTAL OR SPECIAL DAMAGES EVEN IF WE HAVE BEEN ADVISED OF THE POSSIBILITY OF SUCH DAMAGES.

We warrant freedom from patent infringement only on those goods comprising our regular line of goods and only when used for normal purposes in the form in which sold by us. We make no warranty with respect to patents covering composite structures or systems into which such items may be incorporated by Buyer. Buyer assumes all liability for and will hold us, our employees and agents, harmless from any and all patent liability in connection with any goods manufactured to Buyer’s designs or specifications or specifically designed by us or our suppliers to meet Buyers requirements.

THE FOREGOING WARRANTIES ARE IN LIEU OF ALL OTHER WARRANTIES EXPRESSED OR IMPLIED, INCLUDING, BUT NOT LIMITED TO, THE IMPLIED WARRANTIES OF MERCHANTABILITY AND FITNESS FOR A PARTICULAR PURPOSE.

Buyer assumes all risks, liabilities arising from unloading, discharge, storage, handling, and use of the goods, including use of such goods alone or in combination with other substances. Buyer assumes full responsibility for compliance with Governmental laws, rules and regulations governing unloading, discharge, storage handling and use of the goods.

By accepting Buyer’s purchase order, we intend to accept only those terms and conditions which are required to be included in its subcontract by the terms of Buyer’s prime contract with the United States government and no others. We accept no terms or conditions with respect to adjustment of price, patent warranty or licenses, warranty, limitation of liability or special tooling except as appear herein unless the subject of a separate letter specifically accepted by us in writing.

Charges included for tools in “Engineering and Set Up Charges” herein are based on the manufacture of products in quantity as specified in Buyer’s order. Unless changes are made in design, specifications, etc., these charges will be made on the first order only. We retain title to all tools and will keep them in repair and make necessary replacements without additional charge. Tools may be scrapped three years from the date of last order unless special arrangements are made.

The terms of the SOA and this Document shall prevail notwithstanding any variance with the terms and conditions of any present purchase order from Buyer and supercede all previous communications, quotations or understandings, whether written or oral.

This agreement will be governed by the laws of the United States of America and the State of Ohio.

We hereby certify that in the production of the goods and/or the performance of the services covered by the SOA we have complied with all applicable requirements of Section 6, 7 and 12 of the Fair Labor Standards Act as amended and regulations and orders of the United States Department of Labor issued under Section 14 thereof we acknowledge our obligations under Title VII of the Civil Rights Act of 1964 and under the Equal Opportunity clause In Section 202 thereof; Paragraphs 1 through 7 of Executive Order 11246 dated September 24,1965, as amended and relating to equal employment opportunity; and the implementing rules and regulations of the office of Federal Contract Compliance.

The absence of a name or logo in this list does not constitute a waiver of any and all intellectual property rights that Zircoa, Inc. has established in any of its product, feature, or service names or logos.

Please contact us before using any of these trademarks in commerce.

Name or Mark	Status	Descriptor
DenZbor	TM	Product
Mill Mates	®	Product
Mill Mates Plus	TM	Product
Zbor	TM	Product
Zirbeads	TM	Product
Zircoa	®	Company Name, Product
	®	Company Name, Product
Zircoa Cast	TM	Product
Zycron	®	Product
	TM	Icon representing Company or Product

All other trademarks remain the property of their registered owners.

For immediate delivery we inventory the most common crucible sizes, with configurations to suit your particular needs. For more detailed information on available compositions, chemical analysis, physical properties and links to MSDS, please visit our Crucible Homepages (below).

Zirconia Crucibles

Trust Zircoa for a High-Temperature Crucible with Superior Melting and Casting Performance Crucibles are one of the most critical parts in melting and casting processes, and zirconia crucibles offer superior performance and durability for many alloy types compared to alternative …

Alumina Crucibles

Engineered Alumina Crucible Solutions with Premium Manufacturing Quality While many suppliers offer basic alumina crucibles as simple one-shot liners, Zircoa combines cost-effective alumina material with our premium manufacturing processes and quality management systems. Our Composition 6105 alumina crucibles are hydraulically …

Specifications

PDF Data Sheets for Compositions – To open the PDF, click the composition number you are interested in.

Engineering Drawings – To request an engineering drawing via email, click the Part Number of the crucible you are interested in.

Alternative Compositions – Crucibles can be produced in any of the available compositions. Click “info” to inquire about an alternative composition for any crucible listed below.

(a) * 1″ (25 mm) below the lip of the crucible using carbon steel, density of 0.280 lbs/in³ (7.8 g/cm³), at room temperature density.

(b) Features Legend

For Even Longer Crucible Life

Extend the life of your furnace, and maintain tighter control over your furnace temperatures with Zircoa’s pre-sintered grog refractory backup .

• Zircoa Backup 1859 — Partially stabilized with magnesia and calcia. Available in -8 + 100 Tyler mesh size.
• Zircoa Backup 3001 — Partially stabilized with magnesia. Available in -8 + 28 Tyler mesh size.

To Use the Calculator

Microsoft Excel is required to view and use the calculator.

• Open Calculator in a New Window
• Select: “Open” (if prompted.)

A. From the alloy pull-down list, select the alloy you wish to use. The density of the alloy you select will show up in the alloy density slot to the right.

B. When this happens you will note that “Pounds Full” and “Capacity 1″ below Lip” data will change automatically. By following down the “Capacity 1″ below lip” data, you will find the crucible that will hold the desired amount of alloy.

C. If you wish to have more space at the top of the crucible than 1″, you may do that by changing %fill at the top of the list. If you want the crucible to be 60% full, change the 100% to .60 and the “Pounds Full” column will then indicate which crucible will hold the desired amount.

D. For a special alloy that is not on the pull-down list, you may add the density you need by selecting “User Input Density” from the alloy pull-down menu. Once you make the selection, you will need to enter the known density into the “User Input Density” slot to the right.

E. Once that is done you will note the changes that appear on the individual size listings.

Please Note: We intend this to be a reliable guide, but we do not guarantee the applicability, completeness, or accuracy of the information. Users should make their own tests to determine suitability for their application.

Use the table below to determine the quantity of Zircoa’s 2″ high arch and straight bricks required to construct 6″ to 72″ diameter rings. For detailed information on Calcia or Yttria stabilized Zirconium Oxide pressed or tongue and groove refractory brick, please visit our refractory brick homepage.

#3 Arch

#2 Arch

#1 Arch

Straight

* ring to brick diameter variation: +/- 2%

By accessing or using this Website (https://www.zircoa.com) you agree to the Terms of Use as outlined below. If you do not agree to these terms, please do not access or use this site. Zircoa Inc. reserves the right to change the Terms of Use from time to time at its sole discretion. Your use of this Website will be subject to the most current version at the time of such use.

Legal Notice

Recommendations, property values, and application information we publish are based on various sources including measurements by us and others, and estimates of experience. We intend this to be a reliable guide, but we do not guarantee the applicability, completeness, or accuracy of the information. Users should make their own tests to determine the suitability of any product for their application.

Errata

This Website may include technical inaccuracies, typographical errors that will be corrected as they are discovered, or reported, at our sole discretion.

Other Websites

Zircoa Inc. is not responsible for the Terms of Use, and makes no representations whatsoever about other Websites to which we may link, including but not limited to Websites that may contain a link to, or information about Zircoa Inc.

Broken Links

Please report any broken links to our Webmaster. Although we appreciate your assistance in this regard, we make no guarantee that a broken link can be repaired, or will be replaced with a similar link.

Copyrights, Trademarks & Service Marks

This Website contains copyrighted material, trademarks, service marks and other proprietary information. Zircoa Inc. claims copyright to the selection, coordination, arrangement and enhancement of such content, as well as in the content original to it.

All other Websites own the copyright in content original to them. our use of same does not in any way, suggest endorsement of any kind whatsoever, by said owner(s).

Except as otherwise expressly permitted under copyright law, you may not copy, redistribute, publish, display or commercially exploit any material from this Website without the express permission of Zircoa Inc., or the third party copyright owner.

All trademarks and service marks displayed on this Website remain the property of the registered or otherwise owner(s). You acknowledge that you do not acquire any ownership rights by downloading any copyrighted material.

Disclaimer of Warranty

This Website and the information, names, images, pictures, logos and icons regarding or relating to products and services and links to any other Service, or other Website content, are provided on an “AS IS” and “AS AVAILABLE” basis without any representation or endorsement made and without warranty of any kind, whether expressed or implied, including, but not limited to the implied warranties of merchantability, fitness for a particular purpose or non-infringement. In no event will Zircoa Inc., its parent company, subsidiaries, affiliates, contractors or their respective employees or agents, be liable for any damages whatsoever, whether in an action of contract, negligence or other cause of action or theory of recovery whatsoever, arising out of or in connection with the use or performance of this Website, including without limitation, Internet failures, computer equipment failures, telecommunication equipment failures, other equipment failures, electrical power failures, special, indirect or consequential damages resulting from loss of use, data or profits or otherwise, even if we are expressly advised of the possibility of such damages.

Governing Law

This agreement shall be governed and interpreted under the laws of the State of Ohio, USA, as now or hereafter may be in existence.

Customer acknowledges and understands and agrees that this agreement shall be construed and enforced under the laws of the State of Ohio, USA. Customer represents that Customer understands that Ohio courts are best suited for both interpretation and enforcement of Ohio law. Customer further acknowledges that Zircoa Inc. is located in Cuyahoga County, Ohio, USA and that the Customer is aware of the exact geographic location of Cuyahoga County within the state of Ohio, USA.

