Introduction
Honeycomb ceramics are a new type of functional ceramic material characterized by a regular porous honeycomb structure. They are typically fabricated from raw materials such as silicon carbide (SiC), cordierite (Mg₂Al₄Si₅O₁₈), and mullite (3Al₂O₃·2SiO₂) through extrusion molding and high-temperature sintering.
Designed to store and release thermal energy, honeycomb ceramics are widely applied in energy-saving technologies for industrial thermal equipment. Their basic structure consists of numerous small pores arranged in hexagonal or square patterns, forming a honeycomb lattice. This design enhances surface area, improves thermal conductivity, and enables efficient heat absorption and release, thereby providing a stable and long-lasting heat source.
Advantage
Thermal Performance: The Paradoxical Unity of High-Efficiency Heat Storage and Insulation
Ultra-Efficient Heat Exchange Capacity: The dense pores create a "heat sponge" effect, causing turbulent flow of high-temperature flue gas and air within the pores. This reduces heat exchange time from 5 seconds (with traditional checker bricks) to less than 1 second.
The porous honeycomb structure gives honeycomb ceramics a specific surface area of 100–500 m²/m³ (traditional refractory bricks have only 1–10 m²/m³). For example, in a steel reheating furnace, using cordierite honeycomb ceramics increased flue gas waste heat recovery efficiency from 60% to over 90%, reduced fuel consumption by 30%, and achieved annual energy savings equivalent to 2,000 tons of standard coal.
Balance of Low Thermal Conductivity and Thermal Shock Resistance
Honeycomb ceramics have a thermal conductivity of only 0.2–1.0 W/(m·K) (high-alumina bricks have 1.5–3.0 W/(m·K)), which can reduce kiln outer wall temperatures by 50–80°C and heat loss by 15–20%. Meanwhile, the porous structure acts as a "shock absorber" to dissipate thermal stress. Cordierite-based honeycomb ceramics can withstand thermal shock of 800°C (traditional refractory bricks only 300–500°C), making them less prone to cracking during glass kiln start-stop cycles.
Erosion Resistance: Innovative Corrosion Resistance in Diverse Scenarios
Strong Resistance to Metal and Glass Melts
In aluminum alloy casting, SiC honeycomb ceramic filters capture inclusions larger than 50 μm, reducing casting impurity content from 0.3% to below 0.05%. They also exhibit a wear rate of less than 0.1 mm per 1000 cycles under 1100°C aluminum melt scouring (compared to 0.5 mm/1000 cycles for traditional quartz sand filters).
In glass kilns, mullite-based honeycomb ceramics show four times stronger resistance to Na₂O and other oxide erosion than clay bricks. Their service life in 1600°C glass melt volatile environments reaches five years (traditional refractory bricks last only two years).
Adaptability to Complex Atmospheres
In waste incinerators, SiC honeycomb ceramics withstand corrosion from acidic gases (e.g., HCl, SO₂) in 850°C+ flue gas while preheating combustion air to above 800°C, promoting dioxin decomposition rates exceeding 99.9%.
Structural Advantage: Subversive Breakthrough in Lightweight and High Strength
Double Optimization of Volume and Weight
With a porosity of 70–90%, honeycomb ceramics reduce volume by 50% and weight by 30% compared to traditional refractory bricks under the same heat storage capacity.
Scratch Resistance and Long Service Life
The pore wall surface of honeycomb ceramics is smooth (roughness Ra < 5 μm), with a wear rate of less than 0.05 mm/year under high-temperature flue gas scouring (flow rate 15–20 m/s)-significantly lower than traditional refractory bricks (0.2 mm/year).
Green and Energy-Saving: Core Materials for Carbon Reduction in Industrial Kilns
Honeycomb ceramic heat storage systems enhance kiln thermal efficiency by 25–35%. Used honeycomb ceramics can be crushed and reused as aggregate for new products, with recovery rates up to 90% for SiC-based and 70% for cordierite-based materials. This significantly reduces solid waste emissions compared to traditional refractory bricks (recovery rate less than 30%).
Catalytic-Thermal Storage Integration
In ceramic kiln exhaust gas treatment, TiO₂-loaded honeycomb ceramics enable simultaneous waste heat recovery (preheating air to 300°C) and catalytic VOC degradation (efficiency over 95%), reducing equipment investment by 40%.
