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Catalyst Carrier Ball

Catalyst Carrier

This product was made from activated alumina and false monohydrate aluminum adhesive. It owns stable surface, good crushing strength, low abrasion, suitable pore shape, low impurity, good active component impregnation.

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Product Description

Catalyst Carrier Balls & Inert Support Media - Technical Specification

Inert Ceramic & Alumina Support Media Standard: HG/T 3686-2014 / ISO 9001

Catalyst Carrier & Support Balls

Name: Catalyst Carrier Ball
SKU: 0

Engineered for extreme reactor environments in oil refining, petrochemical, fertilizer, and gas processing plants. Functions as catalyst bed cover, support media, and fluid distribution packing with maximum crushing strength, chemical inertness, and thermal endurance.

Al₂O₃ Content Range

17% – 99.5%+

Crushing Strength

Up to >1200 N/ball

Max Working Temp

1100°C – 1650°C

Water Absorption

≤ 1.0% (Inert Grade)

Reactor Bed Layering & Ball Diameter Mapping

A multi-stage spherical size gradient ensures uniform fluid distribution, high crush resistance, and zero catalyst migration.

Figure 1: Cross-Sectional Packing Diagram of Fixed-Bed Catalyst Column

1. Top Cover Layer (压顶防冲刷层) 13mm – 25mm (1/2" – 1")

Cushions gas/liquid fluid impact at the inlet, prevents bed turbulence/fluidization, and filters fine particulates.

2. Top Intermediary Gradation (上过渡层) 6mm – 10mm (1/4" – 3/8")

Provides a smooth size gradient transition to the active catalyst pellets and ensures homogeneous feedstock distribution.

⚙️ Active Catalyst Bed (活性催化剂层) Reaction Zone

Core reaction zone securely supported and held in place by upper and lower inert ceramic ball beds.

3. Bottom Intermediary Gradation (下过渡支撑层) 3mm – 10mm (1/8" – 3/8")

Prevents active catalyst migration/leaking into large bottom ball voids while facilitating uniform flow collection.

4. Bottom Support Base Layer (底部主支撑层) 19mm – 50mm (3/4" – 2")

Rests on the bottom grid plate. Absorbs massive static loads (>3500 N/ball) and provides maximum void space to reduce outlet pressure drop.

Recommended Application by Layer Position

Optimized spherical diameter selection based on vessel mechanics and hydrodynamics.

Diameter: 13mm – 25mm (1/2" – 1")

Top Topping Layer

Placed at the top of the reactor bed to cushion against incoming gas/liquid fluid impact and catch particulate debris.

Prevents fluid channeling and erosion
Distributes inlet feedstock evenly
High impact & thermal shock resistance

Diameter: 3mm – 10mm (1/8" – 3/8")

Intermediary Transition Layer

Positioned directly adjacent to active catalyst particles to prevent migration into larger support voids.

Smooth diameter gradation transition
Prevents catalyst plugging & abrasion
Uniform pressure drop distribution

Diameter: 19mm – 50mm (3/4" – 2")

Bottom Support Base Layer

Loaded at the vessel bottom above the support grid to withstand the massive static weight of the entire catalyst column.

Ultra-high crush load capacity
Maximum void space for outlet gas flow
Chemical resistance to corrosive effluents

Material Grade Technical Specifications

Comprehensive physical and chemical specifications covering standard ceramic to ultra-pure corundum balls.

Technical Property	Standard Inert (17-23% Al₂O₃)	High Alumina (92-95% Al₂O₃)	Corundum Grade (99.5%+ Al₂O₃)
Al₂O₃ Content (wt%)	17% – 23%	92% – 95%	≥ 99.5%
SiO₂ Content (wt%)	70% – 76%	3% – 5%	≤ 0.15%
Fe₂O₃ Content (wt%)	≤ 1.0%	≤ 0.2%	≤ 0.05%
Water Absorption (%)	≤ 1.0%	≤ 0.5%	≤ 0.2%
Bulk Density (g/cm³)	1.35 – 1.45	1.90 – 2.10	2.20 – 2.40
Crush Strength (6mm / 1/4")	≥ 300 N/ball	≥ 600 N/ball	≥ 900 N/ball
Crush Strength (19mm / 3/4")	≥ 1000 N/ball	≥ 2200 N/ball	≥ 3500 N/ball
Max Operating Temperature	1100°C	1450°C	1650°C
Acid Resistance (wt loss)	≥ 99.5% (ASTM C279)	≥ 99.8%	≥ 99.9%

Engineering Advantages in Fixed-Bed Reactors

Manufactured under strict ISO quality control with automated hydraulic pressing and high-temperature sintering.

1. Superior Mechanical Crushing Resistance

Engineered to withstand severe thermal expansion, rapid depressurization cycles, and heavy static catalyst loads without cracking or thermal shock spalling.

2. Zero Leaching & Extreme Inertness

Virtually free of free silica and trace metals in High-Alumina grades, preventing catalyst poisoning and unwanted side-reactions in sensitive hydrotreating reactors.

3. Optimized Bed Fluid Dynamics

Precise spherical sphericity (>98%) ensures predictable void fractions (~40%), lowering pressure drop ($Delta P$) across the reactor column and saving compressor energy.