Application of Honeycomb Ceramics in Fillers

The application of honeycomb ceramics in packing materials is an extremely important field, playing a crucial role, especially in the chemical, environmental protection, and energy industries. Here, its role transforms from a filtration unit into a highly efficient gas-liquid or gas-solid mass transfer and reaction platform. Its core value lies in its unique structure, which provides a huge specific surface area per unit volume and creates ordered fluid channels, thereby greatly enhancing mass transfer efficiency and reducing system pressure drop.

Chemical Towers: Structured Packing Materials for High-Efficiency Mass Transfer and Separation

In chemical separation processes, honeycomb ceramics, as structured packing materials, play a key role in enhancing mass transfer, reducing resistance, and increasing throughput. Utilizing its parallel and vertical channel structure, it provides ordered and predictable flow paths for the gas and liquid phases, greatly increasing the interphase contact area while minimizing fluid resistance.

Typical Applications:

Absorption Towers: Used to remove specific components from gases using liquid absorbents. For example, in gas scrubbing towers, honeycomb ceramic packing greatly promotes the contact between the scrubbing liquid and the gas, efficiently removing impurities such as hydrogen sulfide and dust. Its low pressure drop characteristics are crucial for handling large volumes of gas.

Distillation/Rectification Columns: As internal packing material, replacing traditional random packing (such as Pall rings) or trays. Structured honeycomb ceramic packing offers higher separation efficiency and larger throughput, while significantly reducing energy consumption (mainly in the load of bottom heating and top condensation).

Extraction Columns: Facilitates mass transfer between two immiscible liquids.

Advantages:

Extremely low pressure drop: Straight and unobstructed channels, far lower than random packing, resulting in a significant reduction in fan/pump energy consumption.

High throughput: Allows for higher gas-liquid velocities, increasing single-column processing capacity.

Small scale-up effect: Uniform fluid distribution, making scale-up from laboratory to industrial more reliable.

Environmental Protection: The physical basis of desulfurization and denitrification.

Used as mass transfer packing in wet desulfurization/denitrification absorption towers. Taking desulfurization as an example, in spray or packed towers, alkaline absorbent slurry (such as limestone slurry) comes into countercurrent contact with flue gas. Honeycomb ceramic packing significantly increases the gas-liquid contact area, promoting the mass transfer and absorption of SO₂ from the gas phase to the liquid phase. This process combines physical absorption and chemical reaction, but the role of honeycomb ceramics is to enhance physical mass transfer.

Advantages: Corrosion resistance, erosion resistance, long service life, and low pressure drop helps reduce induced draft fan power consumption.

Energy and Metallurgy: Filtration and Mass Transfer in Extreme Environments

In this field, honeycomb ceramics, with their excellent high-temperature resistance and thermal shock resistance, are used in the most demanding environments.

Gas Scrubbing and Purification

Core Function: As packing material for hot gas scrubbing in gas scrubbing towers.

Working Principle: The crude gas from the gasifier or coke oven is high in temperature and contains a large amount of dust, tar, and other impurities. In the scrubbing tower, honeycomb ceramic packing promotes contact between the cooling scrubbing liquid and the hot gas, cooling the gas through direct contact heat exchange and removing impurities through scrubbing and trapping. This is a typical process combining heat and mass transfer.

Advantages: Resistant to the impact of high-temperature hot gas and the adhesion of substances such as tar, with a stable structure.

Molten Metal Filtration

Core Function: As a deep filtration material, it improves the quality of metal products.

Working Principle: This is a purely physical sieving and deep filtration process. When molten aluminum, copper, steel, and other molten metals flow through the channels of the honeycomb ceramic filter, its internal interwoven microporous structure effectively traps oxides, slag, and other non-metallic inclusions in the molten metal.

Advantages: Resistant to high-temperature erosion by molten metals, good thermal shock resistance (no cracking from room temperature to melting temperature), high filtration accuracy, and can significantly improve the mechanical properties and yield of castings.

Summary

In all these non-catalytic applications, the core value of honeycomb ceramics lies in its unique physical structure. By providing a large, ordered contact surface, and with extremely low fluid resistance and excellent physicochemical stability, it has become a key basic material for achieving efficient, energy-saving, and long-life operation in mass transfer, heat transfer, and filtration processes in chemical separation, environmental governance, and metallurgical energy fields. We are a Chinese manufacturer of cellophane ceramics. For more information, please contact us at annayu@169chem.net or WhatsApp at +8618909016373.