What are the differences in application scenarios of energy-saving supports across various kilns?

2025-09-18

The application differences of energy-saving supports across various kilns primarily revolve around the kiln's firing method (continuous vs. batch), temperature requirements, and the type of greenware being processed. Here’s how they adapt to specific scenarios: **Tunnel Kilns (Continuous Firing):** These are best suited for wear-resistant, thermally shock-resistant supports—such as high-alumina or mullite pillars and grid structures. Since these kilns continuously transport greenware while enduring slight vibrations over extended periods, the supports must also align with the kiln’s steady heating curve to prevent cracking caused by thermal stress. Typically paired with shelf plates or mesh racks, these supports efficiently hold uniform, mass-produced items like tiles and everyday ceramics. Additionally, their low thermal conductivity helps minimize heat loss from the kiln walls, making them ideal for meeting the energy-efficiency demands of continuous production. **Shuttle/Reverse Flame Kilns (Batch Firing):** In these kilns, where temperatures rise and fall rapidly between batches, flexible support systems—such as pillar-type structures or shelf-pin assemblies—are employed. The layout can be easily adjusted according to the size and shape of each batch, whether it consists of large-scale pottery pieces or specialized ceramics. Given the frequent thermal cycling, mullite-based supports are preferred for their exceptional resistance to thermal shock, ensuring durability against cold-and-hot impacts. Primarily designed to lift and organize saggers or irregularly shaped greenware in layers, these supports also help reduce localized heat loss within the kiln, perfectly matching the flexible temperature-control needs of batch firing processes. **High-Temperature Kilns (e.g., Specialized Ceramics Kilns Above 1600°C):** For kilns operating at extremely high temperatures, only high-alumina or corundum-based supports are suitable due to their outstanding ability to withstand intense heat without melting or deforming. These supports are often simplified into short columns or block-like designs to minimize heat absorption while preventing chemical reactions with the greenware even under scorching conditions. This ensures superior firing quality and is essential for maintaining the integrity of specialty ceramic materials. **Medium- and Low-Temperature Kilns (e.g., Stoneware Kilns, Certain Building Ceramic Kilns, 1200–1400°C):** In these kilns, insulating supports made from cordierite—known for its excellent electrical insulation and lower thermal conductivity—are commonly used. They not only provide reliable layer-by-layer support for the greenware but also maximize heat retention by minimizing heat loss to the kiln’s exterior. Such designs, often incorporating a mesh-like structure, enhance airflow circulation within the kiln, promoting more uniform firing and further boosting energy efficiency—a perfect match for the energy-saving needs of medium- and low-temperature ceramic production.

What types of energy-efficient ceramic supports are available for kilns?

2025-09-18

Pillar Type: A single, column-like structure used for supporting small greenware or saggers at a single point, offering flexible adaptation to various kiln layouts. Shelf Support (Support Pins/Column Sets): Typically short pillars or block-shaped pieces with raised features, designed for use with ceramic shelf boards. They securely hold an entire layer of shelves along with the ware placed on top, enabling efficient multi-layer firing. Grid Rack Type: Featuring a grid-like or frame-style design, these racks provide exceptional overall load-bearing capacity. They are ideal for supporting uniform, regular-shaped ware in bulk (such as tiles or everyday ceramics), while also optimizing airflow and heat distribution within the kiln.

The role of energy-saving ceramic supports in kilns

2025-09-18

Support and Fixation: Lifts and secures ceramic bodies, saggers, and other items inside the kiln, preventing deformation from stacking or contamination caused by contact with the kiln floor—ensuring stable positioning during firing. Energy Efficiency and Consumption Reduction: With poor thermal conductivity, these materials minimize heat loss from the kiln interior to the outer walls, while also optimizing internal heat circulation. This reduces the energy required to maintain high temperatures, leading to lower operational costs. High-Temperature Durability and Resistance to Damage: Designed to withstand extreme kiln temperatures—typically exceeding 1000°C—they remain resistant to melting or cracking. Additionally, they effectively shield against erosion from kiln dust and intense hot airflows, extending their lifespan and ensuring consistent performance throughout the firing process.