Common Methods of Fixing Honeycomb Ceramics in Equipment
A brief introduction to the common methods of fixing honeycomb ceramics in equipment.
Common Methods of Fixing Honeycomb Ceramics in Equipment
When used as catalyst carriers, heat storage media, or filter media in industrial equipment, honeycomb ceramics must be securely fixed in a suitable manner to ensure positional stability under conditions such as airflow impact, thermal expansion, and pressure fluctuations. The choice of fixing method directly affects the equipment's sealing performance, pressure drop, and service life.
Wound Fixing
A cylindrical honeycomb structure is wrapped with a ceramic fiber blanket. After being inserted into a cylindrical container, the blanket is compressed, and the resulting elastic force holds the honeycomb tightly.
Suitable for automotive exhaust purifiers, small tubular reactors, and RTO regenerators. Advantages include simple installation, automatic adjustment to thermal expansion and contraction, high temperature resistance, and low cost.
Compression Fixing
Pressure plates are installed at both ends of the honeycomb structure along its axial direction. Pressure is applied using springs or bolts to compress multiple layers of honeycomb into a single unit.
Suitable for SCR catalyst modules, VOCs rotors, and multi-layer RTO beds. Advantages include reliable axial fixation, adaptability to multi-layer stacking, and springs that absorb thermal expansion.
Grid Support Fixing
A metal grid or bracket is installed on the inner wall of the equipment. The honeycomb structure is placed on top, with the grid openings aligned with the honeycomb channels to avoid air blockage. Suitable for SCR reactor support, RTO bed bottoms, and fixed bed packing support. Advantages include simple structure, layered arrangement, and removable grid.
Casting Fixing with Castable Resin
High-temperature castable resin or refractory mortar is filled into the gaps between the honeycomb cells and between the cells and the vessel wall, forming a rigid fixing layer after curing. Suitable for large furnaces, RTO regenerators, high-temperature flues, and molten metal filtration.
Advantages include thorough fixing, high overall strength, and high temperature resistance. Disadvantages include difficult disassembly, need to match thermal expansion, and long construction period.
Modular Frame Fixing
Multiple honeycomb ceramic cells are installed into a metal frame to form an integral module, which is then hoisted and embedded into the equipment. Suitable for large SCR denitrification units and large RTO regenerator modules.
Advantages include standardized production, convenient installation and replacement, and the ability to set lifting points. Typical module dimensions are 150mm or 300mm square, with a stainless steel frame.
Gravity Stacking Fixing
The honeycomb cells are stacked within the equipment by their own weight without additional clamping devices. Mostly used for RTO regenerator balls or ceramic rings; honeycomb ceramics are less common. Suitable for small RTO beds and laboratory devices.
Advantages include extreme simplicity and easy loading and unloading. The disadvantages are poor fixing effect, easy short circuit, weak impact resistance, and it is only suitable for low pressure difference and low flow rate conditions.
Common Equipment Fixing Solutions
Equipment Type | Common Shapes | Main Fixing Methods |
Automotive Exhaust Gas Purifier | Cylindrical | Wound Fixing (Ceramic Fiber Blanket) |
Industrial SCR Denitrification Reactor | Square Module | Bottom Grille Support + Top Spring Compression |
RTO Regenerator Chamber | Cylindrical/Square | Bottom Grille Support + Top Limiting/Refractory Filling |
VOCs Adsorption Rotary Wheel | Disc Shape | Central Shaft Fixing + Outer Peripheral Sealing |
Molten Metal Filter | Hexagonal Assembly | Internal Positioning Groove + Refractory Mortar Filling |
Laboratory Tubular Reactor | Cylindrical | Internal Positioning Ring + Wound Fixing |
Selection Principles
By Temperature:
<600℃: Metal springs, grids, and fiber blankets are all acceptable.
600-1000℃: Heat-resistant alloy + high-temperature fiber blanket required.
1000℃: Castable refractory and ceramic supports preferred.
By Pressure Difference:
Low pressure difference: Self-weight stacking or simple limiting.
Medium pressure difference: Requires compression fixing.
High pressure difference: Must be rigidly fixed.
By Replacement Frequency:
Frequent replacement: Modular frame + detachable compression.
Long cycle: Permanent fixing such as castable refractory is acceptable.
By Shape:
Cylindrical: Winding is the most convenient.
Square: Modular frame + grid support.
Hexagonal: Assembly + castable refractory.
Summary
The fixing method of honeycomb ceramics is essentially a comprehensive trade-off between temperature, pressure, maintenance needs, and equipment structure. From the elastic clamping of winding to the rigid locking of castable refractory, each method has its irreplaceable applicable scenarios. Understanding the principles and limitations of these fixing methods is key to ensuring the long-term stable operation of honeycomb ceramics in industrial equipment. We are a Chinese industrial ceramics manufacturer. For more information, please contact us via email at annayu@169chem.net or WhatsApp at +8618909016373.