Common Shapes of Honeycomb Ceramics
A brief introduction to the common shapes of honeycomb ceramics.
Common Shapes of Honeycomb Ceramics
Honeycomb ceramics are porous ceramic products with parallel channel arrays. Their high specific surface area, low coefficient of thermal expansion, and excellent thermal stability make them ideal for catalyst supports, heat storage media, and filters. In industrial applications, the shape design of honeycomb ceramics is not arbitrary but rather an engineering adaptation based on equipment structure, airflow distribution, sealing requirements, and filling methods. Cylindrical, square, and hexagonal shapes are currently the three most common shapes, each with its own applicable logic.
Geometric Characteristics and Molding Processes of Three Shapes
Shape | Geometric Characteristics | Main Molding Method | Channel Cross-section |
Cylindrical | Circular cross-section, diameter typically 50-300mm, length 50-600mm | Extrusion molding followed by rotary cutting | Square/Triangle/Hexagonal |
Square | Square or rectangular cross-section, side length typically 50-150mm | Extrusion molding followed by cutting | Predominantly square |
Hexagonal | Regular hexagonal cross-section, resembling honeycomb-like blocks | Extrusion molding or splicing | Square/Hexagonal |
Regardless of the shape, the internal channels of honeycomb ceramics are regular parallel straight holes, with channel density (mesh count) ranging from tens to hundreds of meshes/square inch. The differences in shape primarily serve to improve filling adaptability and thermal stress distribution.
Cylindrical Honeycomb Ceramic
Process Features:
Extruded into cylindrical rods, then rotary-cut to a fixed length; mature process, long die life, and high yield.
Advantages:
Perfectly matches circular containers, gap-free filling, avoiding airflow bypass.
Uniform stress distribution, crack-resistant.
Easy sealing (ceramic fiber blanket wrapping).
Applications:
Automotive exhaust purification carrier: Three-way catalytic converter, DOC, SCR, directly installed in circular exhaust pipes.
Industrial flue gas denitrification (SCR): Cylindrical reactors in thermal power plants and cement plants, easy to hoist and seal.
RTO heat storage medium: Circular heat storage chamber, symmetrical airflow distribution.
Small experimental devices: Directly installed in tubular reactors.
Rectangular Honeycomb Ceramic
Process Features:
Extruded and cut into squares or multiple pieces spliced together; square die outlet.
Advantages:
High space utilization (rectangular units can be 100% filled)
Modular design for easy handling and replacement
Easy to drill holes (temperature measurement holes, sampling holes)
Applicable Scenarios:
Large-scale industrial denitrification (SCR): Rectangular reactor, 150/300mm standard module stacking, near 100% space utilization
VOCs adsorption rotor: Square units facilitate layout and cutting
Fume purification/air filtration: Rectangular shell can be directly pushed in for installation
Large square RTO: Achieves full filling, avoiding short-circuiting of airflow at corners
Hexagonal Honeycomb Ceramic
Process characteristics:
Directly extruded hexagonal rods, or cut large plates into hexagonal units, often equipped with hexagonal channels.
Advantages:
Optimal thermal shock resistance, suitable for severe temperature fluctuations
Dense joints, no straight seams, uniform airflow distribution
High structural strength (optimal compressive strength for the same wall thickness)
Applicable Scenarios:
Molten metal filtration: Aluminum alloy/copper alloy casting, 700-800℃ thermal shock, can be assembled to cover large runners
Infrared radiation combustion plate: Gas stoves, industrial dryers, uniform gas mixing, flat flame
Chemical catalyst support/distribution plate: Layered support requiring extremely uniform airflow
High-end RTO regenerator: Extremely high requirements for thermal stress and airflow distribution
Selection Guide
By container shape: Round container → Cylindrical; Rectangular container → Square
By thermal shock: Severe temperature fluctuations → Hexagonal
By airflow distribution: Requires extremely uniform distribution → Square + sealed or hexagonal assembly
By maintenance frequency: Periodic replacement → Square module; Long-term maintenance-free → Cylindrical
By cost: High-volume cost-sensitive → Cylindrical; Performance priority → Hexagonal
Summary
The three shapes—cylindrical, square, and hexagonal—are essentially the result of adapting the geometry and functional requirements of industrial equipment. Cylindrical shapes are mature and universally applicable, dominating automotive exhaust systems and tubular reactors; square shapes prioritize space efficiency, ruling out large rectangular denitrification units; and hexagonal shapes, with their structural advantages, are irreplaceable in special scenarios requiring high-temperature shock and uniform gas distribution. The core logic for selection can be summarized as follows: container shape determines the foundation, thermal shock resistance determines trade-offs, maintenance methods determine modules, and cost budget defines the boundaries. We are a Chinese industrial ceramics manufacturer. For more information, please contact us via email at annayu@169chem.net or WhatsApp at +8618909016373.