E-mail:lizhi@pxball.cna comprehensive guide to ceramic balls
I. Introduction
Inert ceramic balls, as a key material widely used in the industrial field, are increasingly attracting attention from various industries. With their unique physical and chemical properties, such as high hardness, excellent chemical stability, and good thermal stability, inert ceramic balls play an indispensable role in numerous processes. From petrochemicals to environmental protection, from fertilizer production to natural gas purification, they contribute significantly to enhancing production efficiency and ensuring the stable operation of equipment. This article will delve into the definition, characteristics, classification, application areas, and case studies of inert ceramic balls, providing readers with a comprehensive understanding of this important industrial material. Please provide the text you would like translated.
II. Definition and Characteristics of Inert Ceramic Balls
(1) Definition
Inert ceramic balls are spherical ceramic products made from high-quality chemical clay, alumina powder, and other main raw materials through specific processing techniques and high-temperature firing. They are named as such because they exhibit chemical inertness in most chemical reaction environments and do not participate in the reaction process. Please provide the text you would like translated.
(2) Characteristics
Chemical stability: Inert ceramic balls exhibit outstanding resistance to acids, bases, salts, and various organic solvents. Even highly corrosive substances such as sulfuric acid, hydrochloric acid, and sodium hydroxide find it difficult to erode their structure, ensuring stable performance in complex chemical environments. Please provide the text you would like translated.
Thermal stability: It can withstand significant temperature fluctuations. Even in high-temperature environments, such as at 1000°C or even higher, it can maintain its structural integrity and performance stability without cracking or deforming due to thermal expansion and contraction. This characteristic makes it suitable for high-temperature reaction processes, such as petrochemical cracking and catalytic reforming. Please provide the text you would like translated.
High strength and wear resistance: Through advanced production processes and high-quality raw materials, inert ceramic balls have high mechanical strength and excellent wear resistance. Under harsh working conditions such as high pressure and high flow rate, they can operate stably for a long time, are not prone to breakage or wear, and effectively extend the maintenance cycle and service life of the equipment. Please provide the text you would like translated.
Low water absorption: Its internal structure is dense, with extremely low water absorption. This not only helps maintain its physical properties in damp or liquid environments but also prevents weight gain and performance decline due to water absorption, ensuring stable performance under various working conditions. Please provide the text you would like translated.
III. Classification of Inert Ceramic Balls
Based on their main components and performance characteristics, inert ceramic balls can be roughly classified into the following categories:
(1) Common Ceramic Balls
These are typically made from common ceramic clay and have relatively low costs. They are suitable for conventional industrial scenarios where the requirements for chemical stability, thermal stability, and mechanical strength are not particularly strict, such as simple support or filling in some small-scale chemical reaction devices with relatively lenient process conditions. Please provide the text you would like translated.
(2) Low-aluminum ceramic balls
The content of aluminum oxide (Al₂O₃) is relatively low, generally around 20% to 45%. Compared with ordinary ceramic balls, they have certain improvements in corrosion resistance, mechanical strength and thermal stability, and can be used in some environments with moderate corrosion, temperature and pressure conditions that are not particularly extreme, such as certain reaction equipment in the production of ordinary fertilizers. Please provide the text you would like translated.
(3) Aluminum Oxide Ceramic Balls
With Al₂O₃ content ranging from 45% to 70%, their comprehensive performance is further enhanced. They possess superior high-temperature resistance, acid and alkali corrosion resistance, and high mechanical strength. They are widely used in petrochemical, coal chemical and other industries, such as serving as catalyst support materials in reactors where equipment stability and service life are of certain requirements. Please provide the text you would like translated.
(4) High alumina ceramic balls
The Al₂O₃ content is usually above 70%, and can even reach 99%. These ceramic balls possess extremely excellent properties, such as extremely high hardness, superior high-temperature resistance (able to withstand temperatures above 1500°C), outstanding chemical stability, and high mechanical strength. They are often used in extremely harsh industrial environments such as high temperature, high pressure, and strong corrosion, for example, in key equipment like hydrogenation cracking reactors and strong acid and strong alkali reaction towers in the petrochemical industry. Please provide the text you would like translated.
IV. Application Fields and Cases of Inert Ceramic Balls
(1) Petrochemical Industry
Support and Protection of Catalysts
In the hydrogenation reactors of the petroleum refining process, high-alumina inert ceramic balls play a crucial role. For instance, in a large-scale oil refinery’s hydrofining unit, a large quantity of 95% high-alumina inert ceramic balls were filled in the reactor. These ceramic balls serve as a support layer for the catalysts, evenly distributed beneath them. On one hand, they can withstand the high pressure and temperature during the reaction process (reaction temperature can reach 400℃-500℃, pressure is approximately 10MPa-20MPa), effectively preventing the catalysts from piling up or being lost due to gravity and gas flow impact. On the other hand, they buffer the direct impact of liquids and gases entering the reactor on the catalysts, protecting the expensive and activity-sensitive catalysts, significantly extending the catalysts’ service life from about one year to 1.5-2 years. This reduces the high costs associated with frequent catalyst replacement and ensures the efficient and stable operation of the hydrogenation reaction, improving product quality and production efficiency. Please provide the text you would like translated.
