What Are Catalyst Support Ceramic Balls?

Catalyst support ceramic balls are essential industrial materials widely used in petrochemical processing, environmental protection, and new energy industries. Thanks to their excellent high-temperature resistance, high-pressure tolerance, strong chemical stability, and superior mechanical strength, they have become indispensable catalyst carrier materials in modern reactors.

The primary function of catalyst support ceramic balls is to provide a stable and reliable working environment for catalysts:

• On one hand, they offer physical support to protect relatively fragile active catalysts, preventing catalyst loss and breakage caused by fluid impact.

• On the other hand, they optimize gas and liquid distribution, improving reaction efficiency while significantly extending catalyst service life.

  

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Main Types of Catalyst Carrier Ceramic Balls

1. Inert Alumina Ceramic Balls

Inert alumina ceramic balls are the most widely used and market-dominant catalyst support materials. Based on Al₂O₃ content, they can be classified into:

• Normal ceramic balls (low Al₂O₃ content)

• Medium alumina ceramic balls (70%–90% Al₂O₃)

• High alumina ceramic balls (92%–95% Al₂O₃)

• 99% high alumina ceramic balls (Al₂O₃ > 99%)

Among them, 99% high alumina ceramic balls offer the highest chemical stability, with SiO₂ content < 0.3% and Fe₂O₃ < 0.1%. Their maximum operating temperature exceeds 1200°C, making them ideal for high-temperature and high-pressure reaction systems.

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2. Functional Ceramic Balls

Functional ceramic balls are designed to enhance mass transfer and filtration performance, including:

• Grooved and perforated ceramic balls

• Microporous ceramic balls

• Activated ceramic balls

Perforated ceramic balls feature a special structural design that increases void fraction to over 33% and improves specific surface area by approximately 40%, effectively reducing system pressure drop.

Microporous ceramic balls typically have a porosity of 20%–30% and achieve an impurity removal efficiency exceeding 75%, making them widely used in hydrotreating and hydrogenation refining units.

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Key Features and Advantages of Catalyst Support Ceramic Balls

1. High Specific Surface Area and Adjustable Pore Structure

Ceramic balls manufactured using advanced processes develop a complex internal pore network with a high specific surface area. This structure provides sufficient space for loading active catalytic components and creates efficient diffusion pathways for reactants and products.

The pore size distribution can be precisely tailored to meet different catalytic reaction requirements, ensuring optimal mass transfer efficiency.

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2. Outstanding Thermal Stability and Chemical Inertness

Made from high-purity materials such as alumina, silica, and zirconia, catalyst carrier ceramic balls can withstand extreme operating temperatures (typically above 1000°C) without sintering or structural collapse.

Their excellent chemical inertness ensures long-term stability in corrosive and reactive environments, maintaining catalyst purity and consistent performance.

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3. Superior Mechanical Strength and Wear Resistance

In fluidized beds and moving-bed reactors, catalyst carriers experience continuous collision and abrasion. High-strength ceramic balls effectively resist breakage and wear, minimizing dust formation, extending catalyst life, and reducing maintenance costs.

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4. Uniform Shape and Size Distribution

The standard spherical shape and consistent particle size help achieve uniform fluid distribution and stable pressure drop within the reactor. This prevents channeling and dead zones, ensuring smooth and controllable reaction processes.

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Main Application Areas

Petrochemical Industry

Catalyst support ceramic balls are widely used in hydrotreating, catalytic cracking, and olefin polymerization processes, improving product quality and operational efficiency.

Environmental Protection

They serve as catalyst carriers in automotive exhaust purification, industrial VOCs and NOx catalytic combustion, and flue gas desulfurization and denitrification systems, contributing to cleaner air and emission reduction.

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Selection Guide and Purchasing Considerations

When selecting catalyst support ceramic balls, it is essential to match operating conditions and catalyst characteristics. Key factors include:

Material Selection

• Acidic environments: High alumina ceramic balls are recommended

• High-temperature conditions (>1000°C): 99% high alumina or silicon nitride ceramic balls

• Strongly corrosive environments: Silicon carbide composite ceramic balls

Particle Size and Strength

• Ceramic ball diameter should be 2–5 mm larger than catalyst particles to prevent bed blockage

• Compressive strength should meet reactor pressure requirements; ≥150 MPa is recommended for high-pressure systems

Structural Design

• For high-throughput systems, choose grooved or perforated ceramic balls with void fraction ≥30%

• For filtration applications, microporous ceramic balls are preferred to ensure effective impurity removal

• Technical Parameter:

• Model:	Inert Ceramic Ball
  Color:	Light Grey
  Shape:	Ball
  Typical Technical Composition		Min. %		Max. %	Usual %
  SiO2		64		75	68.5
  Al2O3		23		26	24.5
  Fe2O3		******		1.0	0.9
  TiO2		******		0.5	0.46
  CaO		******		0.5	0.42
  MgO		******		0.5	0.38
  Na2O		******		2	1.12
  K2O		******		3.5	3.28
  Al2O3 + SiO2		90		94	93
  Physical properties
  Index			Value		Value
  Leachable Iron			≤ 0.1%		******
  Apparent Porosity by Weight, dia. ≥ 10mm			≤ 0.4%		******
  Apparent Porosity by Weight, dia. = 6mm			≤ 1.0%		******
  Apparent Porosity by Weight, dia. = 3mm			≤ 3.0%		******
  Moh’s Hardness Scale			>6.5		******
  Water Absorption			<0.5wt.%		******
  Acid Resistance			>99.8%		******
  Alkaline Resistance			>85%		******
  Thermal Conductivity			0.9-1.0 w/m2.k		******
  Thermal Expansion @ 500℃			0.20%		******
  Specific Heat			628-837 j/kg		******
  Thermal Shock Stability, 500 ℃ then water cooling			10 times		******
  Max. Operating Temperature			1050℃		1922
  Specific Density			2300 kg/m3		144 lb/ft3
  Bulk Density (Packing Density)			1350 kg/m3		84 lb/ft3
  Size /		Crush Strength
  Nominal Size		(lbs)		(kg)	(N/pc)
  mm	Inch	min.		min.	min.
  3	1/8	84		38	372
  6	1/4	209		95	931
  10	3/8	282		128	1254
  13	1/2	616		280	2744
  16	5/8	770		350	3430
  19	3/4	1738		790	7742
  25	1	1936		880	8624
  38	1.5	2156		980	9604
  50	2	3564		1620	15876
  Typical Application	a)Widely used support media in the world because of their excellent consistence and reliability. b)Manufactured from very high quality chemical-porcelain clay materials, which has quite excellent stability, high mechanical strength and resistance to thermal shock, This makes them all ideal choice for support of all types of catalyst.
  Warranty:	a) By National Standard HG/T 3683.1-2000 b) Offer lifetime consultation on problems occurred