Technical requirements for customised ceramic Bauer ring packings
Release time：2025-04-03
Release time：2025-04-03
In chemical, environmental protection, petroleum, and other industries, packing tower performance directly affects production efficiency and energy consumption. Ceramic Bauer rings are widely used as one of the core packing materials for their corrosion resistance, high-temperature resistance, and good mass transfer performance. However, standardized ceramic Bauer rings may not be able to meet the needs of all working conditions, so customized production has become the choice of many companies.
1. Material selection: determining corrosion resistance and strength
The material of the ceramic Bauer ring directly affects its service life. Common materials include:
Ordinary ceramics are suitable for general acid and alkali environments and have a low cost.
High-alumina ceramics (Al₂O₃ content ≥ 90%): resistant to strong acid, alkali, and high-temperature conditions, suitable for petrochemical, pharmaceutical, and other industries.
Corundum ceramics (Al₂O₃≥95%): higher hardness, wear-resistant, suitable for solid particles containing waste gas treatment.
Customized points: Users need to select the appropriate ceramic formula according to the actual medium pH, temperature, and corrosivity, to avoid packing crumbling or pulverization due to material mismatch.
2. Structural optimization: improving mass transfer efficiency
The window design of the standard Bauer ring is mature, but it can still be adjusted when customized:
The number and shape of holes: increasing the number of holes can improve the specific surface area, but needs to take into account the strength.
Adjustment of wall thickness: Under high flow rate conditions, increasing the wall thickness can reduce the breakage rate.
Surface treatment: Some companies require surface glazing to reduce fouling and clogging.
Custom points: need to combine the tower gas-liquid flow rate, medium viscosity, and other factors, optimize the structural design, to avoid excessive pursuit of specific surface area and affect the mechanical strength.
3. Dimensional tolerances: ensuring uniform distribution in the tower
The size of the ceramic Ball ring directly affects the packing layer's packing density and fluid distribution. It needs to be considered when customized:
Outside diameter and height tolerance: generally controlled within ± 1%, to prevent local voids or extrusion after installation.
Roundness and perpendicularity: affect the uniformity of the packing layer, which needs to be guaranteed by the accuracy of the mold.
Customized points: for large packing towers (such as diameter > 3m), need to specifically request the supplier to provide a sampling test report to ensure batch consistency.
4. Performance test: verify the applicability
Customised products should be subject to several tests before leaving the factory, including:
Compressive strength test: simulate the load-bearing situation of the packing layer in the tower.
Acid and alkali resistance immersion test: to verify the stability of the material under long-term working conditions.
Stacking density and porosity test: to ensure compliance with the requirements of mass transfer calculations.
Customised points: Users can ask the supplier to provide third-party test reports, or provide a small batch of samples for pilot testing.
5. Packaging and transport: preventing breakage
Ceramic filler is fragile and needs to be clear when customizing:
Shock-proof packaging: such as wooden crates + foam fixed to reduce transport losses.
Shipment in batches: avoid stacking too high to cause the bottom layer to break.
Conclusion
Customised ceramic Bauer ring is not a simple adjustment of size, but needs to match the actual working conditions from the material, structure, testing and other dimensions. When purchasing, enterprises should fully communicate with suppliers about process requirements and provide detailed technical agreements to ensure that the performance of the filler meets expectations. At the same time, selecting manufacturers with mature production experience can effectively reduce the risk of customization and guarantee long-term stable operation.
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