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Ceramic Honeycomb  Monolith for Heat Exchange

   

        Alias: Ceramic Honeycomb Heat Recovery Bed, heat exchange bed, Thermal storage& recovery ceramic media, heat exchange elements /media.  Ceramic monoliths media evidently save energy in steel works and metallurgy industry, Regenerative thermal oxidizers (RTO). Honeycomb monolith is the key components of the style furnace, it is extensively used in many kinds of heater, sirocco furnace, heat treatment furnace, cracking column, roaster, melting furnace, balance heating stove and etc. This technology can save more than 40-70% of energy.

       It is also widely used in abatement of Volatile organic compounds  (VOC) , hazardous air pollutants (HAP), carbon monoxide (CO), nitrogen oxides (Nox), organic particulate matter (OPM), HC nytron, SO2, odors, and other air toxics in oil and chemical industry through a regenerative thermal oxidizer (RTO) device. Dust burning stove/ incinerator, power plant also needs ceramic honeycomb. An RTO device contains a ceramic heat exchanger bed which is used for the preheating and cooling of the waste gases before the gases enter and exit the combustion chamber, respectively.

Advantages over ceramic saddles and balls:

        Compared with other ceramic media, such as saddles or ceramic balls, which have conventionally been used in RTOs.   The advantages of the honeycomb monolith include a greater thermal efficiency and a lower pressure drop across the heat exchanger bed. The increase in thermal efficiency and lower pressure drop generally results in a smaller equipment design, lower capital costs and lower operating costs. Honeycomb ceramic provide a more efficient alternative for the following reasons: cutting fan load for significant energy savings( low pressure drop owing to straight channels ), Less volume, thin wall thickness, faster in thermal exchange. High surface area means high conversion efficiency in converters occupying small volumes.  Lighter weight, so less structural support is required.

Thermal Oxidizers
         Thermal oxidizers are ideal for areas with high fume concentrations and where emissions contain solvents, sulfides, silicones or heavy metals. Simplicity of design makes thermal oxidizers the best choice for many of today's pollution problems.
         Key Benefits: Flexibility of horizontal or vertical design, Low maintenance issues.
Catalytic Oxidizers
         Catalytic oxidizers are designed with low maintenance and fuel efficiency in mind. The oxidizers include an all welded stainless steel inner chamber, noble/precious metal monolith catalyst cells, industrial grade combustion system and controls. 
          Key Benefits: Optional heat recovery system and Low fuel consumption.

Note:

       The information contained in the tables below is believed to be accurate and reliable but is not to be construed as implying any warranty or guarantee of performance.

       Cell structure density ranges from 1 to 800 cells per square inch (CPSI). Material are typically available in cordierite, mullite and alumina etc on customer request. Cell shape in square, circle, hexagon, triangle etc. The following specification is just a small part of our available specification, just for your reference. We are also glad to accept customized product order.

Technical Specifications of Ceramic Monolith for Heat Exchange

Type Dimensions (mm) Specifications English Units Metric Units Remarks
1 150 * 150 * 300 25 * 25 channels
Width of Channels
Wall thickness
Specific surface area
Free cross section
0.191 in
0.04 in
164.6 ft2/ft3
67%
4.9 mm
1 mm
540 m2/m3
67%

Also available with any length between 150 mm and 500 mm

2 150 * 150 * 300 40 * 40 channels
Width of Channels
Wall thickness
Specific surface area
Free cross section
0.177 in
0.027 in
251.4 ft2/ft3
65%
4.9 mm
0.7 mm
825 m2/m3
65%
Also available with any length between 150 mm and 500 mm
3 150 * 150 * 300 50 * 50 channels
Width of Channels
Wall thickness
Specific surface area
Free cross section
0.088 in
0.027 in
306.3 ft2/ft3
57%
4.9 mm
0.7 mm
1005 m2/m3
57%
Also available with any length between 150 mm and 500 mm
4 150 * 150 * 300 43 * 43 channels
Width of Channels
Wall thickness
Specific surface area
Free cross section
0.113 in
0.02 in
304.8 ft2/ft3
72%
4.9 mm
0.5 mm
1000 m2/m3
72%
Also available with any length between 150 mm and 500 mm
5 150 * 150 * 300 34 * 34 channels
Width of Channels
Wall thickness
Specific surface area
Free cross section
0.152 in
0.016 in
245.4 ft2/ft3
79%
4.9 mm
0.4 mm
805 m2/m3
79%
Also available with any length between 150 mm and 500 mm

 Weight Info

Type Dimensions (mm) Material lb/block lb/ft3 kg/block kg/m3
1 150 * 150 * 300
25 * 25 channels
Mullite
Alumina Porcelain
11.0
12.1
46.2
50.9
5.0
5.5
740
815
2 150 * 150 * 300
40 * 40 channels
Mullite
Alumina Porcelain
Cordierite, dense
Cordierite, porous
13.2
14.3
13.4
13.2
55.6
59.9
56.2
55.6
6.0
6.5
6.1
6.0
890
960
900
890
3 150 * 150 * 300
50 * 50 channels
Cordierite, dense 13.2 55.6 6.0 890
4 150 * 150 * 300
43 * 43 channels
Mullite 9.9 41.8 4.5 670
5 150 * 150 * 300
34 * 34 channels
Mullite
Alumina Porcelain
6.6
8.4
27.8
35.5
3.0
3.8
445
570

 Physical and Chemical Properties

Property Units Alumina Porcelain Mullite Cordierite Dense Cordierite Porous Stoneware
Coefficient of thermal
expansion (20 - 1000
degree Celsius )
10-6K-1 5 - 7 6.2 1.3 - 3.4 2.5 - 5 4 - 7
Heat capacity
(20 - 1000 degree Celsius)
J/kgK
BTU/lb Fahrenheit
800 - 900
0.19 - 0.22
850 - 1050
0.20 - 0.22
800 - 1200
0.19 - 0.29
750 - 800
0.18 - 0.19
840-920
0.20 - 0.22
Resistance to thermal
shocks
K 150 350 250 300 250
Maximum operating
temperature

Celsius

Fahrenheit

1300
2372
1600
2912
1300
2372
1300
2372
1200
2192
Alumina content % 50 70 35 34 19

Pressure tests of ceramic materials are made at standard samples (according to DIN VDE 0335) and cannot formally be applied to the honeycomb monoliths. 

Chemical Composition by Weight Percent

Component Alumina Porcelain Mullite Cordierite Dense Cordierite Porous Stoneware
SiO2 42.8 27.8 47.8 47.9 70.2
Al2O3 50.5 70.1 35.1 33.7 19.4
MgO - - 6.7 8.5 0.18
Fe2O3 0.6 0.8 0.78 1.6 0.70
Na2O + K2O + CaO 4.8 1.0 2.8 1.3 3.3
TiO2 + BaO - - 0.39 0.78 0.25
 

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