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Raw Materials
Thermal Storage Honeycomb Ceramics
Materials: Cordierite, Mullite
Main Size of Honeycomb Ceramics
|
L*W*G(mm) |
150x 150 x 300(150) |
||||
|
Number of Cell |
25x25=625 |
40x40= 1600 |
43x43=1849 |
50x50=2500 |
60x60=3600 |
|
Width of Cell(mm) |
4.95 |
3.02 |
2.81 |
2.38 |
1.98 |
|
Thickness of inner wall(mm) |
1 |
0.7 |
0.65 |
0.6 |
0.5 |
|
Surface Area(m2/m3) |
577 |
886 |
950 |
1084 |
1294 |
|
Opening Ratio(%) |
68 |
65 |
65 |
63 |
63 |
Physical Properties of Honeycomb Ceramics
|
Item |
Aluminum Porceian-cordierite |
Dense aluminum porcelain |
Cordierite |
Mullite-Cordierite |
Mullite |
Enamel |
|
Density(g/cm3) |
2.0~2.3 |
2.4~2.6 |
1.6~1.9 |
1.7~2.0 |
2.0~2.4 |
1.7~2.0 |
|
Bulk density (g/cm3) |
0.65~0.8 |
0.65~0.8 |
0.6~0.7 |
0.65~0.75 |
0.65~0.8 |
0.65~0.75 |
|
Thermal Expansion Coefficient (X10-6°C-1) (RT-800°C) |
≤6 |
≤6 |
≤3 |
≤3.5 |
≤5.5 |
≤6.5 |
|
Specific heat capacity (J/Kg.k) |
950~1150 |
1000~1200 |
900~1100 |
900~1100 |
1000~1150 |
900~1100 |
|
Thermal Conductivity (w/m.k)(20-1000°C) |
1.5~2.0 |
1.5~2.0 |
1.2~1.8 |
1.4~1.9 |
1.5~2.0 |
1.4~1.9 |
|
Thermal shock resistance Max Temperature(℃) |
≥400 |
≥300 |
≥450 |
≥350 |
≥350 |
≥300 |
|
Advised Max Temperature(℃) |
1250 |
1350 |
1150 |
1250 |
1450 |
1200 |
|
Water Absorption Rate(%) |
≤20 |
≤5 |
≤22 |
≤20 |
≤20 |
≤10 |
Chemical composition of Honeycomb Ceramics
|
Item |
Aluminum Porceian-cordierite |
Dense aluminum porcelain |
Cordierite |
Mullite-Cordierite |
Mullite |
Enamel |
|
SiO2 |
25~35 |
25~35 |
45~55 |
40~50 |
25~35 |
68~72 |
|
Al2O3 |
55~65 |
55~65 |
28~38 |
55~65 |
55~65 |
22~26 |
|
MgO |
2~4 |
2~4 |
11~14 |
5~9 |
≤2 |
≤0.5 |
|
Fe203+TiO2 |
1~4 |
1~4 |
1~3 |
1~3 |
1~4 |
1~3 |
|
Others |
≤5 |
≤5 |
≤5 |
≤5 |
≤5 |
≤5 |
Process
Raw Material Preparation
High-purity powders (e.g., SiC with purity >99%) must be refined via ball milling to a D50 below 2 μm to ensure molding uniformity.
Extrusion Molding
Key Parameters: Pressure 5–10 MPa, temperature 50–80°C. The straightness deviation of the pores must be controlled below 1% to avoid "collapsed hole" defects.
High-Temperature Sintering
Cordierite ceramics require sintering at 1350–1450°C for 20–30 hours.
SiC ceramics must be sintered at ≥2000°C in an inert atmosphere, which consumes more energy.
Application
Performance Requirements of Honeycomb Ceramics in the Refractory Industry
Temperature Adaptation
Cordierite-based honeycomb ceramics have a refractory temperature over 1300°C, while SiC-based types exceed 1700°C. These are suitable for 1200–1600°C high-temperature environments in steel, glass, and other industries.
Thermal Shock Stability
The porous structure alleviates thermal stress from sudden temperature changes. Cordierite honeycomb ceramics can withstand thermal shocks of 800°C without cracking (traditional refractory bricks tolerate only 300–500°C temperature differences).
Typical Application Scenarios and Technical Advantages
Industrial Furnace and Kiln Thermal Storage System
Application Location: Heat storage chamber lattice of steel plant reheating furnaces and glass kilns.
Advantages:
Enhanced Heat Storage Efficiency: The specific surface area of honeycomb ceramics reaches 100–500 m²/m³ (traditional checker bricks only 10–30 m²/m³), boosting heat recovery efficiency from 60% to over 90%. For instance, after installing cordierite honeycomb ceramics in a steel reheating furnace, fuel consumption decreased by 30%, saving 1.2 million m³ of natural gas annually.
Volume and Weight Optimization: With a porosity of 70–90%, honeycomb ceramics reduce volume by 50% and furnace body weight by 30% compared to traditional refractory bricks under the same heat storage capacity, minimizing steel structure loads.
High-Temperature Kiln Lining and Insulation
Application Scenario: Lining or backing insulation for ceramic sintering kilns and refractory firing kilns.
Advantages:
Thermal Insulation: Honeycomb ceramics have a thermal conductivity of 0.2–1.0 W/(m·K) (traditional refractory bricks: 1.5–3.0 W/(m·K)), reducing kiln outer wall temperature by 50–80°C and heat loss by 15–20%.
Erosion Resistance: In aluminum electrolyzer linings, SiC honeycomb ceramics resist cryolite (Na₃AlF₆) erosion three times better than high-alumina bricks, extending service life from 2 years to over 5 years.
Molten Metal Filtration and Purification
Application: Filtration of liquid metal in aluminum and copper alloy casting processes.
Advantages:
Impurity Capture: The honeycomb ceramic pore structure (pore size 1–3 mm) captures inclusions over 50 μm, reducing oxide impurities in aluminum alloy castings from 0.3% to ≤0.05%. This enhances mechanical properties (tensile strength) by 15%.
High-Temperature Metal Melt Scour Resistance: SiC honeycomb ceramics (hardness HV >2500) exhibit a wear rate below 0.1 mm per 1000 cycles under 1100°C copper melt scouring-significantly lower than traditional quartz sand filters (0.5 mm/1000 cycles).
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