In the ceramic manufacturing industry, the selection of kiln trays is a critical decision that significantly impacts product quality and production efficiency. However, many ceramic production enterprises often fall into common pitfalls when choosing kiln trays, leading to a decline in product yield. This article aims to provide in - depth insights into the selection of ceramic kiln trays, especially focusing on the performance advantages of composite corundum mullite trays in typical ceramic firing scenarios.
Various ceramic products, such as mosaics, sanitary ware, and roof tiles, have distinct requirements for kiln trays. For example, mosaics usually require trays with high flatness and fine surface finish to ensure the integrity of the small ceramic pieces during firing. Sanitary ware, on the other hand, needs trays with good thermal stability and high - strength resistance to withstand the relatively large size and weight of the products. Roof tiles demand trays with excellent wear - resistance due to their rough surface and frequent contact with the trays.
Let's take a look at some key performance indicators. The coefficient of thermal expansion is a crucial factor. A tray with a high coefficient of thermal expansion may cause product deformation or cracking during the heating and cooling process. Research shows that in a temperature range of 1000°C - 1400°C, a tray with a thermal expansion coefficient within 0.5% - 0.8% can effectively reduce the risk of product damage. The flexural strength also plays an important role. Trays with a flexural strength of over 30MPa are more likely to maintain their shape under the weight of ceramic products, reducing the probability of product collapse.
When comparing traditional refractory bricks and ordinary ceramic trays with composite corundum mullite trays, significant differences can be observed in terms of thermal stability, thermal shock resistance, and service life. Traditional refractory bricks often have a relatively high thermal expansion coefficient, which may lead to product deformation at high temperatures. Their thermal shock resistance is also limited, and they are prone to cracking after multiple heating - cooling cycles.
| Material | Thermal Stability | Thermal Shock Resistance | Service Life (Cycles) |
|---|---|---|---|
| Traditional Refractory Bricks | Low | Poor | About 50 - 100 |
| Ordinary Ceramic Trays | Medium | Fair | About 100 - 200 |
| Composite Corundum Mullite Trays | High | Excellent | Over 300 |
Composite corundum mullite trays, in contrast, have a lower thermal expansion coefficient, better thermal shock resistance, and a longer service life. They can effectively reduce the problems of product collapse and deformation caused by material mismatch, thereby improving the firing yield.
To ensure the proper use of trays and improve their utilization rate, it is necessary to manage the tray life based on the temperature range. In the temperature range of 1000°C - 1400°C, regular inspections should be carried out. For example, trays used at 1000°C - 1200°C can be inspected every 50 firing cycles, while those used at 1200°C - 1400°C should be inspected every 30 cycles.
It is also important to record the usage cycle of each tray. By analyzing the data, enterprises can identify the aging signs of trays in advance. For instance, if a tray's flexural strength decreases by 10% compared to its initial value, it may be a sign of aging. Some typical customer cases have shown that by implementing a scientific tray life management strategy, enterprises can reduce the replacement frequency of trays by about 20% and improve the equipment utilization rate by 15%.
Instead of relying solely on experience, ceramic production enterprises should make data - driven decisions when selecting kiln trays. By understanding the specific performance requirements of different ceramic products, comparing the performance of various tray materials, and implementing scientific tray life management strategies, technical leaders and procurement decision - makers can make more informed choices, ultimately improving the firing yield and production efficiency.
To solve the problem of improper tray selection, enterprises can establish a comprehensive tray evaluation system. This system should include performance testing of trays, such as thermal expansion coefficient, flexural strength, and wear - resistance testing. At the same time, regular data analysis of tray usage should be carried out to continuously optimize the selection and management of trays.
If you want to learn more about ceramic tray selection, including more detailed performance data, case studies, and scientific selection methods, we invite you to download our Ceramic Tray Selection White Paper in PDF format. This white paper is a valuable resource that can help you make more scientific and rational decisions in ceramic tray selection.
