Honeycomb Ceramic
What Is Honeycomb Ceramic
The cellular structure of a honeycomb is modeled after nature – a solution that produces the largest possible surface with the smallest possible volume. For flow-related tasks, very thin walls keep the pressure loss very moderate while ensuring full contact of the gas molecules with the surface. The surface characteristics can be varied along a very wide range by selecting specific ceramic materials. This makes honeycomb ceramics suited for filter applications, as catalyst carriers or as heat storage media. The carrier structures for the catalytic purification of combustion gas from gasoline engines and for the filtration of soot particles from the exhaust flows of diesel engines consist of honeycomb ceramics. Furthermore, honeycomb ceramics are used for the treatment of industrial exhaust flows loaded with various organic and inorganic contaminants.
Advantages of Honeycomb Ceramic
High temperature working strength
Honeycomb ceramic has very high temperature working strength, thermal shock resistance, and resistance to metal flow impact. It does not have any slag drop or cracking phenomenon during work, which ensures the filtering quality of molten metal.
High room temperature strength and resistance
Honeycomb ceramic has extremely high room temperature strength and resistance to mechanical shock. There is no crack or damage during use and transportation, which greatly facilitates the use and operation of the filter.
Reduce the turbulence
Honeycomb ceramic can effectively reduce the turbulence of molten metal caused by pouring, smooth the filling, and avoid surface defects of the casting.
High chemical stability
The honeycomb ceramic has high chemical stability, is not affected by the acidity and alkalinity of the molten metal, and does not change the chemical composition of the molten metal.
Why Choose Us
Our factory
Pingxiang Zhongci Environmental Ceramics Material Co., Ltd. was founded in 2014. It is a professional manufacturer of ceramic, plastic and metal bulk structured packings, microporous ceramics and other chemical tower packings, ceramic balls, molecular sieves, activated alumina balls, and water treatment products. The company has more than 10 million yuan in fixed assets, an annual production capacity of 150 million yuan, 12 technical personnel, and more than 200 employees.
Our product
Ceramic Plastic Metal Materials Tower Packing, Inert Alumina Ceramic Ball, RTO Honeycomb Ceramic, Activated Alumina, Molecular Sieve Carbon Raschig Ring, Silica Gel, etc. Other new related type cargos can be customized! Our products are widely used in Steel Electric Power, Petroleum Chemical Fertilizer, Metallurgy, Environmental Protection, Pharmaceutical, Aerospace, Aviation and other industries.
Production equipment
Our company have plastic molding machines, die casting machines, kiln machines, mixers, screening machines, etc.
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ISO9001, ISO14001, ISO45001, Certificated Plant.
What Is The Use Of Honeycomb Ceramics?
Honeycomb ceramic regenerator
The heat capacity of the honeycomb ceramic regenerator is above j/kgk1000, and the maximum service temperature of the product is ≥1700°c. It can save fuel by more than 40% and increase the output by more than 15% in furnaces such as heating furnaces, roasters, soaking furnaces, and cracking furnaces. , the exhaust gas temperature is lower than 150°c.
Honeycomb ceramic filler
Honeycomb ceramic filler has the advantages of larger specific surface area and better strength than other shape fillers, which can make the vapor-liquid distribution more uniform, reduce bed resistance, better effect, and prolong service life. It is widely used in the petrochemical, pharmaceutical and fine chemical industries. It works quite well as a filler.
Honeycomb ceramic catalyst substrate
Honeycomb ceramics have more advantages in catalysts. The honeycomb ceramic material is used as the substrate, and the unique coating material is used. It is made of precious metals, rare earth metals and transition metals, so it has the advantages of high catalytic activity, good thermal stability, long service life, and high strength. Honeycomb ceramic catalysts are constantly being innovated, and the market demand is also increasing. The honeycomb ceramic catalysts with large sizes and porous numbers have emerged and have a strong development momentum.
Honeycomb ceramic filter
It is mainly used in the metallurgical industry. The specific surface area of the honeycomb ceramic body is large, which improves the ability of the filter to absorb and capture small impurities, and has a better filtering effect than traditional porous ceramics, and the molten metal flows smoothly.
Honeycomb Ceramic Manufacturing Process
The ceramic honeycomb is the last three decades the development of a structure like honeycomb shape a new type of ceramic products. First used in a small car exhaust purification widely used in chemical, electric power, metallurgy, petroleum, electronics, electrical appliances, machinery and other industries, but also more widely, the prospects for development is considerable.
