RTO Regenerative Mullite Honeycomb Ceramic Regenerator

Regenerative High-Temperature Air Combustion Technology (abbreviated as HTAC) is an energy-saving and environmentally friendly technology in the field of high-temperature kiln combustion. In the 1980s, the development of regenerators led to the emergence of small-diameter spherical or spot-welded (pebble-like) ceramic bodies. However, these suffered from high pressure drop and slow heat transfer rates during use. In contrast, honeycomb ceramic regenerators feature a structure of mutually parallel straight channels, which significantly reduces the resistance to gas flow and greatly enhances the single-channel volumetric heat exchange efficiency of the regenerator.
Our company's honeycomb ceramic regenerators are primarily made from raw materials such as mullite and cordierite, which are resistant to high temperatures and have low thermal expansion coefficients. They are produced using inorganic-organic composite binders, mixed and kneaded, then formed by extrusion molding, followed by microwave-infrared combined drying technology, sintering, and other processes. Depending on the raw materials used, the products can be applied in low-temperature, medium-temperature, medium-high-temperature, and high-temperature ranges. Honeycomb regenerators made from these materials exhibit low thermal expansion, high specific heat capacity, and, due to their large specific surface area, offer advantages such as low pressure drop, minimal pressure loss, low thermal resistance, fast heat transfer, excellent thermal conductivity, resistance to thermal shock, and long service life.

Features of Honeycomb Ceramic Regenerator Products:
1. Reduce waste gas heat loss, maximize fuel utilization, and lower unit energy consumption; 2. Increase the theoretical combustion temperature, improve combustion conditions, meet the temperature resistance requirements of thermal equipment, expand the application range of low-calorific-value fuels, especially blast furnace gas, and enhance the utilization efficiency of fuel calorific value; 3. Improve furnace heat exchange conditions, increase equipment output and product quality, and reduce equipment investment; 4. Decrease the emission of waste gas and harmful gases per unit product of thermal equipment, reduce atmospheric pollution, and improve the environment.
Schematic Diagram of Usage Structure
This technology uses a switching device to alternate heat absorption and exchange between two regenerators, maximizing the recovery of heat from flue gas, and then preheats combustion air and gas to above 1000°C. Even low-calorific-value inferior fuels (such as blast furnace gas) can achieve stable ignition and efficient combustion. It can save fuel by 40%-70%, increase production by over 15%, reduce billet oxidation loss by more than 40%, lower flue gas emission temperature to below 140°C, and reduce NOx emissions to less than 100 ppm.

Application Range of Honeycomb Ceramic Regenerator Products: Used in regenerative high-temperature combustion technology (HTAC) in industries such as steel, machinery, petrochemicals, and power generation. It integrates waste heat recovery from flue gas with combustion and NOx reduction technologies to achieve the goal of lowering NOx emissions. Applications include hot blast stoves, heating furnaces, heat treatment furnaces, power industry boilers, gas turbines, engineering heating equipment, ethylene cracking furnaces in industries like steel, waste incinerators, waste gas treatment thermal equipment, petrochemicals, non-ferrous metal smelting, and power generation. They can also replace inert ceramic balls or open-pore ceramic balls in petrochemical, petroleum, and coal chemical projects, offering advantages such as large specific surface area, high and uniform porosity, and excellent fluid gas-liquid distribution performance. The products are also commonly referred to as bird's nest catalysts.