Catalyst Support Ceramic Ball: Everything You Need to Know!
Trusted by many industries, inert alumina ceramic balls have uncountable attributes that make them ideal for use in demanding applications across petroleum, chemical, fertilizer, natural gas, and environmental protection industries, where they serve as reliable catalyst support and tower packing materials. Their primary role is to boost the spots of gas and liquid distribution, while supporting and protecting the catalyst.
In this blog, we will look at the catalyst support ceramic balls and their uses.
What is a Catalyst Support Ceramic Ball?
Small, spherical, tough balls made up of high-quality alumina wear-resistant particle material are known as ceramic alumina balls. These balls are so strong that they can handle high temperature and pressure, even resisting damage from powerful chemicals and acids. The inert alumina ceramic balls are widely used in catalysts, adsorbents, and reactors.
You must be knowing that the inert ceramic balls are used in the oil refining industry, but do you know why? So basically, in an oil refinery, the crude oil is processed in a unit called a hydrotreater, which removes sulphur and other impurities. Catalysts are used inside the hydrotreater to speed up the chemical reactions. However, these catalysts are sensitive and can break down under high pressure from the weight of other materials. To prevent this from happening, the inert ceramic balls are placed at the bottom and top of the catalyst bed.
These balls support the catalyst by distributing the flow of gas or liquid evenly and protecting the delicate catalyst particles. The inert ceramic balls don't take part in the reaction, but they make the process reliable and extend the life of the catalyst.
Key Features of Catalyst Support Ceramic Ball -
- High purity alumina - the ceramic balls are made up of pure alumina, which helps them resist reacting with chemicals, and they don't break even when the heat is high.
- Low porosity - due to the structure of ceramic balls (with fewer tiny holes), they work better and longer as these tiny holes don't soak up liquid or gases.
- Chemical resistance - The chemical resistance property of ceramic balls is such that they don't get damaged easily, even by strong acids, bases, or other harmful chemicals.
- Excellent mechanical strength - they are durable and extremely strong, and they are preferred in hard-working machines or systems.
- The final product you get using alumina grinding balls is free from impurities, as they do not react with any chemical, so this means they are ideal for grinding and mixing sensitive products.
Application of Catalyst Support Ceramic Balls -
Due to their high strength, heat resistance and chemical stability, the inert ceramic balls are used in a wide range of industries; they are made up of high-purity alumina( 99.7%). The balls do not react with other substances, which makes them ideal for harsh environments. The main job of these balls is to protect the catalyst beds inside reactors. These balls protect the catalyst used in various processes from thermal shocks and pressure fluctuations.
The inert ceramic balls also serve as support media, hold the catalyst in place and maintain a stable environment for chemical reactions. The life and performance of the system improve using ceramic inert balls, as they evenly distribute gases and liquids.
Are Ceramic Balls Suitable for Processes Like Hydrotreating, Catalytic Cracking, and Ammonia Synthesis?
The short answer is yes, alumina ceramic balls are suitable for special processes like catalytic cracking, hydrotreating, ammonia synthesis, etc. The use of ceramic balls is mainly to support catalysts in these processes, as they are strong and don't react with chemicals, making them perfect for supporting catalysts in many petrochemical processes.
How Ceramic Balls Help in Oil Refining?
Ceramic balls are an essential component of the internal structure of catalytic reactors used in oil refineries. They don’t participate in the chemical reactions themselves, but are critical for protecting catalysts and ensuring smooth operation inside reactors.
Here’s how they help in oil refining -
1. Hydrotreating - Hydro Treat - The first step is hydropower measurements to generate clean fuel and protect the catalyst. The ceramic balls form a basic layer under the activated catalyst bed and provide a smooth distribution of hydrogen gas throughout the reactor.
2. Hydrocracking refers to the process that breaks down heavy hydrocarbon molecules into lighter products, increasing their value, such as diesel, jet fuel and gasoline. How do ceramic balls help? It provides mechanical support to the catalyst, making it unbreakable.
3. Isomerization
This process is done to improve the octane rating of gasoline, so that it can burn more efficiently in engines. The ceramic ball acts as a physical support for the catalyst bed, so that the structure remains consistent throughout the process.
4. Desulfurization
Desulfurization is intended to remove sulphur from fuels to meet environmentally defined security standards. Ceramic balls provide a support layer for sulphur-related catalysts.
Activated Alumina vs. Inert Ceramic Ball
One thing is common in activated alumina ceramic balls and inert alumina ceramic balls: they both contain aluminum oxide(Al2O3), and that's why people consider them similar, but they are not. Let's find out the difference among them -
Activated Alumina
As the name suggests, activated alumina balls are known for their high moisture adsorbing capacity, due to their porous structure and large surface area. They are used as a desiccant and adsorbent, and also act as a catalyst as they help dry gases, remove certain chemicals, and help with chemical reactions.
One significant difference between activated alumina and inert alumina lies in the name "activated"; it means that it can capture materials, like water, oxides, acid, and alkalis, while inert alumina can't! Activated alumina is widely used in industries such as petroleum, gas, water purification and air treatment. It can absorb 2.85 milligram of fluoride per cubic meter, which is essential in removing fluoride from Heat Treatment.
Inert Ceramic Ball
Do you know why the inert ceramic balls are known as "inert"? Because they don't react with any chemicals! High strength, high chemical stability and thermal stability are three major characteristics of the inert ceramic ball. In a chemical process, the need to protect the catalyst is fulfilled by the inert ceramic balls; they not only speed up the chemical reaction but also increase the life of the unit processor.
Once they are placed before and after the catalyst layer inside a reactor, their job begins. The inert balls protect the catalyst from damage caused by flowing liquids or gases, and handle high pressure and temperature without breaking. The liquid and gases are spread more evenly due to the inert alumina balls. Apart from their use of Alumina Catalyst Bed Support Balls in the oil refining industry, they are also used in chemicals, fertilizers, and natural gas industries.
One significant difference between activated alumina balls and inert balls is hidden in their name; inert alumina balls are also known as Ceramic balls, but activated alumina balls are not called ceramic or porcelain balls.
However, the number one rule towards quality is purchasing inert ceramic balls from a trusted Supplier; the rest will fall into place! Our inert ceramic balls are the ideal choice of top industries for various processes like hydrocracking, catalytic conversion, hydrotreating, and oxidation. You can submit your query or quotation request on our website.
