SiC Cyclone Liner
Main Chemical Compositions & Categories
SiC Cyclone Liners are structural, wear-resistant ceramics composed primarily of high-purity SILICON CARBIDE (SiC). They are typically manufactured as monolithic or segmental shapes using advanced bonding techniques to ensure a dense, uniform, and hard structure.
| CATEGORY | BONDING / MANUFACTURING | KEY FEATURE | PRIMARY ADVANTAGE |
| Reaction-Bonded SiC (RBSiC) | SiC bonded with residual Si | High density, excellent hardness | Maximum abrasion and thermal shock resistance |
| Sintered SiC (SSiC) | Pure SiC bond | Highest purity, minimal free Si | Extreme chemical inertness and hot strength |
Key Properties and Performance
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Abrasion Resistance | OUTSTANDING | SiC is extremely hard (Mohs 9.5), resisting wear from high-velocity particles (e.g., coal dust, cement clinker). |
| Thermal Shock Resistance | EXCELLENT | High thermal conductivity and low coefficient of thermal expansion (CTE) allow the liner to tolerate rapid temperature fluctuations. |
| High Temperature Stability | VERY HIGH | Maintains strength and dimensional stability up to 1400°C (RBSiC) or 1650°C (SSiC). |
| Erosion/Corrosion | EXCELLENT | Highly inert to most acids, alkalis, and complex flue gas chemistries. |
Advantages and Key Characteristics
SiC Cyclone Liners are specialized to provide extended service life in zones where the kinetic energy of particles, high heat, and corrosive gases combine to rapidly destroy metallic or common oxide refractory linings.
- Extreme Wear Protection: Cyclones operate by creating a vortex that throws abrasive particles against the wall at high velocity. SiC‘s intrinsic hardness is one of the highest available, resulting in a liner that can survive these conditions for years, dramatically reducing maintenance downtime.
- Thermal Tolerance: Often used in pre-heater systems (e.g., in cement or lime production) where temperatures are high and can change rapidly. SiC‘s excellent thermal properties prevent the cracking (spalling) failure common with less conductive materials.
- Dimensional Precision: SiC is often precision-manufactured into smooth, seamless segments or monolithic shapes. This precision is critical for maintaining the necessary aerodynamic profile of the cyclone for optimal separation efficiency.
- Chemical Inertness: Used in processes involving corrosive components like sulfur compounds, alkalis, and metal oxides (e.g., in fluid catalytic cracking units or waste incineration), where SiC is highly stable.
Typical Industries and Applications
SiC Liners are vital for particle separation in high-temperature processes:
- Cement & Lime Industry: Pre-heater cyclones and calciner towers, where hot, abrasive raw meal and clinker dust are handled.
- Petrochemical Industry: Fluidized Catalytic Cracking (FCC) unit regenerators and reactors, where SiC is used in cyclones to separate catalyst particles.
- Power Generation: Linings in coal gasification, combustion boilers, and flue gas desulfurization systems handling abrasive fly ash.
Furnace Areas and Service Zones
They are specified for all surfaces in direct contact with the high-velocity, abrasive particle stream:
- CYCLONE BODY AND CONE: The entire inner surface of the cyclone, where particles are concentrated.
- VORTEX FINDER: The internal tube that separates the clean gas from the solids, requiring high dimensional accuracy.
- OUTLET DUST VALVES: Areas subject to concentrated, high-speed particle discharge.
Key Data Sheet Properties to Consider
Selection criteria focus on hardness, density, and operating conditions:
- Abrasion Resistance Index: Look for specific data confirming superior wear life (often expressed as a relative wear index).
- Bulk Density (BD) and Apparent Porosity (AP): CRITICAL VALUE. RBSiC typically has a very high BD (e.g., > 3.0 g/cm3) and very low AP (< 1%) to maximize hardness and prevent penetration.
- Bonding Type (RBSiC vs. SSiC): RBSiC is cost-effective and highly wear-resistant but has a T limit of 1400°C (due to free Si); SSiC is for higher T and chemical purity.
- SiC Content: High content (e.g., > 85% by volume) is preferred for maximum hardness.
Technical Guidance: SiC Cyclone Liners are a long-term capital investment justified by avoiding repeated, costly maintenance and unexpected shutdowns. They are often installed as pre-formed segments, which are then cemented into the steel shell using high-temperature refractory castable or mortar.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
