What are Technical Ceramics?

Technical Ceramics, also known as engineering ceramics or advanced ceramics, are a class of ceramic materials that are specifically engineered to possess exceptional mechanical, thermal, electrical, or chemical properties. These ceramics are designed to meet the demanding requirements or various industrial applications where traditional materials such as metals, polymers, or conventional ceramics fall short. Technical ceramics offer a unique combination of properties that make them suitable for high-performance and specialised applications.  

Technical Ceramics and Process Cooling 

Process cooling equipment plays a significant role in technical ceramics research and production by maintaining precise and controlled temperatures during various stages of the process. Technical ceramics often require specific temperature conditions for synthesis, shaping, sintering, and post-processing. Some examples of how process cooling is employed in technical ceramics research and production include:

Ceramic Powder Preparation

• In the production of technical ceramics, ceramic powders are often synthesised or obtained from commercial sources. Process cooling can be employed during powder synthesis or milling steps to prevent excessive heat build-up and maintain the desired particle size, morphology, and chemical properties of the ceramic powders.

Shaping and Forming

• Technical ceramics are shaped into various forms, such as green bodies or pre-sintered components, using techniques like powder compaction, extrusion, injection moulding, or tape casting. Cooling can be utilised during shaping processes to control the temperature of the ceramic materials and prevent deformation or dimensional inaccuracies. Cooling can also improve the strength and stability of the shaped components.

Binder Removal

• In some shaping processes, binders or additives are used to facilitate the formation of green bodies. These binders need to be removed before the final sintering process. Process cooling can be employed during binder removal steps, such as debinding or solvent evaporation, to control the rate of binder removal and prevent thermal damage to the green bodies.

Sintering

• Sintering is a critical step in the production of technical ceramics, where the shaped green bodies are heated to high temperatures to promote densification and grain growth. Process cooling equipment is used to regulate the temperature inside the sintering furnace or kiln, ensuring precise and controlled heating and cooling rates. This control is crucial for achieving the desired densification, microstructure, and mechanical properties of the final ceramic product.

Post-Processing

• After sintering, technical ceramics may undergo post-processing steps such as machining, grinding, or surface finishing. Process cooling can be employed during these steps to dissipate the heat generated during material removal, preventing excessive heat build-up and minimising thermal damage to the ceramic components.

Instrumentation and Characterisation

• Cooling is essential during the characterisation and testing of technical ceramics. Techniques such as thermal analysis, mechanical testing, or microscopy require controlled temperatures for accurate measurements. Cooling equipment can be used to cool sample holders, stages, or chambers, ensuring stable conditions and reliable characterisation results.

Recirculating Chillers

Recirculating chillers offer several benefits in technical ceramics research and production processes, providing precise temperature control and efficient cooling. Some of the advantages of using recirculating chillers in technical ceramics research and production include:

Temperature control:

• Recirculating chillers ensure precise and stable temperature control, which is crucial for the synthesis, shaping, and processing of technical ceramics. Technical ceramics often require controlled temperature profiles to achieve desired material properties and characteristics. The precise temperature control offered by recirculating chillers allows researchers and manufacturers to maintain consistent and reproducible results.

Cooling capacity:

• Recirculating chillers provide efficient cooling capacity, capable of dissipating the heat generated during various stages of technical ceramics production. Processes such as sintering or firing of ceramics involve high temperatures, and excess heat must be removed to prevent thermal damage and maintain the integrity of the materials. Recirculating chillers effectively remove heat, ensuring efficient cooling and process stability.

Versatile temperature range:

• Recirculating chillers offer a wide temperature range, allowing researchers and manufacturers to achieve and maintain the specific temperatures required for different stages of technical ceramics production. From low-temperature processes like drying and shaping to high-temperature processes like sintering, recirculating chillers can provide the necessary cooling across the temperature spectrum.

System integration:

• Chillers can be easily integrated into ceramic production systems, providing cooling to specific components or processes. They can be connected to reactors, kilns, shaping machines, or other equipment, ensuring efficient temperature control and thermal management.

Process stability:

• By maintaining stable and controlled temperatures, chillers contribute to process stability. Temperature fluctuations can impact the properties and performance of technical ceramics. With precise temperature control, chillers help to ensure consistent and reliable results, reducing variations and improving the overall quality of the ceramic products. 

Heat Exchangers

Heat exchangers provide comparable advantages to recirculating chillers in technical ceramics research and production, offering lower upfront expenses and reduced energy usage. They play a significant role in facilitating efficient heat transfer, precise temperature control, and ensuring high-quality technical ceramics materials. Specific benefits of using heat exchangers in the context of technical ceramics research and production include:

Heat dissipation:

• Heat exchangers efficiently dissipate excess heat generated during ceramic processing steps, preventing overheating and thermal damage to the ceramic materials. They help to maintain optimal temperature conditions, ensuring the desired properties and integrity of the ceramics.

Energy efficiency:

• Heat exchangers contribute to energy efficiency in ceramic production. By transferring heat from the process to the surrounding environment, they reduce the energy consumption associated with maintaining desired temperatures. This can result in cost savings and environmental benefits.

Equipment protection:

• Heat exchangers help to protect sensitive equipment and components from overheating. They remove heat generated during shaping, sintering, or post-processing steps, preventing damage and extending the lifespan of the equipment.

Process flexibility:

• Heat exchangers can accommodate a wide range of operating temperatures, making them suitable for different stages of the ceramic production process. They can handle both high-temperature and low-temperature cooling requirements, providing flexibility in process design and optimisation.

Versatility:

• Heat exchangers can be air-cooled or water-cooled, offering options to match the specific cooling needs and available infrastructure. They can be customised to fit different setups and can be integrated into various ceramic production systems.

 

The choice of process cooling equipment depends on the specific needs of the technical ceramics research or production process, including cooling capacity, temperature range, and scalability. Often, a combination of different cooling techniques and equipment is employed to achieve precise temperature control throughout the various stages or ceramic synthesis, processing, and characterisation.

 

We are excited to be exhibiting at Advanced Materials 2023. Find us on stand 1418 for a chat about how we can support with your process cooling requirements.