Improving fluid distribution
In the packed towers of the petrochemical industry, inert ceramic balls are used to optimize fluid distribution. Taking a distillation tower in an ethylene production plant as an example, ceramic balls of different particle sizes are filled in the tower. Through reasonable grading, the ascending gas phase and descending liquid phase can contact more uniformly. The spherical structure of the ceramic balls reduces the “channeling” phenomenon of the fluid, increases the gas-liquid contact area, and improves the mass transfer efficiency. After optimizing with inert ceramic balls, the separation efficiency of the distillation tower has increased by 10% to 15%, the purity of the product has been significantly improved, and at the same time, energy consumption has been reduced and production costs have been saved. Please provide the text you would like translated.
(2) Environmental Protection Field
Wastewater Treatment
In some industrial wastewater treatment plants, inert ceramic balls are used for filtration and adsorption of impurities. For instance, in a certain electroplating wastewater treatment facility, inert ceramic balls are adopted as the filtration medium. Given that electroplating wastewater contains a large amount of heavy metal ions and acidic or alkaline pollutants, the corrosion resistance of the filtration material is required to be extremely high. Inert ceramic balls, with their excellent chemical stability, can operate stably in both acidic and alkaline wastewater. Impurities in the wastewater are trapped in the pores and on the surface of the ceramic balls, achieving initial purification. After filtration by the ceramic balls, the removal rate of solid suspended matter in the wastewater can reach 70% to 80%, reducing the burden on subsequent deep treatment, improving the efficiency and stability of the entire wastewater treatment system, and ensuring that the effluent quality meets the discharge standards. Please provide the text you would like translated.
Influe gas treatment
Influe gas desulfurization systems also widely apply inert ceramic balls. In a flue gas desulfurization tower of a coal-fired power plant, a large number of medium-aluminum inert ceramic balls are filled inside. These ceramic balls serve as carriers for the absorbent, increasing the contact area between the absorbent and the flue gas. In a high-temperature environment (about 100℃ – 150℃) with corrosive gases such as sulfur, inert ceramic balls are stable and reliable. Through the synergistic effect with the sprayed alkaline absorbent, they efficiently adsorb pollutants such as sulfur dioxide in the flue gas. After treatment, the concentration of sulfur dioxide in the flue gas is significantly reduced, from several thousand milligrams per cubic meter to several tens of milligrams per cubic meter, meeting strict environmental protection emission standards and making important contributions to air pollution control. Please provide the text you would like translated.
(3) Fertilizer Industry
In the production process of synthetic ammonia, inert ceramic balls are used in equipment such as shift converters. Taking a factory with an annual production capacity of 300,000 tons of synthetic ammonia as an example, the shift converter is filled with a mixture of medium alumina and high alumina inert ceramic balls. During the shift reaction, the gas temperature can reach 400℃ to 500℃ and is accompanied by certain pressure. Inert ceramic balls not only provide stable support for the catalyst but also optimize the distribution of gas within the furnace, making the reaction proceed more uniformly. Through the rational use of inert ceramic balls, the service life of the catalyst in the shift converter has been extended by approximately 20%, while also increasing the conversion rate of carbon monoxide to carbon dioxide from around 85% to over 90%, thereby increasing the output of synthetic ammonia and reducing production costs. Please provide the text you would like translated.
(4) Natural Gas Industry
In natural gas purification facilities, inert ceramic balls are used in adsorption towers and other equipment. A certain natural gas purification plant filled a large number of low-aluminum and medium-aluminum inert ceramic balls in the adsorption tower to remove impurities and acidic gases from natural gas. These ceramic balls serve as the support and dispersion material for the adsorbent. During the natural gas processing, they can withstand certain temperature and pressure fluctuations (the general operating temperature is between 30℃ and 60℃, and the pressure is between 2MPa and 5MPa). By working in synergy with the adsorbent, they effectively remove impurities such as hydrogen sulfide and carbon dioxide from the natural gas, improving its quality. The processed natural gas meets the standards for pipeline transportation and industrial use, ensuring the safe and stable supply of natural gas. Please provide the text you would like translated.
V. Precautions for the Selection and Use of Inert Ceramic Balls
(1) Key Points for Selection
Select types based on working conditions: According to factors such as temperature, pressure, and the degree of chemical corrosion in the actual usage environment, rationally choose different types of inert ceramic balls. For instance, in high-temperature, high-pressure, and highly corrosive conditions, high-alumina ceramic balls should be prioritized; while in milder conditions, low-alumina or medium-alumina ceramic balls may be more economical and suitable. Please provide the text you would like translated.
