Why aren’t steel balls or glass balls chosen as inert fillers for reactors?
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In many reactors, the packing is a catalyst bed; the reactants undergo reactions through this catalyst, and it is precisely this catalyst bed that facilitates the reaction. However, in most reactors, the packing consists of inert porcelain balls combined with active packing; the inert porcelain balls serve as a support mechanism, which slows down the flow rate of the reaction materials and increases their contact time, thereby enabling a more thorough reaction. Inert ceramic balls are widely used in the petrochemical industry, as well as in the environmental protection and natural gas sectors. Based on their aluminum content, inert ceramic balls can be classified into ordinary ceramic balls, medium-aluminum ceramic balls, high-aluminum ceramic balls, etc. But during the reaction process, why not use steel balls or glass balls instead of inert porcelain balls?
Inert ceramic balls possess high strength, as well as high chemical and thermal stability. They can withstand high temperatures, high pressures, and the corrosion caused by acids, bases, salts, and various organic solvents. Inert ceramic balls are widely used in industries such as petroleum, chemicals, fertilizers, natural gas, and environmental protection. Inert ceramic balls, used as supporting and covering materials for catalysts in reactors, can cushion the impact of liquids and gases entering the reactor on the catalysts, protect them, and improve the distribution of liquids and gases within the reactor.
Preparation of inert porcelain balls: (1) Before loading the porcelain balls, all dust and debris inside the tower must be thoroughly cleaned away. (2) Inside the tower, mark the respective filling height lines for the ceramic balls and catalyst according to the filling diagram. (3) For projects with a large scale of construction, necessary machinery such as cranes and hoists should be prepared. (4) The staff involved in loading the ceramic balls must have clear divisions of labor and dedicated responsibilities to avoid confusion. (5) Ensure that the ceramic balls and catalysts meet the requirements specified for loading them. Construction process: (1) When filling the tower to the first layer, care must be taken to avoid damaging other systems inside the tower; after the first layer is laid, tools should be used to spread the material evenly so that the surface of that layer is at the same level. (2) After completing the installation of the first layer, panels should be laid to allow construction workers to install the second layer on top, thereby preventing horizontal movement of the porcelain ball layer as the workers stand directly on those balls while working. (3) The thickness of each layer of ceramic balls should be accurate and uniform; the surface should be smoothed using a shovel or scraper, and its height should match the horizontal line indicating the paving height. Precautions: (1) To facilitate operation by staff, low-voltage lighting should be connected inside the tower. (2) Before starting the operation, the staff must remove any items that could fall off them, wear proper work uniforms, and take other safety measures. (3) Construction must be carried out strictly in accordance with the construction drawings for porcelain ball filling, and a reinspection is required upon completion. (4) One or two operators enter the lower head through the access hole at the bottom of the synthesis tower, fill the bottom of the tower with ceramic balls up to the specified filling level, and level them out using a spade tool. (5) Measure the height of the remaining space, calculate its volume as well as the amount of ceramic balls required. (6) Then, after installation is complete, a thorough review of the entire construction process is necessary.
1. Materials for inert alumina ceramic balls: feldspar-based, feldspar-mullite-based, mullite-based, mullite-corundum-based, corundum-based.
2. Technical specifications for inert alumina ceramic balls: Water absorption ≤5%; Acid resistance ≥98%; Alkali resistance ≥80–95%; Heat resistance ≥1300–1700°C.
3. Chemical composition of inert alumina ceramic balls: Feldspar-based types contain 20–30% Al2O3; feldspar-mullite-based types contain 30–45% Al2O3; mullite-based types contain 45–70% Al2O3; mullite-corundum-based types contain 70–90% Al2O3; corundum-based types contain ≥90% Al2O3; Al2O3+SiO2 ≥90%; Fe2O3 ≤1%.
4. Standard applicable to inert alumina ceramic balls: Chemical industry standard of the People’s Republic of China, HG/T 3683.1–2000, “Industrial Ceramic Balls – Inert Ceramic Balls”.
5. Sizes available for inert alumina ceramic balls: 3mm, 6mm, 8mm, 10mm, 12mm, 13mm, 15mm, 20mm, 25mm, 40mm, 50mm, 60mm. Note: When placing an order for inert ceramic balls, it is necessary to specify the required product size, model, and total content of aluminum and silicon
2. Technical specifications for inert alumina ceramic balls: Water absorption ≤5%; Acid resistance ≥98%; Alkali resistance ≥80–95%; Heat resistance ≥1300–1700°C.
3. Chemical composition of inert alumina ceramic balls: Feldspar-based types contain 20–30% Al2O3; feldspar-mullite-based types contain 30–45% Al2O3; mullite-based types contain 45–70% Al2O3; mullite-corundum-based types contain 70–90% Al2O3; corundum-based types contain ≥90% Al2O3; Al2O3+SiO2 ≥90%; Fe2O3 ≤1%.
4. Standard applicable to inert alumina ceramic balls: Chemical industry standard of the People’s Republic of China, HG/T 3683.1–2000, “Industrial Ceramic Balls – Inert Ceramic Balls”.
5. Sizes available for inert alumina ceramic balls: 3mm, 6mm, 8mm, 10mm, 12mm, 13mm, 15mm, 20mm, 25mm, 40mm, 50mm, 60mm. Note: When placing an order for inert ceramic balls, it is necessary to specify the required product size, model, and total content of aluminum and silicon