Customer further acknowledges that the agreement is both factually and legally made in Cuyahoga County, Ohio, USA. Customer further understands that any litigation may require that the customer pay for the costs and expense of witnesses, travel, lodging, meals, attorneys fees and other unknown amounts necessary for the Customer to maintain any litigation. Customer accepts the responsibility of bearing all of the above costs and any other necessarily and properly related thereto as part of the costs and economic burden of conducting business.

As a consequence of understanding all of the above, Customer agrees and understands that any litigation commenced to enforce any term, condition, obligation, right or responsibility stated or implied above shall be brought in Cuyahoga County, Ohio, USA.

Posted: 2002 08-01

Privacy text © 2001 RBR Associates, all rights reserved. Used with permission.

By accessing or using this Website (https://www.zircoa.com) or by engaging with our sales team, you agree to the Privacy Policy as outlined below. This Privacy Policy explains when, why, and how Zircoa Inc. (“Zircoa,” “we,” “our,” or “us”) collects, uses, and stores personal information about persons who visit this Website and engage with our sales team. If you do not agree to these terms, please do not access or use this Website. Zircoa reserves the right to change the Privacy Policy from time to time at its sole discretion. Your use of this Website will be subject to the most current version at the time of such use. All changes are effective as soon as they are posted. Your continued use of the Website following updates to the Privacy Policy constitutes your acceptance and agreement to be bound by the updated Privacy Policy. If you do not consent to the collection and use of your information in accordance with this Privacy Policy, please follow the instructions below in “Changing Your Privacy Preferences” and do not access or use this Website thereafter.

Collection of Personally Identifiable Information or Personal Data

When you engage in certain activities on this Website we may ask you to provide certain information about yourself by filling out and submitting an online form. These forms are provided for your convenience. When you elect to submit any of our forms you will be required to provide personally identifiable information or personal data. We use this information solely for the purpose(s) described in the form. You will not be contacted as a result of submitting any of these forms for any reason other than as stated on the form. Your submission of these forms is interpreted as your explicit consent to our processing of your personal data for the purposes described herein. If you require the assistance that any of our forms provide but do not wish to submit personal information online, please call our offices for assistance:

• Monday – Friday, 8:00 AM – 5:00 PM U.S. Eastern Time
• +1-440-248-0500

When you engage with our sales team, our team members may collect personally identifiable information or personal data about you in connection with purchase orders and sales reports for the purpose of recording your purchase history and enhancing your customer experience.

Type of Information Collected

We may collect personally identifiable information or personal data from you such as your first and last name, e-mail address, telephone number, IP address, information regarding the pages you accessed and when, and other identifying information that may be necessary in order to communicate with you and record and support your participation in the activities you select. It is completely optional for you as to whether you engage in these activities. Depending upon the activity, some of the information that we ask you to provide is mandatory for you to continue with that activity and some is voluntary. If you decline to provide information to us, or if you provide erroneous or incomplete information, it may not be possible for you to gain access to certain parts of the site or for us to respond to your inquiries.

If you choose to purchase a product from us, we or our third-party payment processors will collect your payment information. This payment information will not be used for any purpose other than processing the purchase you have made.

Use of Collected Information

Zircoa may use your information to process orders that you have submitted; to carry out our obligations arising from any contracts entered into by us to provide you with our services and products; seek your feedback or comments on the services and products we provide in order to improve those services; notify you of changes to our services; send you communications which you have requested and that may be of interest to you with respect to Zircoa, our products, and services. Zircoa Inc. will not rent or sell your personally identifiable information or personal data to others but may share information with our third-party service providers and vendors for purposes of completing certain tasks and providing services and products to you on our behalf. We may share your information for the purposes of administering this website, providing customer support, or transferring information in the event of a sale, merger, or consolidation of our business. When Zircoa does use third party service providers, we disclose only the personal information that is necessary to deliver the service. We may also share your information to the extent that it is required by law.

When you submit personal information to Zircoa Inc. through this Website or through engagement with our sales team, you understand and agree that this information may be transferred across state or national boundaries and may be stored and processed in any of the countries and locations in which Zircoa Inc., its parent company, affiliates, subsidiaries and trusted vendors maintain web servers or offices, including, without limitation, the United States. You also acknowledge that in certain locations or with respect to certain activities, the collection, transferring, storage and processing of your information may be undertaken by trusted vendors of Zircoa Inc.

International Privacy Laws

Zircoa Inc. processes personal information both as a Processor and as a Controller as defined in the General Data Protection Regulation (Regulation EU 2016/679). If you are visiting our Website from outside the United States, please be aware that you are sending information to the United States where our servers are located and that by using our Website and providing us with your data you are consenting to such a transfer. That information may then be transferred within the United States or back out of the United States to other countries outside of your country of residence, depending on the type of information. These countries (including the United States) may not necessarily have data protection laws as comprehensive or protective as those in your country of residence; however, our collection, storage, and use of your information will at all times continue to be governed by this Privacy Policy.

Notices

Zircoa acts as both the processor and controller where the GDPR is concerned. You may contact Zircoa directly via email at TLeitzel@Zircoa.com. You may also send a traditional letter to the address listed at the end of this policy.

Zircoa is not required to appoint a DPO under the current law, although appropriate safeguards are in place to protect or disguise all personal data in its possession.

Personal data will not be processed without explicit consent from the data subject. These data will be processed for the reasons listed above.

Zircoa may share personal data collected as outlined in the paragraph titled “Use of Collected Information” above. These recipients include, but are not limited to, Zircoa Inc., its parent company and affiliates, and trusted vendors. These parties compliant with the GDPR to the extent that Zircoa understands it.

Subjects for which Zircoa collects personal data have the right to request access to their personal data, the purposes of the processing of their data, what categories of data Zircoa possesses, how Zircoa came to possess that data, how long Zircoa will store that data and what criteria Zircoa will use for the destruction of that data, if the data have been shared, and what safeguards were in place if the data were transmitted to a 3rd country. Data subjects have the right to request that Zircoa modify, erase, or restrict or object to the use of any of the personal data that Zircoa have on them at any time. A data subject may request that Zircoa transfer their personal data to another controller if this transfer proves to be technically feasible. These requests will be handled free of charge to the data subject.

A data subject may lodge a complaint with a supervisory authority if their request is not handled within 30 days of our receipt of their request.

These notices apply whether Zircoa has obtained personal data directly from the data subject, or the data were obtained from a third party.

Should a data subject choose to file a complaint they may do so by contacting the Hessian data protection officer or, if in the United States, the State Attorney General’s office for Ohio. Their contact information follows:

Information Retention, Protection, and Other Websites

Data submitted through this website will be retained in principal for 10 years and shall only be used for the business purposes for which it was submitted. Data collected shall be periodically reviewed for continued relevance and shall be purged when no longer relevant for the reason it was submitted.

Zircoa Inc. recognizes and appreciates the importance of responsible use and protection of your information, and has implemented appropriate physical, technical, and managerial safeguards to protect your information, but no method of transmission over the Internet or method of electronic storage is 100% secure. Therefore, we cannot guarantee its absolute security.

Zircoa Inc. is not responsible for the privacy statements of other Websites to which we may link, and makes no representations whatsoever about other websites, including but not limited to Websites that may contain a link to, or information about Zircoa Inc. You should examine the privacy statements posted on those third-party websites to understand their procedures for collecting, using, and disclosing personal information. This Website may incorporate Google Maps and YouTube videos. If you are logged in to your Google or YouTube account and access any page on this Website containing a Google map or a YouTube video, that usage will be logged to your Google account profile and may be used by them elsewhere for purposes beyond our control. To avoid this inadvertent use, please always log out of these accounts before clicking any such features on this Website. This Website cannot control your logged-in status with Google or YouTube or other such sites and has no access to or control over that information.

Use of Cookies

With this cookie policy, the website operator informs the user of the website about the use of cookies or similar storage technologies (hereinafter referred to as “cookies”) on this website.

What are cookies?

Cookies are small text files that are stored by the web browser on the user’s device for storing certain information. The next time you visit our website using the same device, the information stored in cookies will be returned to our website (“First Party Cookie”) or another website to which the cookie belongs (“Third Party Cookie”).

The information stored in the cookie and returned by the respective website recognizes that the user has already accessed and visited it using the web browser of their device. We use this information to optimally display the website to the user according to their preferences.

However, only the cookie itself on the terminal is identified here. Any further storage of personal data will only take place if the user gives us his explicit consent or if this storage is absolutely necessary in order to use the offered and called service.

Consent to the use of cookies

Cookies, which are not absolutely necessary to make the services available on this website, are only used after the consent. By continuing to actively use this website after the display of the cookie banner, the user consents to the use of cookies.

The cookie settings can be customized by the user at any time, for example by activating or deactivating individual cookie categories.

How the user generally deactivates or can delete cookies in his browser (including the strictly required cookies) is described under “deactivating or deleting all cookies”.

Categories of used cookies

Depending on the purpose and function, we divide the cookies used by the website into the following categories:

• Absolutely necessary cookies;
• Functional cookies;
• Performance cookies;
• Marketing / Third Party / Approved Cookies

ESSENTIAL COOKIES

Absolutely necessary cookies ensure that this website or service works properly. This means that without these cookies, this website, or the service, can not be used as intended. This type of cookie is used exclusively by the website operator (First Party Cookies) and all information stored in the cookies is only sent to this website.

The following strictly required cookies are used on our website:

The use of strictly necessary cookies on this website is possible without the consent of the user. For this reason, essential cookies can not be disabled or activated individually. This feature is only available for cookies that require consent, such as Functional Cookies, Performance Cookies, and Marketing / Third Party / Approval Cookies. However, the user always has the option of generally deactivating cookies in his browser (see point “Disabling or deleting all cookies”).

The legal basis for the use of the First Party Cookies is a legitimate interest (ie interest in the analysis, optimization and economic operation of this website and services) within the meaning of Art. 6 (1) sentence 1 lit. f DSGVO.