Particle size and gradation: Based on the size of the reactor or equipment, its internal structure, and the properties of the fluid, determine the appropriate particle size and gradation of the ceramic balls. Reasonable particle size and gradation can optimize fluid distribution, reduce pressure drop, and improve the operational efficiency of the equipment. For instance, in the application of catalyst support, the principle that the diameter of the ceramic balls is twice that of the adjacent catalyst (2X rule) is usually followed to achieve the best gas flow distribution and minimize pressure drop. Please provide the text you would like translated.
Quality and performance indicators: Pay attention to the quality and performance indicators of the product, such as compressive strength, water absorption rate, chemical stability, etc. Choose suppliers with good reputation and reliable product quality to ensure that the inert ceramic balls purchased can meet the requirements of long-term stable operation. For example, the compressive strength should be selected based on the actual pressure it will bear to avoid the ceramic balls breaking during use and affecting the operation of the equipment. Please provide the text you would like translated.
(2) Precautions for Use
Installation and Loading: Correct installation and loading of inert ceramic balls in the equipment is of vital importance. Ensure even loading to avoid voids or uneven accumulation, which may affect fluid distribution and equipment performance. Additionally, when necessary, suitable isolation materials such as screens should be added between the ceramic balls and catalysts or other components to prevent mutual interference. Please provide the text you would like translated.
Temperature control: Although inert ceramic balls have good thermal stability, they are sensitive to sudden temperature changes. During the start-up heating and shutdown cooling processes of the equipment, it should be carried out slowly to avoid sudden temperature rises and rapid cooling, preventing the ceramic balls from cracking due to excessive thermal stress. For example, in terms of heating or cooling rates, it is generally recommended to control within a certain range, such as not exceeding 50℃ – 100℃ per hour. Please provide the text you would like translated.
Regular maintenance and inspection: Regularly inspect the inert ceramic balls in use to observe whether there is any breakage, wear, or blockage by impurities. If any problems are found, they should be dealt with promptly according to the specific situation, such as cleaning impurities or replacing broken ceramic balls. It is generally recommended to conduct a comprehensive inspection and maintenance at least once a year to ensure their continuous normal operation and the stable running of the equipment. Please provide the text you would like translated.
Technical Data
| Item | Type 1 | Type 2 | Type 3 | Type 4 | |
| Equal to | Denstone 2000 | Denstone 57 | Denstone 99 | ||
| AL2O3 | 17-19% | 23-26% | 90% | >99% | |
| Acid resistance | >=98% | ||||
| Alkali resistance | >80% | >82% | >90% | >95% | |
| Thermal shock reistance | >=300 | >=400 | >=700 | >=800 | |
| Operation temperature (℃) | 982 | 1100 | 1350 | 1500 | |
| Bulk density(kg.m3) | 1300-1400 | 1400-1500 | 1600-1800 | >=1800 | |
| Crushing Strength (N/pellet) | 1/8”(3mm) | >350 | >350 | >510 | >510 |
| 1/4”(6mm) | >600 | >600 | >1500 | >1500 | |
| 3/8”(10mm) | >850 | >850 | >6000 | >6000 | |
| 1/2”(13mm) | >1850 | >1850 | >8000 | >8000 | |
| 5/8″(16mm) | >3600 | >3600 | >9000 | >9000 | |
| 3/4”(19mm) | >4870 | >4870 | >11000 | >11000 | |
| 1”(25mm) | >8500 | >8500 | >20000 | >20000 | |
| 1.5″(38mm) | >12000 | >12000 | >33000 | >33000 | |
| 2”(50mm) | >56000 | >56000 | >150000 | >150000 | |
| 3″(76mm) | >56000 | >56000 | >150000 | >150000 | |
Size and Tolerance (mm)
| Size | 3/6/9 | 9/13 | 19/25/38 | 50 |
| Tolerance | ±1.0 | ±1.5 | ±2 | ±2.5 |
VI. Conclusion
Inert ceramic balls, with their unique properties, have demonstrated significant application value in numerous industrial fields. From supporting and protecting catalysts to optimizing fluid distribution, from treating wastewater and exhaust gas to ensuring the production in the energy industry, they provide strong support for the efficient, stable, and environmentally friendly production of various industries. In the future, with the continuous development of industrial technology and the increasing requirements for equipment performance, inert ceramic balls are expected to further enhance their performance and expand their application fields through material innovation and process improvement, making greater contributions to industrial development. Understanding and correctly selecting and using inert ceramic balls are of great significance for enterprises in various industries to improve production efficiency, reduce costs, and achieve sustainable development.