Ceramic honeycomb countless equal holes of various shapes, the largest number of holes have reached every square cm of 20 to 40, the density of 4 to 6 grams per cubic centimeter, the water absorption up to 20%. The geometric surface area of the carrier due to the characteristics of the porous thin wall, greatly increased and improved thermal shock resistance, current products, the mesh holes on the triangle and the Quartet, The Triangle is much better than the quad endurance, number of holes is also more, which is especially important as a catalyst carrier. With the number of holes per unit area of the improvement and the reduction of carrier pore wall thickness, the thermal shock resistance of the ceramic substrate in the trend is to improve the thermal shock damage temperature is raised. Ceramic honeycomb must be to reduce the coefficient of expansion and increase the number of holes per unit area.
The coefficient of thermal expansion is the key performance indicators, the current level of ≤ 1.0 × 10-6 /℃ (25-1000 ° C). The first production of ceramic honeycomb raw materials such as kaolin, talc, aluminum powder, clay, and today has exceeded, especially diatomaceous earth, zeolites, expansive soils, and refractory applications, ceramic honeycomb increasingly widespread application performance increasingly the better.
The main products of the ceramic honeycomb regenerative filler, activated carbon, activated alumina, molecular sieves, porcelain balls, tower packing and catalyst of dozens of products. Honeycomb ceramic regenerator packing heat capacity of 1000J / (kgK) above, the use of temperature ≥ 1700 ° C, up to 40% fuel savings in the furnace, baking, soaking furnace, pyrolysis furnace, kiln, production increased by more than 15% of the flue gas temperature below 150 ° C.
Activated carbon powder or particles made of a ceramic honeycomb shape, which greatly improves the purification of water treatment and waste water treatment capacity, especially in the pharmaceutical industry, antibiotics, hormones, vitamins, nucleic acid injection, and a variety of injections, drugs such as dehydration decolorization impurities.
Honeycomb ceramic packing filler than any other shape of greater specific surface area, strength and better enable the vapor-liquid distribution is more uniform, lower bed resistance, better, and extend the service life in the petrochemical, pharmaceutical and fine chemical industry for the filler effect is quite good.
Ceramic honeycomb used in the catalyst advantage. Honeycomb ceramic materials using a unique coating materials, precious metals, rare earth and transition metal preparation, and thus has the advantages of high catalytic activity, good thermal stability, long life, high strength.
What Defines the Material Integrity of Automotive Honeycomb Ceramics?
Porosity
Automotive ceramic honeycombs need to maintain a fine balance in porosity. Too porous, and the strength is compromised; too dense, and it could hamper its function. The ideal porosity ensures that the ceramics can filter exhaust gases efficiently.
Thermal Stability
Cars run hot. Hence, the ceramic honeycomb needs to withstand extreme temperatures without degrading. High thermal stability ensures that the ceramic doesn’t crack or break under intense heat.
Mechanical Strength
Given the wear and tear in vehicles, the mechanical strength of the ceramic honeycomb is crucial. It needs to be robust enough to endure the physical stresses during vehicle operation.
Chemical Resistance
Automotive exhaust gases are a cocktail of chemicals. The ceramic honeycomb’s ability to resist chemical degradation ensures its longevity and consistent performance.
The interplay of these material specifications directly influences the honeycomb’s efficiency. For instance, a ceramic honeycomb with the right porosity levels ensures optimal exhaust filtration, reducing pollutants. Likewise, ceramics with excellent thermal stability can endure long drives without any performance dip. Quality assurance is vital. Engaging with suppliers who adhere to industry benchmarks, like those set by ASTM, ensures high-grade ceramic honeycombs. Regular testing and material analysis can further validate the material specifications. In this way, the performance of the catalytic converter can be improved from the source.
Honeycomb Ceramics for Dross Removal and Metal Filtration Applications
Honeycomb ceramics are applied as heat storage media in regenerative thermal processes to recover thermal energy. Typical ceramic filtration application examples are thermal air pollution abatement systems, based on regenerative thermal oxidation (RTO), thermal regenerators for process gases, heat storage media for decentralized Regenerative Housing Ventilation systems (RHV) or heat storage applications in renewable energy generation systems. The main area of application for honeycomb ceramics are still RTOs for destruction of Volatile Organic Compounds (VOCs).