FUNCTIONAL COOKIES

Functional cookies allow this website, information provided, such. For example, the user name or the language selection to save and provide the user based on improved and personalized features. These cookies collect and store only anonymized information.

The following functional cookies are used on our website:

The user can object to the use of Functional Cookies at any time by adjusting his cookie settingsaccordingly.

The legal basis for the use of functional cookies is a legitimate interest (ie interest in the analysis, optimization and economic operation of this website and services) within the meaning of Art. 6 (1) sentence 1 lit. f DSGVO.

PERFORMANCE COOKIES

Performance cookies collect information about how our websites are used to improve their attractiveness, content and functionality. These cookies help us determine, for example, whether and which subpages of our website are visited and what content users are particularly interested. We record the number of visits to a page, the number of pages visited, the time spent on our website, the order of pages visited, which search terms our users have brought to us, the country, the region and, if applicable, the city of the Access, as well as the proportion of mobile devices that access our web pages.

The user of the website also has the right, for reasons that arise from his particular situation, in the processing of personal data related to him for statistical purposes gem. Art. 89 para. 1 GDPR is to be contradicted. In order to exercise these and other data subjects’ rights, a data subject can turn to the contact address specified in the imprint or in the privacy policy at any time.

The following performance cookies are used on our website:

The user of the website may at any time object to the use of performance cookies by adjusting his cookie settings accordingly.

The legal basis for the use of performance cookies is a legitimate interest (ie interest in the analysis, optimization and economic operation of our website and services) within the meaning of Art. 6 (1) sentence 1 lit. f DSGVO.

MARKETING / THIRD PARTY / APPROVED COOKIES

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Privacy Policy for the web analytics service Google Analytics

This website uses Google Analytics, a web analytics service provided by Google Inc. (“Google”). Google Analytics uses so-called “cookies”, text files that are stored on your computer and that allow an analysis of the use of the website by you. The information generated by the cookie about your use of this website is usually transmitted to a Google server in the USA and stored there. We have activated IP anonymization. Google’s IP address on this website is therefore shortened beforehand within member states of the European Union or other parties to the Agreement on the European Economic Area. Only in exceptional cases will the full IP address be sent to a Google server in the US and shortened there. On behalf of the operator of this website, Google will use this information to evaluate your use of the website, to compile reports on website activity and to provide other services related to website activity and internet usage to the website operator. The IP address provided by Google Analytics as part of Google Analytics will not be merged with other Google information. You can prevent the storage of cookies by a corresponding setting of your browser software; however, we point out that in this case you may not be able to use all the functions of this website in full. You may also record the data generated by the cookie and related to your use of the website (https://tools.google.com/dlpage/gaoptout?hl=en).

Information about data processing in connection with Google Analytics

This website uses Google Analytics, a web analytics service provided by Google Ireland Limited. If the person responsible for data processing on this website is located outside the European Economic Area or Switzerland, then Google Analytics will be processed by Google LLC. Google LLC and Google Ireland Limited are hereinafter referred to as “Google.”

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Google Analytics is used exclusively with the extension “_anonymizeIp ()” on this website. This extension ensures anonymization of the IP address by shortening and excludes a direct personal reference. The extension truncates Google’s IP address within member states of the European Union or other parties to the Agreement on the European Economic Area. Only in exceptional cases will the full IP address be sent to a Google server in the US and shortened there. The IP address transmitted by Google Analytics within the context of Google Analytics will not be merged with other data provided by Google.

On behalf of the site operator, Google will use the resulting information to evaluate the use of the website, to compile reports on website activity and to provide other services related to website activity and internet usage to the site operator (Art. 6 (1) lit. DSGVO). The legitimate interest in data processing lies in the optimization of this website, the analysis of the use of the website and the adaptation of the content. The interests of the users are adequately protected by the pseudonymization.

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Our webserver automatically records certain information about each visit to the Website. This information does not track visitors, is not attributable to an individual, and is not merged with other data sources.

Other information may be collected through your use of the Website via cookies and Google Analytics. Cookies are used to collect some non-personally identifiable information such as anonymous usage data, browser and platform types and versions, and number of clicks.

The coding method we utilize with Google Analytics generates data that does not personally identify you. The code includes “anonymize_ip,” which abbreviates the IP address reported when you are visiting the Website. The abbreviated IP address prevents Google from individually identifying your visit to this Website.

Forms you submit to us may also automatically log this information as well as the date and time the form was submitted. The collected information is used to provide an overview of how and where people are accessing and using the Website in order to improve and optimize the Website and for security purposes. It is not used for any additional purpose. Under no circumstances does Zircoa Inc. use this information to identify you personally. We reserve the right to provide aggregate data to third parties for statistical analysis. Such data will not be linked to any particular individuals or contain personally identifiable information.

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You may indicate your desire to change your privacy preferences at any time. You have the right to request access to, correct, or delete the information that Zircoa Inc. has about you. You can contact us at any time to request access to, correct, or delete any information that Zircoa Inc. has about you. In order to comply with your request, we may ask you to verify your identity. Please include your name, address, and/or e-mail address when you contact us, with as much detail as possible regarding the change you wish to make. Direct your request to the address listed in the “Contact Us” section of this Privacy Policy below.

Please note that we will acknowledge and follow any changes to your privacy preferences as of the date of the creation of this policy but may not be able to implement such changes with respect to information that Zircoa Inc. has already used or transmitted in the past based on its reliance of your prior preferences.

Contact Us

If you have any questions about this Privacy Policy or our treatment of your personal information, please write to:

Zircoa Inc.
Internet Privacy
31501 Solon Rd.,
Solon, OH 44139-3526

Zircoa manufactures three distinct categories of zirconia products, each engineered for different performance requirements and operating environments. Whatever your challenge — extreme heat, abrasion, or custom material performance — Zircoa’s ZrO₂ products deliver reliable, application-driven solutions.

Use the filters below to quickly find products by process category or application, or explore our complete product categories to discover solutions you may not have considered. Already know what you need? Connect with our team to initiate your project.

Filter ZrO₂ Products to Find Your Solution

Filter by Product Type, Process Category, and/or Application. Use our interactive filters to narrow down options based on your specific needs:

• By Product Type: Specialty Refractory Products, Product Type, Granular Products
• By Process Category: High-Temperature Refractory Lining, Metal Melting & Processing, Abrasive, Corrosive and Specialty Processes
• By Application: High-Temperature Furnaces, Metal Melting, Continuous Casting, Extrusion, Grinding & Milling, Insulation, Custom Components

A Grain Zirconia Powder

Alumina Crucibles

Brick

Castable

Coarse Grain Tubes

Components

Custom Shapes

Extrusion Dies

Granular Zirconia (GROG)

Grinding Media

Powder Metal Atomization Nozzles

Setter Plates And Discs

Slide Gate Plates

Tundish Metering Nozzles

Zirbeads™ Dispersion Media

Zirconia Crucibles

Complete ZrO₂ Product Categories

Want to take a closer look at everything Zircoa provides? Explore each of our products in depth under each category.

Granular Products

Foundation materials including our proprietary A Grain zirconia and refractory backup materials. These loose zirconia products enable custom solutions as raw materials or superior thermal insulation for furnace optimization when paired with Zircoa’s Specialty Refractory Products.

Specialty Refractory Products

Coarse-grain zirconia products engineered to perform at extreme temperatures of up to 2100°C and beyond. These provide superior thermal shock and high erosion resistance as high-temperature furnace linings, vessels for melting non-ferrous metals, and flow control components for ferrous metals.

Technical Ceramic Products

Dense, fine-grain ceramics designed for high-wear and corrosion-resistant applications. These impervious materials deliver exceptional mechanical strength and chemical resistance, perfect for various extrusion, milling, and dispersion applications.

The Zircoa Advantage

We’ve honed our zirconia expertise since 1952 and don’t just manufacture ZrO₂ products — we engineer solutions for your specific challenges. Our comprehensive product range ensures you can find the right material for any high-temperature, high-wear, or chemically aggressive application.

Every product is backed by our application engineering support and quality assurance systems. When you need ZrO₂ products that perform reliably in extreme conditions, Zircoa delivers the solutions that keep your operations running efficiently.

Tailored Zirconium Oxide Solutions

Since 1952, Zircoa has been the trusted leader in specialty zirconium oxide, producing monoclinic powders, engineered ceramics, and refractory products that succeed where standard materials fail. By harnessing zirconia’s uniquely tailorable properties, we design solutions that meet the precise demands of industries such as aerospace, investment casting, steel, glass and many more. When extreme conditions require uncompromising reliability, the world’s most demanding processes turn to Zircoa.

Superior ZrO₂ Performance for Critical Applications

Zirconium oxide represents the pinnacle of high-temperature material performance, and Zircoa’s proprietary compositions and manufacturing processes deliver unmatched reliability in the most demanding environments. Our specialized ZrO₂ products provide the thermal shock resistance, chemical inertness, and mechanical strength needed for applications where failure simply isn’t an option.

Zirconia Quick Fact #1

Zirconia Quick Fact #2

Zirconia Quick Fact #3

Zirconia Quick Fact #4

Zirconia Products & Applications

Explore our comprehensive range of zirconium oxide products engineered for your specific performance requirements. From high-temperature refractories to precision components, we deliver solutions that empower your success.

Granular Products

Foundation materials including our proprietary A Grain zirconia and refractory backup materials. These loose zirconia products enable custom solutions as raw materials or superior thermal insulation for furnace optimization when paired with Zircoa’s Specialty Refractory Products.

View Products

Specialty Refractory Products

Coarse-grain zirconia products engineered to perform at extreme temperatures of up to 2100°C and beyond. These provide superior thermal shock and high erosion resistance as high-temperature furnace linings, vessels for melting non-ferrous metals, and flow control components for ferrous metals.

