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High temperature refractory ceramic rollers for kilns

The rollers are applicable in the sintered zone of roller hearth kiln, which produces daily porcelain, sanitary ceramics, construction ceramics and so on. The roller is a key part of roller hearth kiln,which has excellent load-bearing ability and thermal shock resistance under high temperature,and can be applied in high temperature zone of roller hearth kiln for tableware,sanitary ware and electronic porcelain.

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Silicon Carbide Roller - Comprehensive Introduction

1. Definition and Overview

A silicon carbide roller, often referred to as an SiC roller, is a high-temperature load-bearing component in the form of a tube or rod. It is primarily made from silicon carbide (SiC), a high-performance engineering ceramic, through specialized processes such as reaction bonding, pressureless sintering, or recrystallization.

It is a core component of modern industrial kilns, especially high-temperature roller hearth kilns, and its performance directly determines the kiln's production efficiency, product quality, and operating costs.

2. Core Characteristics and Advantages

The silicon carbide material imparts exceptional properties to the rollers, far surpassing traditional alumina or metal rollers:

• Extremely High Temperature Resistance: Can operate stably in long-term high-temperature environments of 1200°C – 1600°C, with short-term maximum use temperatures exceeding 1700°C.

• Excellent High-Temperature Strength and Rigidity: High high-temperature bending strength and strong creep resistance. It resists deformation and bending under prolonged high-temperature loads, providing stable support for products being fired (e.g., tiles, lithium battery materials).

• Superior Thermal Stability and Thermal Shock Resistance: Highly adaptable to rapid temperature fluctuations inside the kiln, resistant to cracking from thermal shocks, making it suitable for fast-firing processes.

• High Hardness and Wear Resistance: High surface hardness resists wear from powder and product movement, ensuring a long service life.

• Good Oxidation and Corrosion Resistance: Stable performance in both oxidizing and reducing atmospheres, resistant to certain chemical corrosion within the kiln.

• Excellent Thermal Conductivity: Thermal conductivity is significantly higher than other ceramic materials, aiding in uniform temperature distribution within the kiln and improving product firing quality.

3. Main Application Areas

Silicon carbide rollers are the preferred carriers for high-temperature, precise, and rapid firing processes, mainly used in:

• Building Ceramics Industry: Core components of roller hearth kilns for producing high-end tiles such as polished tiles, glazed tiles, microcrystalline stones, and rustic tiles.

• Lithium Battery & New Energy Industry: Used in pusher kilns and roller hearth kilns for sintering lithium battery cathode and anode materials (e.g., lithium iron phosphate, ternary materials).

• Electronic Ceramics Industry: Sintering electronic substrates, magnetic materials, MLCCs, etc.

• Special Ceramics Industry: Used for high-temperature sintering of structural ceramics, functional ceramics, etc.

• Other Fields: High-temperature conveying equipment in glass heat treatment, metallurgy, chemical industry, and other sectors.

4. Main Types and Manufacturing Processes

Depending on the manufacturing process and microstructure, mainstream silicon carbide rollers on the market can be classified into:

• Reaction-Bonded Silicon Carbide (RBSC) Rollers

  • Characteristics: High density, high strength, good densification, relatively low cost. The most widely used type.

  • Process: A mixture of silicon carbide powder, carbon powder, and a binder is formed and then reacted with molten silicon at high temperatures, generating new silicon carbide to bond the body.

• Recrystallized Silicon Carbide (R-SiC) Rollers

  • Characteristics: Extremely high purity (>99%), outstanding high-temperature performance, stronger oxidation resistance, longer service life, but highest cost.

  • Process: Sintered at extremely high temperatures (>2000°C) via the evaporation-condensation mechanism of silicon carbide crystals, containing no secondary phases like metallic silicon.

• Pressureless Sintered Silicon Carbide (SSIC) Rollers

  • Characteristics: Performance介于 reaction-bonded and recrystallized types, offering good overall performance. An important developmental direction.

  • Process: Sintered at atmospheric pressure and high temperature with the addition of small amounts of sintering aids.