| Application: | Catalyst carriers, Fillers, Filter materials, Heat storage materials |
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| Cell Shape: | Round |
| Material: | Cordierite |
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Product Name: Honeycomb Ceramic catalyst support
Product Description:
Honeycomb Ceramic products are advanced, high-performance ceramic structures characterized by a uniform, parallel array of numerous small, straight channels (cells) passing through the material, resembling a bee's honeycomb. Manufactured primarily from specialized ceramic materials like cordierite, silicon carbide (SiC), mullite, or alumina, these structures offer an exceptional combination of properties:
*Extremely High Geometric Surface Area: The dense network of channels provides a vast surface area within a compact volume, essential for efficient catalytic reactions, filtration, or heat exchange.
*Low Thermal Expansion & High Thermal Shock Resistance: Engineered materials like cordierite exhibit minimal expansion upon heating, allowing them to withstand rapid temperature changes without cracking - critical for applications like automotive exhaust systems.
*Low Back Pressure: The straight, parallel channels offer minimal resistance to fluid flow (gas or liquid), optimizing system efficiency.
*High Mechanical Strength: Despite their porous cellular structure, these ceramics possess significant structural integrity to handle mechanical loads and vibrations.
*Excellent Chemical & Corrosion Resistance: Highly resistant to attack from harsh chemicals, acids, bases, and corrosive gases encountered in industrial processes.
*Tailorable Properties: Material composition, cell density, wall thickness, channel geometry (square, hexagonal, triangular), and overall dimensions can be precisely engineered to meet specific application requirements.
| Parameter | Description | Typical Values/Range | Notes |
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| Material | Primary ceramic composition | Cordierite (2MgO·2Al2O3·5SiO2), Silicon Carbide (SiC), Mullite (3Al2O3·2SiO2), Alumina (Al2O3), Lithium Aluminum Silicate (LAS) | Choice depends on required temp resistance, thermal shock, chemical resistance, strength, & cost. |
| Cell Density | Number of channels (cells) per square inch of cross-sectional area (CPSI / CPI) | 100 CPI, 200 CPI, 300 CPI, 400 CPI, 600 CPI, 900 CPI, 1200 CPI+ | Higher CPI = more surface area, but higher back pressure. Common for catalysts: 400-600 CPI, DPFs: 200-300 CPI. |
| Cell Shape | Geometry of the individual channels | Square, Hexagonal, Triangular | Square is most common. |
| Wall Thickness | Thickness of the ceramic material separating adjacent channels (mil or mm) | 4 mil (0.10mm), 6 mil (0.15mm), 8 mil (0.20mm), 10 mil (0.25mm), 12 mil (0.30mm) + | Thinner walls = lower back pressure & less mass, but potentially lower strength. |
| Open Frontal Area (OFA) | Percentage of the total cross-sectional area open to flow | 60% - 80%+ | Calculated from Cell Density and Wall Thickness. Higher OFA = lower back pressure. |
| Geometric Surface Area (GSA) | Total surface area of the channel walls per unit volume (m²/L or ft²/in³) | 0.5 m²/L to > 3.0 m²/L+ | Increases with higher Cell Density and thinner walls. Critical for catalytic activity & filtration. |
| Porosity (%) | For filter applications: Percentage of wall volume consisting of interconnected pores. | 40% - 65%+ | Essential for soot trapping (DPF) or molten metal filtration. Not relevant for solid-wall catalysts. |
| Mean Pore Size (μm) | For filter applications: Average diameter of pores within the ceramic walls. | 5μm - 30μm+ | Determines filtration efficiency and back pressure characteristics. |
| Maximum Operating Temperature | Continuous service temperature limit (°C or °F) | Cordierite: ~1300-1350°C; SiC: >1400°C; Mullite/Alumina: 1500-1600°C+ | Depends heavily on material. |
| Thermal Shock Resistance (ΔT) | Maximum sudden temperature change the structure can withstand without damage (°C or °F) | Cordierite: Very High (>700°C ΔT possible); SiC: Good (~400°C ΔT); Dense Oxides: Lower | Cordierite excels here. |
| Mechanical Strength | Compressive/Crush Strength (MPa or psi) - Strength perpendicular to channels. | Varies widely: 5 MPa to >50 MPa+ (700 psi to >7000 psi+) | Depends on material, cell density, wall thickness. SiC generally strongest. |
| Dimensions | Cross-Section (Diameter or Width x Height) and Length | Highly Customizable: Diameters from <1" to >12"+; Lengths from <1" to >12"+. | Standard & custom shapes (round, oval, square, rectangular). |
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Chemical & Physical index
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Chemical Composition (%)
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SiO2
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45~55
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AI2O3
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30~38
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MgO
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10~15
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K2O+Na2O
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<1.0
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Fe2O3
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<1.5
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Wall Thickness
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100CPSI
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0.42-0.48mm
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200CPSI
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0.32-0.38 mm
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300CPSI
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0.25-0.31 mm
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400CPSI
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0.17-0.20mm
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600CPSI
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0.12-0.15mm
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Thermal Expansion Coefficient 10-6/K-1
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<2
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Specific Heat J/kg·K
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830~900
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Working Temperature ºC
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≤1100
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Acid resistance %
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>=99
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PS: we also can make products at your request and actual operating condition.
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Size
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Size
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Pore size
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150*150*50mm
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100*100*100mm
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1.5±0.1mm
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100*100*40mm
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150*150*150mm
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1.5±0.1mm
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100*100*50mm
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100*100*30
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1.5±0.1mm
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50*50*50mm
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106*68*12mm
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2.0/2.6±0.1mm
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PS: we also can make products at your customized size
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Customization: Honeycomb ceramics are highly customizable. We engineer the material, cell geometry, density, wall thickness, porosity, pore size, and dimensions to precisely match your specific application requirements for optimal performance, efficiency, and durability.
Quality & Reliability: Manufactured under strict process controls to ensure consistent geometry, material properties, and performance critical for demanding industrial and automotive applications.
Primary Applications:
1.Automotive & Diesel Emission Control: The core substrate for catalytic converters (TWC, DOC, SCR, GPF) and diesel particulate filters (DPF, CPF).
2.Industrial Pollution Control: Catalytic supports and filter elements for VOC abatement, NOx reduction, and particulate removal from industrial exhaust streams.
3.Chemical Processing: Catalyst supports for heterogeneous catalysis in reactors.
4.Heat Exchange & Recuperation: Regenerative heat exchangers (e.g., in thermal oxidizers, furnace recuperators) due to efficient heat transfer and storage capacity.
5.Molten Metal Filtration: Filters for removing inclusions from aluminum and other non-ferrous metals during casting.
6.Gas Distribution: Diffusers and spargers for uniform gas distribution in reactors or aeration systems.
7.Sound Absorption: Acoustic dampers utilizing the cellular structure.
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