View Products

Technical Ceramic Products

Dense, fine-grain ceramics designed for high-wear and corrosion-resistant applications. These impervious materials deliver exceptional mechanical strength and chemical resistance, perfect for various extrusion, milling, and dispersion applications.

View Products

Engineered Performance

Zircoa engineered materials showcase our zirconia ceramic expertise with customizable compositions for specialized applications.

About Zircoa

Founded in 1952, Zircoa continues our pioneering mission to innovate and manufacture specialty zirconium oxide solutions for industry. With over seven decades of materials expertise and global supply partners, we don’t just make products — we solve problems that standard materials cannot.

Resources

Access our comprehensive library of technical resources designed to support your material selection and application development. From detailed engineering guides to interactive tools, our resources reflect decades of zirconium oxide expertise to help you achieve optimal performance in your specific applications.

Streamline your material selection and application development with our suite of interactive engineering tools. These practical resources help you quickly identify optimal solutions, calculate key parameters, and make informed decisions about material selection and application design for your specific requirements.

Ring Calculator

Ring Calculator for 2” High Tongue & Groove Refractory Brick Use the table below to determine the quantity of Zircoa's 2" high arch and straight bricks required to construct 6" to 72" diameter rings. For detailed information on Calcia or …

Crucible Selector

Capacity Calculator for Zirconia Crucibles To Use the Calculator Microsoft Excel is required to view and use the calculator. Open Calculator in a New Window Select: "Open" (if prompted.) {{ vc_btn: title=Download+.XLS+File&css=&link=url%3A%252Fwp-content%252Fuploads%252F2025%252F10%252Fcrucibles.zirconia.capacities.xls%7Ctarget%3A_blank }} A. From the alloy pull-down list, select …

Crucibles – Master Reference

Standard and Inventoried Zirconia and Alumina Crucible Sizes and Compositions For immediate delivery we inventory the most common crucible sizes, with configurations to suit your particular needs. For more detailed information on available compositions, chemical analysis, physical properties and links …

Explore detailed case studies showcasing how Zircoa materials solve complex industrial challenges across diverse applications. These real-world examples demonstrate proven performance, highlight innovative solutions, and share practical insights from successful implementations in demanding environments where standard materials simply cannot perform.

How Ceramic Extrusion Die Inserts Transformed Copper Tube Production

Custom Zirconia Refractory Linings for Extended Carbon Black Production

Supporting Nuclear Safety: How Zircoa’s Refractory System Enabled a Nuclear Power Plant Life Extension

How Zircoa Brought its High-Performance MgO-PSZ to Ceramic Injection Molding

Eliminating Contamination: How Zircoa Solved Critical Aerospace Powder Qualification Challenges

Access our comprehensive library of technical documentation designed to support your material selection and application development. From detailed specifications to installation guidelines, these resources provide the critical information needed to optimize performance and ensure successful implementation of Zircoa materials.

A-Grain – A Closer Look

A-Grain Monoclinic Zirconia Powder

Alumina Crucibles

Crucible Engineering Guide

Crucibles: For Increased Productivity & Cleaner Melts

Domestic Terms and Conditions of Sale of Products

Extrusion Dies

Grinding Media

Insulating Structures

International Terms and Conditions of Sale of Products

ISO 9001:2015 with Design

Maximizing Reactor Performance

Optimizing Investment Casting for Super Alloys

Powder Metal Atomization Nozzles

Refractory Solutions for Carbon Black

Resilient Supply Chains: Market-Proven Concepts

Setter Plates and Discs

Slide Gate Plates

Standard Terms of Purchase

Supply Chain Code of Conduct

The Crucible Manufacturer that Investment Casters Use

Tundish Metering Nozzles

Zirbeads Dispersion Media

Zirconia Crucibles: Enabling Reliable Melting of Platinum Group Metals

Zycron L and H

Access our comprehensive library of resources designed to support your material selection, application development, and process optimization. From the latest industry insights to practical engineering tools, our resources reflect decades of zirconia expertise and real-world application experience across demanding industrial environments.

You can explore all of our zirconia oxide products here, or connect with our team any time for more information.

Downloads

Access technical information, application guides, installation manuals, and other essential documentation to support your material selection and application optimization efforts.

Case Studies

Explore real-world success stories showcasing how Zircoa materials solve complex industrial challenges. Learn from practical applications and proven performance across diverse industries.

Tools

Utilize our engineering calculators, material selectors, and other interactive tools designed to streamline your material selection and application development process.

News

Stay current with the latest developments in zirconia technology, industry trends, and Zircoa innovations. Our insights help you understand emerging applications and evolving best practices in specialty materials.

Get Expert Support for Your Material Challenges

Ready to solve your toughest material challenges? Our specialists are here to help with material selection, custom solutions, and technical guidance for your specific applications. Contact us today to discuss how Zircoa can deliver the performance you need.

Have questions about our products or capabilities? Use the form to the right or contact our offices directly for prompt assistance.

Global Reach with Local Expertise

Worldwide Operations and Partnerships

Zircoa serves customers globally through our integrated network of facilities and partnerships:

Zircoa Inc. – Solon, Ohio, USA

Our corporate headquarters houses administration, engineering, sales, and manufacturing operations. This integrated approach ensures seamless collaboration between our R&D, engineering, production, sales, and marketing teams.

Zircoa GmbH – Wiesbaden, Germany

Our European sales office provides local support for customers throughout Europe, the Middle East, Africa, and India, ensuring responsive service and technical support across diverse markets.

Dyson Technical Ceramics

Head office: Sheffield, UK
Manufacturing facility: West Hunwick, UK
Strategic partnership expanding our technical ceramic capabilities

Representatives Throughout the World

Our global network includes representatives in key markets, ensuring local support for customers worldwide.

China
Alan Yang
+86-135-0127-6286

Our Locations

USA

Zircoa Inc.
31501 Solon Road
Solon, Ohio 44139
Phone: +1-440-248-0500
Fax: +1-440-248-8864
Email: zircoa@zircoa.com

Europe, Middle East, Africa & India

Zircoa GmbH
Hagenauer Str. 47
D-65293 Wiesbaden, Germany
Phone: +49-611-335497-0
Fax: +49-611-335497-55
Email: info@zircoa.de or specialtyceramics@zircoa.com

Why Contact Zircoa?

Technical Expertise: Direct access to materials specialists with decades of zirconia experience
Custom Solutions: Engineered materials tailored to your specific requirements
Global Support: Local expertise and responsive service worldwide
Proven Performance: Solutions backed by manufacturing excellence and quality control

Established in 1952 and now based in Solon, Ohio, Zircoa began by developing a groundbreaking process for making zirconia and answering industry’s call for higher-temperature furnace linings. Today, we continue that pioneering spirit as the leading specialty zirconia manufacturer, delivering engineered solutions that enable our customers to push the boundaries of what’s possible in extreme industrial applications.

Our mission of “Delivering What Matters” is centered around innovating and manufacturing specialty zirconia for industry. We serve a global customer base with over seven decades of materials expertise. We don’t just make products — we solve problems that standard materials, service, and delivery solutions cannot address.

Learn more about Zircoa below, or review our complete list of products here. Feel free to reach out to our team for more information about our company, Zircoa Inc., and how we can help.

Zircoa Heritage and Evolution

Zircoa’s journey reflects the evolution of advanced materials manufacturing in America. Starting as Zirconium Corporation of America, we’ve maintained our commitment to innovation through various ownership transitions before becoming the independent Zircoa Inc. in 2010.

This stability and continuity have enabled us to build deep expertise in zirconia science while maintaining the agility to adapt to changing customer needs. Our independence allows us to focus entirely on what we do best: engineering specialty zirconia materials that perform where others fail.

The Zircoa Difference

Material Science Expertise

What sets Zircoa apart is our deep understanding of zirconia’s unique properties and our ability to manipulate these characteristics for specific applications. Our proprietary manufacturing processes and compositions enable performance that conventional materials simply cannot achieve.

Customer-Focused Innovation

We don’t just manufacture materials — we partner with customers to solve their most challenging problems. Our application engineering expertise ensures optimal material selection and performance optimization for each unique requirement.

Proven Performance

Zircoa materials enable critical technologies that impact daily life around the world. Our track record spans decades of reliable performance in high consequence applications.

Our commitment to engineering excellence drives continuous innovation in zirconia technology, ensuring our customers have access to the most advanced materials for their evolving challenges.

Quality and Sustainability Commitment

ISO 9001:2015 Certification with Design

Our quality management system reflects our commitment to consistent excellence in product design, manufacturing, and customer service. This certification with design recognizes our comprehensive approach to quality throughout the entire product development lifecycle.

Sustainability Leadership

Zircoa is committed to sustainable manufacturing practices and environmental stewardship. Our sustainability journey includes third-party assessments and ongoing initiatives to minimize environmental impact while maximizing product performance and longevity.

Supply Chain Code of Conduct

ISO 9001:2015 with Design

Industry Engagement and Memberships

We maintain active memberships across multiple industry organizations, ensuring our expertise remains current with evolving standards and best practices:

AACCM – Association of American Ceramic Component Manufacturers

ACerS – The American Ceramic Society

AIST – Association for Iron & Steel Technology

ICI – Investment Casting Institute

MPIF – Metal Powder Industries Federation

ZIA – Zircon Industry Association

At Zircoa, our materials science research and development capabilities represent the foundation of our custom zirconia innovation. This expertise enables us to develop new compositions, optimize existing materials, and solve complex application challenges that standard materials cannot address. Our extensive internal laboratory supports development, production, and port-mortem analysis.