Typical industries that use such regenerative thermal oxidation systems include the pharmaceutical and chemical industries, paint and paper manufacturers, wood processing companies, and the electronics and semiconductor industries amongst others. The most important advantage of the structured packing using honeycomb ceramics – when compared to conventional random packing technologies (ceramic saddles or plates) – is the highest possible heat recovery at the lowest possible pressure drop. Defined linear flow prevents particle deposits and chemical attacks. Simple operation and very low operating and maintenance costs make such honeycomb regenerator systems an extremely reliable and economically efficient solution.
Regenerator beds in regenerative thermal oxidation systems have to meet many requirements under often very drastic conditions. The properties of honeycomb ceramics must therefore be tailored to different requirements.
Performance Requirements For Honeycomb Ceramic Regenerators
Honeycomb ceramic regenerators are commonly used in various industrial applications, especially in energy-saving systems such as regenerative heat exchangers. Its performance requirements are critical to ensure optimal performance and energy efficiency in these applications.
Heat transfer efficiency
The honeycomb ceramic regenerator should efficiently transfer heat from the exhaust gases to the incoming air flow and vice versa. Heat transfer efficiency is usually measured by the efficiency of the regenerator, which is the ratio of actual heat transfer to the maximum possible heat transfer.
Thermal mass
The thermal mass of the honeycomb ceramic material should be sufficient to store and release heat as needed. It should have the ability to store thermal energy during one phase of the cycle (e.g. heating) and release it during another phase (e.g. cooling).
Thermal shock resistance
Honeycomb ceramic regenerators must be able to withstand rapid temperature changes without cracking or cracking. They should have good thermal shock resistance to ensure longevity and reliability.
Pressure drop
Pressure drops across the honeycomb structure should be minimal to avoid significant energy losses. Low pressure drop ensures the system operates efficiently and does not require excessive fan or blower power.
Material composition
The ceramic materials used in the regenerator should be selected based on their thermal conductivity, high temperature stability and chemical resistance. Common materials include cordierite, mullite, and silicon carbide.
Dimensions and geometry
The size and geometry of the honeycomb structure should be designed to maximize the heat exchange surface area while fitting within the available space. The configuration should be optimized for the specific application.
Temperature range
It must be designed to operate within the specified temperature range of the application, whether in an industrial furnace, gas turbine or other system. They should be able to withstand high temperatures without degrading.
Regeneration cycle time
Cycle times for switching between heating and cooling phases should be kept as short as possible to ensure fast response and efficient energy recovery.
Maintenance and durability
Honeycomb ceramic regenerators should have a long service life and minimal maintenance requirements. Durability is critical to avoid frequent replacements and downtime.
Environmental considerations
The materials used in honeycomb ceramic regenerators should be environmentally friendly and should not emit harmful pollutants during operation.
Characters of High Performance Honeycomb Ceramic Regenerator
High-performance honeycomb regenerators are developed for the actual combustion conditions of heating furnaces , and can be adapted to the actual conditions in most heating furnaces with low control levels and poor combustion conditions.
The storage heat is 20-50% more than the ordinary honeycomb ceramic regenerators, so the commutation cycle is about 20-50% longer than the ordinary honeycomb ceramics, which in turn increases the service life of the reversing device and the honeycomb. For the longer service life, improve, and meet the requirements of the furnace maintenance cycle, can be synchronized with the minor repair cycle furnace.
Good thermal shock resistance, good thermal conductivity, high mechanical strength, better adapting to the working conditions of the regenerative heating furnace, even in the case of abnormality in the regenerative chamber due to abnormal conditions of the heating furnace ,it is also not easy to deform, collapsing slag and adhesive, and can still play the role of regenerative body; Thin and smooth channel wall, low back pressure, large capacity, high heat storage, small footprint; According to requirements and the different environments, we can chose different materials and specifications of the products; With high quality, during installation, the regenerators are discharged neatly with a small dislocation.
Our factory
Pingxiang Zhongci Environmental Ceramics Material Co., Ltd. was founded in 2014. It is a professional manufacturer of ceramic, plastic and metal bulk structured packings, microporous ceramics and other chemical tower packings, ceramic balls, molecular sieves, activated alumina balls, and water treatment products. The company has more than 10 million yuan in fixed assets, an annual production capacity of 150 million yuan, 12 technical personnel, and more than 200 employees. Strong technical capabilities, testing equipment, enterprises have passed ISO9001 quality system certification, the company's advanced product design, sophisticated manufacturing, complete specifications. Products sell well all over the country, by the petroleum, chemical, fertilizer, pharmaceuticals, pesticides, agriculture, environmental protection, electricity, sewage treatment and other industries trust and praise.
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