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- Introduction to Silicon Carbide Kiln Furniture
- Classification by Bonding Methods
- Key Product Types and Specifications
- Technical Performance Indicators
- Applications Across Industries
- Installation and Maintenance Guidelines
- Case Studies and Industry Trends
1. Introduction to Silicon Carbide Kiln Furniture
Silicon carbide (SiC) kiln furniture is a critical component in high-temperature industrial processes, offering unmatched thermal stability, mechanical strength, and corrosion resistance. Widely used in ceramics, metallurgy, and renewable energy sectors, SiC kiln furniture includes saggers, batt plates, burner nozzles, beams, and rollers. This guide explores their types, technical specifications, and applications, leveraging insights from industry standards and advanced manufacturing practices.
2. Classification by Bonding Methods
SiC kiln furniture is categorized based on bonding techniques, which directly influence performance and cost.
| Bonding Type | Key Features | Max Service Temp (°C) | Common Products |
|---|---|---|---|
| Clay-Bonded | Low-cost, simple production; limited strength at high temps | 1400–1500 | Saggars, batt plates |
| Oxide-Bonded | Al₂O₃/SiO₂ binder; improved thermal shock resistance | 1600 | Kiln beams, columns |
| Nitride-Bonded | Si₃N₄ bonds; high mechanical strength, ideal for cyclic heating | 1600–1800 | Burner nozzles, rollers |
| Recrystallized (RBSiC) | Pure SiC; ultra-high density, 10–20x stronger than clay-bonded | 2200–2500 | High-performance saggers, tubes |
3. Key Product Types and Specifications
3.1 Silicon Carbide Saggars (RBSiC/SiSiC)
- Function: Protect ceramics/metals during sintering.
- Specs:
- Al₂O₃ content: <1% (high-purity RBSiC).
- Density: ≥2.6 g/cm³.
- Thermal Conductivity: 40–120 W/m·K.
- Applications: Battery cathode sintering (Li-ion), precision ceramics.
3.2 Silicon Carbide Batt Plates
- Design: Flat plates for stacking ceramic ware.
- Advantages:
- Surface smoothness: Minimizes product adhesion.
- Thermal Shock Resistance: Withstands 300°C/hour temperature swings.
- Grades: RBSiC (high-load), SiSiC (cost-effective).
3.3 Silicon Carbide Burner Nozzles
- Performance:
- Oxidation Resistance: Stable in 1600°C oxidizing atmospheres.
- Erosion Resistance: Ideal for coal/biomass combustion systems.
- Customization: Available in multi-hole designs for uniform flame distribution.
3.4 Structural Components (Beams, Columns, Rollers)
- Beams:
- Load Capacity: 1.5–3 tons/m² (nitride-bonded).
- Applications: Kiln car decks, furnace supports.
- Rollers:
- Roundness Tolerance: ±0.1 mm (for glass tempering lines).
4. Technical Performance Indicators
| Parameter | Test Standard | RBSiC Range | SiSiC Range |
|---|---|---|---|
| Porosity | ASTM C20 | 15–20% | 10–15% |
| Cold Crushing Strength | ASTM C133 | 150–250 MPa | 80–150 MPa |
| Thermal Expansion | ASTM E228 | 4.5×10⁻⁶/°C (RT–1000°C) | 4.3×10⁻⁶/°C |
| Thermal Conductivity | ASTM C201 | 100–120 W/m·K | 40–60 W/m·K |
5. Applications Across Industries
5.1 Ceramics Manufacturing
- Role: Reduce kiln energy consumption by 30% via lightweight SiC setters.
- Case: Replacing alumina trays with SiSiC batt plates in sanitaryware production.
5.2 Renewable Energy
- Solar/PV: SiC rollers for silicon wafer annealing.
- Batteries: RBSiC saggers for lithium cathode sintering (1600°C).
5.3 Metallurgy & Chemicals
- Furnace Linings: Nitride-bonded beams in aluminum smelters.
- Heat Exchangers: SiC tubes for corrosive gas cooling.
6. Installation and Maintenance Guidelines
- Installation:
- Use graphite-based spacers to prevent SiC-to-SiC contact abrasion.
- Allow 2–3 mm expansion gaps for beams.
- Maintenance:
- Clean with compressed air; avoid water to prevent thermal shock.
- Inspect for cracks every 50 heating cycles.
7. Case Studies and Industry Trends
7.1 Case: High-Performance Saggers in EV Battery Production
- Challenge: Frequent failure of alumina saggers at 1500°C.
- Solution: RBSiC saggers with 99% SiC content.
- Result: Lifespan extended from 50 to 200 cycles.
7.2 Emerging Trends
- Demand Surge: SiC kiln furniture in SiC semiconductor production (2025–2030).
- Sustainability: Recycling spent SiC components into abrasives.
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