When your application demands performance beyond what existing zirconia materials can provide, our R&D team leverages advanced material science principles to engineer custom zirconia solutions. From proprietary powder characteristics to specialized formed properties, we transform challenging material requirements into reliable, manufacturable solutions.

Learn more about our custom zirconia development capabilities below. You can always review our existing products here, or contact our team today to discuss your specific material development requirements.

Custom Zirconia Development With Notable Benefits

• Integrated powder production allows for customizable raw material properties
• Control of particle size distribution, chemistry and microstructure to engineer formed products
• Advanced material characterization and testing facilities
• Statistical process control ensures consistent custom material properties
• Comprehensive solutions from advanced powders to formed products
• Comprehensive performance validation and optimization
• Collaborative development approach with customer application teams
• Intellectual property protection for proprietary developments

Advanced Laboratory and Testing Facilities

Our R&D facilities feature comprehensive equipment for custom zirconia development and characterization. From initial composition development through final performance validation, our laboratory capabilities enable complete material development cycles.

Zircoa’s engineered materials represent the foundation of our material science expertise — showcasing our deep understanding of zirconia ceramic properties. Our vertically integrated manufacturing process enables custom formulations and control from powder to a robust selection of formed products.

We’ve developed zirconia materials since 1952, engineering solutions by manipulating crystalline structure, stabilizer systems, grain size, and other properties to optimize specific performance requirements. From ultra-high purity monoclinic zirconia powder to complex stabilized compositions, our material science perspective enables customization that solves challenges conventional materials cannot address.

Read on to explore our engineering capabilities. You can review our range of zirconia oxide products here, or feel free to reach out to our experts for more information about a specific product, project, or application.

The Zircoa Materials Science Advantage

Comprehensive Zirconia Ceramic Capabilities

Our engineered materials showcase demonstrates the breadth of our material manipulation capabilities:

• Raw Advantage: Proprietary powder customization or source selection, based on application requirements
• Purity Levels: From commercial grade to ultra-high purity specifications
• Stabilizer Systems: Magnesia, Calcia, Yttria, and custom stabilizer combinations
• Crystal Structures: Monoclinic, tetragonal, and cubic zirconia phases optimized for specific properties
• Grain Size Control: From fine-grain dense ceramics to coarse-grain refractory materials
• Porosity Engineering: Controlled porosity from dense technical ceramics to insulating refractories
• Comprehensive Solutions: Robust selection of advanced products to meet or exceed unique application requirements

RD&E

Explore our extensive R&D and custom material development capabilities. From initial concept through post-mortem analysis, our engineering team provides complete support for developing and optimizing zirconia materials for legacy and emerging applications.

Performance Based Development

When standard compositions cannot meet your performance requirements, our material science expertise and application engineering experience enable development of custom zirconia ceramic formulations. We work closely with customers to:

• Create custom chemistry for unique operating environments
• Optimize physical properties to improve service life and operational efficiency
• Scale laboratory developments to full production capability

… and deliver innovative solutions to high consequence applications.

Engineering Support and Resources

Initial and ongoing application engineering to optimize performance to customer process, not just applications. Access our comprehensive technical resources including composition data and operation guidelines. Contact our team for consultation to ensure optimal material selection and performance optimization for your specific requirements.

Proven Flow Control Technology for Steel Continuous Casting Operations

Tundish metering nozzles represent proven, legacy technology that directly controls the volume of metal flowing from tundish to mold during continuous casting operations. Unlike complex slide gate plates, these straightforward components provide reliable, consistent flow control for billet and rebar production with predictable performance characteristics.

Zircoa offers multiple bore styles and assemblies engineered specifically for continuous casting of non-aggressive and low-carbon steels. Whether you need 8-hour basic performance or extended 24+ hour casting sequences, we match our technical and development resources to meet the caster’s constantly changing needs.

Learn more about our tundish metering nozzle solutions below, or contact our specialists to discuss your specific continuous casting requirements.

The Benefits of Zircoa Tundish Metering Nozzles

• Reliable flow control for consistent steel casting operations
• Multiple casting time options from 8 hours to 24+ hour sequences
• Engineered bore designs for optimal metal flow characteristics
• Superior erosion resistance for extended service life
• Thermal shock resistance for reliable performance
• Consistent stream flow with minimal flaring
• Statistical process control ensures high-quality consistency
• Cost-effective performance optimized for your casting practice

Primary Industries

• Steel production facilities, including steel mills, mini-mills, low-carbon steel production, and continuous casting operations for non-aggressive grades
• Steel processing and service centers, encompassing integrated production, casting capabilities, and downstream processing

Key Applications

• Continuous and sequential casting operations for non-aggressive and low-carbon steel grades, including billet, rebar, and direct-to-mill production
• Cost-conscious applications where reliable flow control and predictable performance are required without the need for premium materials

Tundish Metering Nozzle Selection and Performance

Composition Options for Different Casting Requirements

Composition 3004 for Non-aggressive Steels, Average Casting Times — Coarse grain metering nozzle mix developed to optimize thermal shock resistance while providing good erosion resistance. Typically provides 8-12 hours of casting time.

Composition 3077 for Low Carbon Steels, Moderate Casting Times — Developed for operations where 24-hour sequence casting isn’t practical, but 14-20 hour times are desirable. Superior erosion resistance compared to 3004, even when casting low-carbon steels.

Composition 2134 for Low Carbon Steels, Extended Casting Times — Two-part design featuring a fine grain, low porosity inner metering nozzle within a coarse grain support block. Optimizes erosion resistance and maximizes casting times with extremely uniform stream flow and casting times exceeding 24 hours.

Critical Components for Superior Steel Continuous Casting Performance

Current tundish and ladle gate refractories cannot always meet the demanding pouring and life requirements for some grades of steel in continuous casting operations. Zircoa slide gate plate inserts provide the advanced solution that OEMs and steel manufacturers need for reliable performance with the toughest steel grades.

Our slide gate plate inserts are complex technical components engineered for integration into larger refractory assemblies used in continuous casting systems. Designed for superior erosion and corrosion resistance, these precision components extend service life while reducing overall steelmaking costs in the most demanding continuous casting environments.

Learn more about our steel continuous casting solutions below, or contact our specialists to discuss your specific slide gate plate requirements for OEM applications.

The Benefits of Zircoa Slide Gate Plate Inserts

• Superior erosion and corrosion resistance for challenging steel grades
• Extended service life reduces refractory replacement costs
• Excellent thermal shock properties for reliable casting operations
• Precision manufacturing for optimal fit in OEM systems
• Advanced zirconia compositions engineered for steel contact
• Reduced overall steelmaking costs through improved performance
• Enhanced pouring reliability for consistent casting quality
• Optimized for both ladle and tundish gate system applications

Primary Industries

• Steel continuous casting operations and mini-mills
• Integrated steel production facilities
• Specialty steel and alloy manufacturers
• OEM equipment manufacturers for steel industry
• Steel service centers and processing facilities

Key Applications

• Ladle gate systems for primary steel tapping
• Tundish gate systems for continuous casting control
• Specialty steel grade processing requiring superior refractory performance
• Long-sequence casting operations demanding extended component life
• Critical casting applications where failure results in significant downtime

Slide Gate Plate Selection and Engineering

Advanced Material Compositions

Zircoa’s Composition 3004 represents high-quality magnesia-stabilized zirconium oxide specifically engineered to meet the demanding requirements of steel continuous casting operations.

Zircoa’s Composition 3055 is an alternate material with unique permeability characteristics, ideal for inert gas injection.

OEM Integration Support

Our engineering team works closely with OEMs to ensure optimal integration of slide gate plate inserts into complete refractory assemblies that serve steel continuous casting:

• Component design optimization for specific system requirements
• Material selection based on steel grade and casting parameters
• Installation guidance and technical support for OEM partners

Saggers and Kiln Furniture for Non-Reactive Component Firing

Setter plates and discs function as essential saggers and kiln furniture, providing stable holding vessels that support and position components during high-temperature firing processes. Zircoa setter plates deliver superior performance for firing electronic components including barium titanate capacitors, thermistors, and PZT piezoelectrics at temperatures above 1300°C with no material reaction or contamination.

These precision kiln furniture pieces are engineered to withstand repeated thermal cycles while maintaining dimensional stability and chemical inertness. Available in various standard dimensions or manufactured to your specific requirements, our saggers ensure consistent positioning and contamination-free processing for critical electronic components.

Learn more about our kiln furniture solutions below, or contact our specialists to discuss your specific setter plate requirements.

The Benefits of Zircoa Saggers and Kiln Furniture

• High-temperature capability above 1300°C with no material reaction
• Chemical inertness prevents contamination of sensitive electronic components
• Dimensional stability maintains precise positioning through thermal cycles
• Superior thermal shock resistance for reliable repeated use
• Non-reactive surface ensures component purity and quality
• Custom dimensions available for specific application requirements
• Extended service life reduces kiln furniture replacement costs
• Consistent performance for repeatable processing results

Primary Industries

• Electronic component manufacturing and assembly
• Capacitor and ceramic component production
• Semiconductor processing and advanced materials
• Medical device component manufacturing
• Precision ceramic and piezoelectric component production

Key Applications

• Barium titanate capacitor firing and sintering
• Thermistor manufacturing and heat treatment
• PZT piezoelectric component processing
• Multi-layer ceramic capacitor (MLCC) production
• Electronic ceramic component sintering and annealing

Setter Plate and Disc Selection

Standard and Custom Configurations

Our saggers and kiln furniture are available in multiple configurations to meet your specific needs:

• Flat round discs for standard component positioning
• Setter plates for larger component arrays
• Two-rail plates for specialized holding applications
• Custom dimensions and configurations for unique requirements

Saggers Material Selection Guidance

Composition 1661 is recommended for initial testing and is used by the majority of our customers. This -28 Tyler mesh partially stabilized zirconia provides optimal performance for most electronic component firing applications.

