Ceramic heat exchanger development history
Since the 1950s, domestic preheaters for heated air have been widely used in industrial furnaces. These early systems mainly included tubular, cylindrical radiant, and cast iron block heat exchangers, but their heat exchange efficiency was relatively low. By the 1980s, new types of heat exchangers—such as jet flow, jet radiation, and multi-level bench designs—were developed domestically to improve waste heat recovery from medium and low-temperature flue gases. These innovations significantly enhanced the efficiency of heat recovery, especially for flue gases below 100°C. However, at high temperatures, traditional materials struggled with durability, leading to short service life, high maintenance costs, or expensive alternatives, which limited widespread adoption.
In the early 2000s, Gongyi City in Henan Province, China, made a breakthrough by developing a silicon carbide ceramic heat exchanger. The production method is similar to that of kiln furniture, focusing on thermal conductivity and oxidation resistance. This ceramic material is placed near the flue outlet where temperatures are high, without needing to mix with cold air or require additional high-temperature protection. When the furnace temperature ranges between 1250°C and 1450°C, the flue gas temperature can be around 1000°C to 1300°C. The ceramic heat exchanger can recover heat up to 450°C to 750°C, which is then used to preheat air for combustion. This process helps reduce fuel consumption and improves economic returns.
Ceramic heat exchangers have become a key solution due to their ability to overcome the limitations of metal-based heat exchangers, particularly in terms of corrosion and high-temperature resistance. They have proven reliable through years of use, offering excellent thermal conductivity, high-temperature strength, good oxidation and thermal shock resistance, long service life, minimal maintenance, and stable performance. As a result, they are now considered the best option for recovering high-temperature waste heat.
CCTV reported that this technology marked the first time in China that the issue of material degradation under high temperatures or harsh conditions was effectively solved. The development of ceramic-based heat exchangers, which replaced traditional metals, has been recognized by the National Torch Program. This innovation allows cold air to be turned into hot air within industrial kilns, boosting both efficiency and energy savings. Given their critical role in improving energy efficiency, ceramic heat exchangers have vast potential for future applications across multiple industries.
Today, ceramic heat exchangers are widely used in various sectors such as metallurgy, non-ferrous metals, refractories, chemicals, and building materials. They play a vital role in global efforts to save energy and reduce emissions, contributing significantly to sustainable industrial practices.
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