Development of a zirconia-mullite based ceramic for recuperator applications

Technical Report · Tue Dec 01 00:00:00 EST 1992

DOI:https://doi.org/10.2172/6403322· OSTI ID:6403322

Gonzalez, J M ^[1]

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1. GTE Products Corp., Towanda, PA (United States)

GTE Products Corporation developed a compact ceramic high temperature recuperator for recovering heat from relatively clean exhaust gases at temperatures up to 2500F. The DOE program allowed GTE to improve the technical and economic characteristics of the recuperator and stimulate industrial acceptance of the recuperator as an energy-saving technology. From January 1981 to December 1984, 561 recuperators were installed by GTE on new or retrofitted furnaces. With over 1200 units sold commercially between 1981 and 1990, GTE has documented the effect (long and short term) of corrosive attack from alkalies and lead. One objective of this contract was to develop Z-1000 a zirconia-mullite mixed oxide ceramic for use in ceramic recuperator applications susceptible to corrosion. To first and second pass of the ceramic recuperator would utilize the current cordierite-mixed-oxide ceramic. A Z-1000 matrix element would be used in the preheated air side's third pass (exhaust inlet). Thermal stresses on Z-1000 cross flow module could be minimized by selecting appropriate heat transfer surface areas for each pass. A large surface area for first and second pass (cordierite section) could provide for sufficient heat transfer for 50% effectiveness. A surface area that generates minimal heat transfer in the third pass (Z-1000) section is envisioned. Heat transferred in this section reduces the differential temperature across the matrix and the thermal stresses. Hence, thermal shock resistance of the material in the third pass becomes less critical; however, its corrosion resistance must be sufficient to withstand corrosive attack. This modular design could utilize a field repairable, disposable matrix. This report is concerned with process technology development for fabricating such a matrix, and a series of corrosion tests that established the potential corrosion resistance of the Z-1000 ceramic.

• Research Organization: Oak Ridge National Lab. (ORNL), Oak Ridge, TN (United States); GTE Products Corp., Towanda, PA (United States)
• Sponsoring Organization: USDOE; USDOE, Washington, DC (United States)
• DOE Contract Number: AC05-84OR21400
• OSTI ID: 6403322
• Report Number(s): ORNL/Sub-86-22044/2; ON: DE93013451
• Country of Publication: United States
• Language: English

Related Subjects

32 ENERGY CONSERVATION, CONSUMPTION, AND UTILIZATION
FURNACES
WASTE HEAT UTILIZATION
CORROSION
CORROSION PROTECTION
EXHAUST GASES
HEAT EXCHANGERS
HEAT RECOVERY
HEAT TRANSFER
HYDROXIDES
INDUSTRIAL PLANTS
LEAD
MATRIX MATERIALS
MULLITE
PROTECTIVE COATINGS
SILICATE MINERALS
ZIRCONIUM OXIDES
CHALCOGENIDES
CHEMICAL REACTIONS
COATINGS
ELEMENTS
ENERGY RECOVERY
ENERGY TRANSFER
FLUIDS
GASEOUS WASTES
GASES
HYDROGEN COMPOUNDS
INORGANIC ION EXCHANGERS
ION EXCHANGE MATERIALS
MATERIALS
METALS
MINERALS
OXIDE MINERALS
OXIDES
OXYGEN COMPOUNDS
TRANSITION ELEMENT COMPOUNDS
WASTE PRODUCT UTILIZATION
WASTES
ZIRCONIUM COMPOUNDS
320304* - Energy Conservation
Consumption
& Utilization- Industrial & Agricultural Processes- Waste Heat Recovery & Utilization