Advanced Atomization Nozzles for Specialty Metal Powder Production

Powder metal atomization nozzles, also known as pour tubes, are precision components primarily used for atomizing specialty metals into powder form. Tight control of the powder properties enables various metallic manufacturing processes, including press & sinter, additive manufacturing, metal injection molding, and hot isostatic pressing.

Zircoa atomization nozzles are utilized in a range of specialized atomization processes, including free fall and water atomization, as well as more complex close-coupled VIGA gas atomization. Our nozzles enable narrow particle size distributions with minimal inclusions and superior powder quality required by many advanced industries.

Learn more about our powder metal atomization solutions below, or contact our team of experts to discuss your specific atomization requirements.

Why Choose Zircoa for Metal Atomization Nozzles

• High thermal resistance enables high-temperature atomization operations
• Superior wear and erosion resistance for longer atomization runs
• Chemically inert properties reduce reactivity with molten alloys
• Low thermal conductivity prevents freeze-offs during operation
• Reduced contamination risk produces cleaner melts and powder
• Enhanced wetting performance prevents alloy adhesion
• Optimized casting sequences with tighter operating parameters
• Control of particle size with precision atomization angles and customizable design features

Primary Industries

• Aerospace and defense manufacturing for critical components
• Additive manufacturing and 3D printing materials production
• Powder metallurgy and metal injection molding operations
• Specialty alloy and superalloy powder production
• Precious metals processing and refining operations

Key Applications

• Nickel, chrome, and cobalt alloy powders
• Stainless steel and Iron-based alloy powders
• High-temperature precious metal powders (Platinum group alloys)
• Copper and brass metal powders

Atomization Nozzle Selection and Performance

Process Compatibility

Our atomization nozzles are engineered for multiple atomization processes:

• Free fall atomization for basic powder production
• Water atomization for controlled cooling and particle size
• Close-coupled VIGA gas atomization for premium powder quality
• Custom configurations for specialized atomization requirements

Material Performance Optimization

Proper nozzle material selection is crucial for achieving desired powder properties including size, shape, and surface finish. Our nozzles enable ideal casting sequences, tighter operating parameters, increased reliability, and fewer inclusions for superior powder quality.

Engineered Alumina Crucible Solutions with Premium Manufacturing Quality

While many suppliers offer basic alumina crucibles as simple one-shot liners, Zircoa combines cost-effective alumina material with our premium manufacturing processes and quality management systems. Our Composition 6105 alumina crucibles are hydraulically pressed for precise dimensions and feature uniform, smooth inner surfaces that deliver cleaner melts and extended service life up to 1700°C.

Alumina crucibles serve two primary functions. On their own, they serve as a melt container for use with induction furnaces in traditional grouted-coil installations. Additionally, our alumina crucibles are ideally suited as backup crucibles in two-crucible installations combined with zirconia crucibles. The sizes are matched between crucible types for safe installation with maximum energy efficiency.

Learn more about the differences achieved with a Zircoa alumina crucible below, or connect with our team to consult about project specifics.

Explore a Better Alumina Crucible

• Hydraulically pressed for precise, consistent dimensions
• Uniform and smooth inner surface for cleaner melt quality
• Extended service life compared to standard alumina crucibles
• Cost-effective performance for applications up to 1700°C
• Compatible sizing with zirconia crucibles for two-crucible systems
• Suitable for vacuum or oxidizing atmospheres
• Premium quality control with reliable, repeatable results
• Engineered for both primary and backup crucible applications

Primary Industries

• Investment casting operations
• Powder metallurgy and metal injection molding
• Steel industry and specialty alloy production

Key Applications

• Variety of metals and alloys with service temperatures up to 1700°C
• Cost-sensitive melting operations requiring reliable performance
• Applications where zirconia performance isn’t required
• Backup crucible systems for enhanced safety and efficiency

Alumina Crucible Selection and Specifications

Interactive Selection Tools

Use our online tools or connect with our experts to select the optimal alumina crucible based on:

• Bottom shape configuration (round bottom vs. flat bottom)
• Proper dimensions with backup material clearances
• Two-crucible system compatibility with zirconia crucibles

Trust Zircoa for a High-Temperature Crucible with Superior Melting and Casting Performance

Crucibles are one of the most critical parts in melting and casting processes, and zirconia crucibles offer superior performance and durability for many alloy types compared to alternative materials such as clay graphite, silicon carbide, or alumina. Designed for use with induction furnaces in traditional grouted-coil or two-crucible installations, Zircoa provides a high-temperature crucible to enable clean melts and reliable performance up to 2200°C.

Zirconia crucibles are engineered for high-end applications under extreme conditions such as high temperature or vacuum environments, particularly for safety-critical products that require super clean melts. Learn more about our high-temperature crucibles below, or reach out to our experts to discuss specifics.

The Benefits of Zircoa High-Temperature Crucibles

• Superior thermal shock resistance for reliable thermal cycling
• Excellent chemical stability against aggressive and corrosive alloys
• Erosion resistance for extended service life
• Low wettability prevents alloy contamination
• Multi-use capability for cost-effective operations
• Energy efficient thermal properties reduce operating costs
• Suitable for oxidizing or vacuum atmospheres
• Clean melt capability for high-purity applications

Primary Industries

• Investment casting for aerospace and industrial gas turbines
• Medical device manufacturing and dental applications
• Powder metallurgy and metal injection molding
• Precious metal casting and refining operations
• Steel industry specialty alloy production

Key Applications

• Superalloy melting (cobalt and nickel-based alloys)
• Precious metal processing for jewelry and industrial applications
• Processing of Platinum Group Metals (PGMs)
• High-temperature vacuum melting operations
• Clean melt requirements for critical components

High Temperature Crucible Selection and Specifications

Crucible selection

Zircoa’s different compositions are optimized for certain metals and alloys, applications, and temperature ranges.

• C3001 – It is recommended as the “best choice” of crucible materials for melting the entire range of commercial alloys. It exhibits superior resistance to both thermal shock and erosion. Low thermal expansion and non-wettability make this one of our most popular compositions for crucibles.
• C1651 – Contains fused grog, and can be used in high temperature (>1800ºC) applications. It provides superior resistance to erosion, exhibits good thermal shock resistance, and is recommended where high purity is required.
• C2291 – Combines inertness to the melt with application temperatures beyond 1900ºC and is the preferred choice for high-quality platinum group metals
• C2004 – Primarily used for melting platinum-group alloys. It is designed for “dirty refining” applications, especially when glassy or siliceous slags are present.

Use our online tools or consult with application specialists to select the optimal crucible based on:

• Application requirements and alloy composition
• Bottom shape configuration (round bottom vs. flat bottom)
• Proper dimensions with backup material clearances
• Lip and spout shape for your specific furnace design

Crucible Engineering Guide
Crucible Selector

Pre-Formed Refractory Lining Solutions Engineered for Your Exact Requirements

When standard brick configurations can’t meet your unique furnace geometry or application requirements, Zircoa custom shapes provide the precise refractory lining solutions you need. Our pre-formed, pre-sintered custom refractory components are engineered to your exact specifications, offering superior forming methods and optimized physical properties for demanding applications.

These advanced custom shapes serve as high-performance replacements for traditional burner blocks while expanding capabilities far beyond glass furnaces into carbon black production, electronics manufacturing, energy systems, and medical applications where precision and reliability are critical. With Zircoa refractory lining, either Calcia, Yttria, or Magnesia-stabilized zirconium oxide compositions help extend burner block life, withstand high temperatures and contaminants present in fuel oil.

Learn more about this offering below, or contact our service representatives to discuss specific requirements.

The Benefits of Zircoa Refractory Lining

• Pre-formed and pre-sintered for consistent performance
• Custom geometries engineered exactly to your specifications
• Superior forming methods for complex configurations
• Optimized physical properties for specific applications
• Enhanced thermal shock resistance for reliable cycling
• Chemical resistance against aggressive process atmospheres
• Dimensional precision for perfect fit and sealing
• Extended service life reduces maintenance and downtime

Primary Industries

• Carbon black production and processing facilities
• Electronics manufacturing and semiconductor processing
• Energy systems and power generation applications
• Medical device manufacturing and pharmaceutical processing
• Glass furnaces and high-temperature melting operations

Key Applications

• Custom burner block replacements for enhanced performance
• Complex furnace geometries requiring precision fit components
• High-temperature process equipment with unique configurations
• Specialized refractory lining systems for aggressive environments
• Critical applications where standard shapes cannot perform

Custom Shape Design and Engineering

Comprehensive Design Support

Our engineering team collaborates directly with you to design custom shapes tailored to your unique application needs and performance challenges.

• CAD design and finite element analysis
• Material selection optimized for your operating conditions
• Forming method selection for optimal properties
• Installation guidance and technical support

Engineered Tubes for Crystal Growth and High-Temperature Cycling Applications

Coarse grain tubes from Zircoa are engineered to withstand the demanding thermal cycling environments essential for crystal growth operations and induction heating applications. These precision-manufactured tubes deliver reliable performance in non-reactive firing processes where material purity and thermal shock resistance are critical to success.

Available in both pressed and cast configurations, our coarse grain tubes are manufactured in various diameters, lengths, and compositions to satisfy the unique requirements of your specific application. Whether for crystal growth furnaces or specialized induction heating systems, these tubes provide the thermal reliability needed for consistent results.

Learn more about our crystal growth and thermal cycling solutions below, or connect with our team to discuss your specific requirements.

The Advantages of Zircoa Coarse Grain Tubes

• Superior thermal shock resistance for reliable cycling from room temperature to 2000°C
• Non-reactive properties preserve material purity in sensitive processes
• Engineered porosity optimized for thermal cycling performance
• Multiple grain sizes and configurations for application-specific requirements
• Pressed and cast options to meet different performance needs
• Chemical inertness prevents contamination in high-purity applications
• Extended service life reduces furnace downtime and replacement costs
• Dimensional stability maintains performance through repeated thermal cycles

Primary Industries

• Crystal growth and semiconductor manufacturing
• High-purity quartz processing operations
• Electronic component manufacturing and processing
• Specialty glass and optical material production
• Advanced materials research and development

Key Applications

• High-temperature induction heated crystal growth furnaces and applicable crystal growth methods
• Non-reactive firing of electronic components and ceramics
• Quartz and sapphire crystal growing operations
• Specialty glass forming and processing applications
• Research furnaces requiring contamination-free environments

Coarse Grain Tube Selection and Specifications

Material Composition Options

Composition 1651, featuring zirconia stabilized with 3.0% calcia by weight, is typically specified for high-temperature induction heated crystal growth furnaces. This composition delivers reliable performance through repeated cycling from room temperature to 2000°C. Other Zircoa compositions are available and listed below.

Manufacturing Options

Choose between pressed and cast configurations based on your specific requirements:

• Pressed tubes for applications requiring dimensional precision
• Cast tubes for complex geometries and specialized configurations
• Custom diameters, lengths, and grain sizes available

Ultimate Customization with Castable Refractory Materials for On-Site Forming

When your application demands another level of customization and flexibility, Zircoa castable refractory materials provide the solution. These loose, wet-form materials allow you to create custom shapes, repairs, and complex geometries directly at your facility, offering unmatched design freedom for unique furnace configurations and field applications.

Unlike pre-fired or pre-sintered products, our castable refractory materials cure and develop their properties in place, enabling seamless installations and perfect conformity to any geometry. Zircoa provides the specialized “cement” formulations along with expert guidance on proper mixing, application, curing, and heat treatment procedures.

Our selective approach ensures you receive exactly the right castable refractory composition for your specific application, backed by our decades of expertise in refractory material science. Learn more below, or reach out to our team for more information.

The Benefits of Zircoa Castable Refractory Materials

• Ultimate customization for any geometry or configuration
• On-site forming eliminates shipping constraints for large components
• Seamless installation with no joints or assembly requirements
• Perfect conformity to complex shapes and existing structures
• Field repair capabilities for emergency maintenance
• Multiple composition options for specific performance requirements
• Expert guidance on mixing, application, and curing procedures
• Cost-effective solution for unique or one-off applications

Primary Industries

• Glass manufacturing with complex furnace geometries
• Chemical processing plants with specialized reactor configurations
• Power generation facilities needing custom insulation solutions
• Industrial furnace manufacturers and rebuilders

Key Applications

• Custom furnace linings and complex geometrical configurations
• Field repairs and emergency maintenance applications
• Specialized reactor linings for chemical processing

Castable Refractory Material Selection and Application

Our refractory specialists work with you to select the optimal castable composition based on:

• Operating temperature requirements and thermal cycling conditions
• Chemical exposure and atmosphere compatibility
• Mechanical stress and structural requirements
• Installation methods and curing constraints

Proper castable application requires expert guidance. Our technical team provides:

• Detailed mixing and application procedures
• Curing schedules and heat treatment protocols
• Quality control recommendations and testing procedures
• Troubleshooting support throughout installation

Enhance Furnace Design and Performance With Engineered Refractory Bricks

Thermal insulation is fundamental to effective furnace design, and refractory bricks form the structural foundation that determines overall system performance. Zircoa refractory bricks deliver exceptional thermal insulation properties combined with the structural integrity needed for demanding high-temperature applications up to 2000°C and beyond.

Our engineered brick systems provide the critical thermal barrier that maximizes energy efficiency, extends furnace life, and ensures consistent process temperatures. Whether for new construction or furnace rebuilds, proper brick selection and installation are essential for optimal thermal performance. Learn more about our refractory bricks below, or get in touch with our experts to discuss project specifics.

Advantages of Zircoa Refractory Bricks

• Superior thermal insulation for maximum energy efficiency
• Exceptional thermal shock resistance for reliable cycling
• High-temperature capability exceeding 2000°C
• Structural integrity for self-supporting furnace construction
• Engineered porosity optimized for insulation performance
• Chemical resistance against aggressive furnace atmospheres
• Dimensional stability under thermal stress
• Extended service life reduces maintenance costs

Primary Industries

• Glass melting and forming operations
• Quartz processing and high-purity applications
• Carbon black production facilities
• Crystal growth and semiconductor processing
• Refractory-metals operations

Key Applications

• Furnace wall construction and hot face linings
• Backup insulation layers for enhanced thermal efficiency
• Self-supporting structures in extreme temperature zones
• Thermal barriers for process temperature control
• Furnace rebuilds and maintenance applications

Refractory Brick Configurations and Selection

Standard and Tongue-and-Groove Options

We use Calcia, Magnesia, or Yttria stabilized zirconium oxide in standard, complex, and custom designs for enhanced structural integrity and thermal sealing.

Zircoa’s tongue and groove refractory bricks are designed for the building of self-supporting structures, making them ideal for high temperature cycling environments. Using tongue and groove brick eliminates line of sight radiation, and adds physical stability to the structure. Rings and circles, with an ID as small as 6″ can be achieved.

Standard refractory bricks are used primarily for custom high-temperature furnace linings, supports, and heat shields. Zircoa’s standard bricks withstand operating temperatures greater than 2000°C (3630°F) with capacity to spare.

Critical Design Considerations

Proper brick selection requires careful consideration of:

• Operating temperature requirements and thermal cycling
• Furnace atmosphere and chemical exposure conditions
• Structural load requirements and thermal expansion
• Installation methods and joint sealing requirements

Engineering Support

Our application specialists provide comprehensive support for furnace design optimization, brick selection, and installation best practices to ensure maximum thermal performance and service life. Use our ring calculator to help you determine the quantity of Zircoa 2″ high arch and straight tongue and groove bricks required to construct 6″ to 72″ diameter rings.

Premium Zirconia Beads for Superior Dispersion and Industrial Mixing

Zirbeads™ represent Zircoa’s proprietary zirconia beads engineered specifically for dispersion applications to create uniform mixtures without contamination. These ultra-tough, high-purity beads are designed for high-shear mixing and dispersion of paints, pigments, and other industrial formulations where achieving uniformity in color and viscosity is critical to product quality.

Unlike standard milling media, Zirbeads function as specialized dispersing media that deliver exceptional performance in automotive paint production, pigment processing, and other demanding mixing applications. Our proprietary zirconia beads provide long-lasting performance with minimal contamination, making them the preferred choice for high-quality industrial mixing processes.

Learn more about our zirconia beads solutions below, or contact our zirconia experts to discuss your specific dispersion and mixing requirements.

The Benefits of Zirbeads™ Zirconia Beads

• Superior dispersion performance for uniform color and viscosity
• Exceptional hardness and wear resistance for extended service life
• Non-porous surface prevents contamination of sensitive formulations
• Chemically inert properties resist attack from acids and alkalis
• Uniform size and shape for consistent mixing performance
• High-density design provides superior kinetic energy for dispersion
• Engineered for high-viscosity formulations up to 50,000 cps

Primary Industries

• Automotive paint and coating manufacturing
• Industrial pigment processing and color matching
• Ink production and printing industry applications
• Specialty coating and finish manufacturing
• Pharmaceutical and cosmetic product development

Key Applications

• Automotive paint dispersion for color uniformity and finish quality
• Pigment processing to achieve consistent color properties
• High-viscosity coating formulation and mixing
• Magnetic coating production for industrial applications
• Specialty ink dispersion for printing and graphics industries

Zirbeads™ Selection and Specifications

Zircoa offers zirconia beads grades for different application requirements:

• SUPER (1.4 to 3.35 mm) — For applications requiring media with wider and more economical distribution. Historically used in vertical mills, now with expanding horizontal mill applications.
• SUPER “XR” (0.6 to 2.3 mm) — Designed for modern horizontal mills, providing narrow size distribution needed for inks, automotive coatings, and magnetic coating applications.
• Custom: Available down to 0.42 mm.

Engineered Ceramic Grinding Media for High-Purity Material Processing

Zircoa’s ceramic grinding media is engineered based on magnesia-stabilized zirconium oxide for grinding electronic ceramics, zircon, zirconia, barium titanate, and other specialty materials in vibratory, ball, jar, and attritor mills. Our grinding media delivers fast, efficient grinding and milling with minimal contamination and exceptional media weight loss performance.

This engineered ceramic grinding media features a different composition than our dispersion beads, specifically optimized for grinding applications where contamination-free processing and extended media life are critical. Our media is manufactured as radius-end cylinders to accommodate your grinding requirements.

Learn more about our ceramic grinding media capabilities below, or contact our team of zirconia oxide experts to discuss your specific grinding and milling application requirements.

Ceramic Grinding Media: What You Need to Know

• Superior grinding efficiency for electronic ceramics and specialty materials
• Minimal contamination ensures product purity in sensitive applications
• Exceptional media weight loss performance for extended service life
• Non-porous, non-conductive, and non-magnetic properties
• Chemically inert composition resists attack from processing environments
• Chip-resistant design prevents media breakdown and contamination
• Engineered for vibratory, ball, jar, and attritor mill applications
• Custom sizes available for specific grinding requirements

Primary Industries

• Electronic component manufacturing and processing
• Advanced ceramics and specialty materials production
• Barium titanate and electronic ceramic grinding operations
• High-purity material processing and preparation
• Research and development applications requiring contamination-free grinding

Key Applications

• Electronic ceramics grinding for component manufacturing
• Zircon and zirconia material preparation and processing
• Barium titanate grinding for capacitor production
• Specialty ceramic material size reduction and preparation
• High-purity grinding applications requiring minimal contamination

Grinding Media Selection and Specifications

Available Configurations

Our ceramic grinding media is manufactured in radius-end cylinder shapes engineered for optimal grinding performance in various mill types. Custom sizes are available to meet your specific application requirements.

Made-to-Order Availability

All grinding media is manufactured to order to ensure optimal performance. Our engineering team works with you to select the appropriate size and configuration for your specific grinding application and mill type.

High-Performance Ceramic Extrusion Dies for Non-Ferrous Alloy Processing

Magnesia-stabilized zirconium oxide extrusion dies from Zircoa are engineered to provide the high-temperature stability, chemical inertness, hardness, wear resistance, and corrosion resistance required to extrude non-ferrous alloys such as copper, copper-nickel, brass, and other copper alloy shapes. These ceramic extrusion dies represent one of our largest precision components, designed for horizontal casting and drawing applications where standard metal dies cannot deliver the required performance.

Our extrusion dies are more standardized than custom components, making them suitable for plug-and-play applications across various extrusion operations. The engineered porosity in our ceramic materials provides unique thermal shock resistance properties that distinguish our dies from other materials, giving operators the reliability needed for demanding extrusion processes.

Learn more about our ceramic extrusion die capabilities below, or contact our specialists to discuss your specific non-ferrous alloy extrusion requirements.

Improve Extruded Surface Finish with Zircoa Extrusion Dies

• Superior high-temperature stability for demanding extrusion operations
• Engineered porosity provides exceptional thermal shock resistance
• Chemical inertness prevents contamination of extruded alloys
• Superior hardness and wear resistance for extended die life
• Corrosion resistance against aggressive extrusion environments
• Consistently outperform traditional tool steel and stellite dies
• Significantly reduce machine shop rework and maintenance

Primary Industries

• Copper and brass extrusion and forming operations
• Wire and cable drawing operations
• Industrial tube and pipe manufacturing

Key Applications

• Copper, copper-nickel, and brass extrusion operations
• Non-ferrous alloy shapes up to 152.4mm (6.0″) OD
• Horizontal casting and drawing applications
• Direct press operations where the billet moves through the die
• Indirect press operations where the die moves through the billet

Extrusion Die Selection and Compositions

Zircoa offers specialized compositions optimized for different extrusion requirements:

• Composition 2016 for Tube Extrusion (up to 152.4mm/6.0″ OD) — Specifically formulated to enhance thermal shock resistance and improve ability to withstand thermal cycling. Well-suited for tube dies requiring superior thermal performance.
• Composition 5027 for Rod and Shape Extrusion (up to 50.8mm/2.0″ diameter) — Features extra strength and toughness needed for high reduction ratio extrusion operations. Optimized for rod and shape applications requiring enhanced mechanical properties.

Engineered Ceramic Bushings and Custom Solutions for Extreme Applications

Engineered ceramic components represent a core competency at Zircoa, delivering customized solutions for applications where metals and other materials simply cannot meet performance requirements. Our ceramic bushings and engineered components are primarily developed for specific customer applications requiring precise dimensional tolerances, complex geometries, and performance in the harshest industrial environments.

While some components are developed based on recurring customer needs, most inquiries involve new, custom developments requiring precise machining and exacting tolerance requirements. Our material science expertise enables us to engineer solutions that withstand extreme wear, corrosion, impact, and high-temperature stress where standard materials fail.

Learn more about our engineered ceramic component capabilities below, or contact our specialists to discuss your specific custom component requirements.

The Benefits of Zircoa Engineered Ceramic Components

• Custom geometries engineered for your specific application requirements
• Precision dimensional tolerances for critical fit and performance
• Superior wear resistance in high-impact and abrasive environments
• Exceptional corrosion resistance against acids, alkalis, and organic solvents
• High-temperature performance with maintained strength up to 1500°F (815°C)
• Transformation toughening prevents crack propagation under stress
• Chemical inertness for contamination-free processing

Primary Industries

• Oil and gas equipment requiring corrosion-resistant components
• Chemical processing plants with aggressive media exposure
• Manufacturing equipment subjected to extreme wear conditions
• Fluid handling systems requiring precision flow control
• Industrial machinery operating in harsh environments

Key Applications

• Ceramic bushings for wear-resistant bearing applications
• Valve trim and pump components for corrosive media
• Wear parts for manufacturing and processing equipment
• Sensors and instrumentation components for extreme conditions
• Custom machine parts requiring precision tolerances

Component Design and Material Selection

Custom Engineering Process

Our engineering team collaborates closely with customers to develop components that solve specific challenges:

• Application assessment and material selection optimization
• CAD design and finite element analysis for performance validation
• Precision machining capabilities for tight dimensional tolerances
• Quality assurance and testing protocols for critical applications

Backup Refractory Insulation for Extended Furnace Performance

Granular zirconia (grog) serves as essential backup refractory insulation that dramatically improves the energy efficiency and operational life of your high-temperature systems. When used as crucible backup or furnace lining insulation, our pre-sintered granular materials deliver approximately five times the insulating value of traditional alumina or magnesia alternatives, helping you achieve tighter temperature control while reducing energy costs.

This complementary material works alongside Zircoa’s primary refractory products to optimize overall system performance. In crucible applications, granular zirconia extends service life and promotes cleaner melts by providing superior thermal barrier properties and minimizing heat loss through furnace walls.

Learn more about our refractory insulation below, or contact our zirconia experts to discuss your specific crucible backup requirements.

How Granular Zirconia (Grog) Outperforms Alternatives

• 5x more effective than alumina or magnesia backup materials
• Reduces thermal stress on primary refractory components
• Minimizes heat loss for reduced operating costs
• Maintains tighter, more consistent furnace temperatures
• Reduces contamination risk in melting applications
• Engineered to withstand extreme temperature cycling
• Available in multiple stabilized compositions for specific environments
• Consistent performance in demanding high-temperature applications

Primary Industries

• Investment casting foundries requiring extended crucible life and energy efficiency
• Aerospace component manufacturing with strict temperature control requirements
• Precious metals processing operations demanding contamination-free environments
• Glass and quartz melting above 1900°C
• Crystal growth operations requiring precise thermal management
• Steel production environments with extreme thermal cycling demands

Key Applications

• Crucible backup insulation for extended service life and cleaner melts
• Furnace lining thermal barriers for improved energy efficiency
• High-temperature insulation systems requiring superior thermal performance
• Backup materials for molten metal contact environments
• Thermal cycling applications in glass and crystal growth operations
• Energy-efficient insulation solutions for steel and aerospace processing

Granular Zirconia Specifications & Selection

Available Stabilization Types

• Magnesia — Molten metal environments and environments subject to extreme wear
• Calcia — Continuous high temperature, or cycling applications with no molten metal contact

Available Compositions

• Zircoa Backup 1859 — Grog, partially stabilized with magnesia and calcia
• Zircoa Backup 1860 — Grog, partially stabilized with magnesia and calcia
• Zircoa Backup GNF — Grog, partially stabilized with calcia
• Zircoa Backup 10B — Bubble, partially stabilized with calcia

Custom particle size distributions and specialized compositions can be engineered to meet specific application requirements.

Proprietary High-Purity Monoclinic Zirconia Powder with Unique Spheroidal Shape

A Grain Zirconia represents a Zircoa specialty and key differentiator in the zirconia market — a proprietary high-purity powder and distinct spheroidal particle shape. This customizable monoclinic zirconia powder is synthesized from zircon sand using our solid-state reaction process, yielding consistently high purity zirconia with unique properties that solve problems conventional zirconia powders cannot address.

Our standard A Grain zirconia powder features a mean particle size of 2.1 microns with exceptional spheroidal particle shape, low surface area (1 m²/g), and superior dispersibility characteristics. These distinctive properties enable critical applications from automotive airbag initiators to asbestos alternatives like chlor-alkali products, representing technologies that impact daily life around the world.

Learn more about our proprietary A Grain zirconia powder below, or contact our specialists to discuss your specific high-purity zirconia requirements.

Zircoa A Grain

Typical Precipitated Zirconia

Typical Fused Zirconia

Zircoa A Grain: Not an Ordinary Zirconia Powder

• Proprietary spheroidal particle shape unique to Zircoa manufacturing method
• High purity monoclinic zirconia with consistent quality control
• Customizable chemical and physical properties
• Low surface area (1 m²/g) for reduced reactivity and superior flow properties
• Exceptional dispersibility enables uniform distribution in various media
• Consistent 2.1-micron mean particle size for reliable performance
• Easily dispersed with high solids loading capabilities (80-90%)
• Lower shrinkage of fired parts improves dimensional control
• Customizable chemical and physical properties to improve processing and efficiency

Key Applications

• Sensors for oxygen measurement and control
• Zirconium metal production in automotive airbag initiators
• Display glass filler for toughening and durability
• Chlor-alkali processes as a non-asbestos material to enhance health and safety
• Catalyst supports and substrates for chemical processing
• Ceramic colorants and opacifiers for specialized applications
• High-temperature applications requiring thermal stability

Primary Industries

• Automotive
• Chemicals
• Electronics
• Glass
• Refractories and Ceramics
• Steel

A Grain Zirconia Specifications and Properties

Unique Manufacturing Process

Zircoa’s proprietary solid-state reaction process synthesized from zircon sand delivers zirconia powder with properties that conventional precipitation or fusion methods cannot achieve. Our manufacturing approach ensures impurities are controlled and the distinctive spheroidal particle shape enables superior performance.

Critical Performance Characteristics

• Mean particle size: 2.1 microns (by Microtrac analysis)
• Surface area: 1 m²/g (by BET analysis method)
• Particle shape: Unique spheroidal configuration
• Phase composition: Monoclinic