Applications of Advanced Ceramics in the Chemical, Plastics & Rubber

Advanced ceramics have emerged as indispensable materials across the chemical, plastics및 rubber sectors, thanks to their exceptional corrosion resistance, wear resistance및 high-temperature stability. From reactor linings in petrochemical plants to ceramic-coated rollers in polymer processing lines, these engineered materials optimize equipment longevity, improve process efficiency, and enable green manufacturing.

Great Ceramic provides precision-engineered ceramic components specifically designed for the chemical, plastics, and rubber industries. These technical ceramics offer unmatched wear resistance, thermal stability, chemical inertness, and electrical insulation, making them essential for upstream, midstream, and downstream applications.

Why Use Advanced Ceramics?

Advanced ceramics are engineered materials characterized by high purity, controlled microstructures, and superior properties compared to traditional ceramics. Key features include:

화학적 불활성

Many industrial chemicals are highly corrosive and reactive with metals or polymers. Advanced ceramics like alumina (Al₂O₃), silicon carbide (SiC), and zirconia (ZrO₂) offer outstanding chemical stability, even in strong acids, alkalis, and solvents.

High Temperature Resistance

Processes in chemical and rubber manufacturing often involve elevated temperatures exceeding 1000°C. Ceramics such as silicon nitride (Si₃N₄) 그리고 질화 알루미늄(AlN) maintain their structural integrity at high temperatures, outperforming metals and engineering plastics.

Exceptional Wear and Abrasion Resistance

Many processing steps—like mixing, extrusion, and pumping—create abrasive conditions. Ceramic components such as valves, seals, bushings및 liners offer extended service life under these conditions, significantly reducing downtime and maintenance.

전기 절연

In environments where electrical isolation is critical, ceramics like machinable glass ceramic (MGC) 그리고 boron nitride (BN) provide both thermal and electrical insulation, protecting equipment and ensuring operational safety.

These attributes make advanced ceramics indispensable in roles where metals or polymers fail—particularly in corrosive, abrasive, or high‐temperature environments.

benefit:

High temperature tolerance (up to 1,600 °C)
Chemical inertness against acids, alkalis, and solvents
Exceptional hardness and wear resistance, extending equipment life
Low thermal expansion and high thermal shock resistance
Electrical insulation or semiconductor behavior for sensors

Key Applications

In the Chemical Industry

Reactor Linings and Trays

Challenge: Reactors and distillation columns are susceptible to corrosion in strong acid and alkaline environments.
Solution: Using alumina ceramic linings or silicon nitride coatings can extend service life by 5–10 times.
Example: A chemical plant replaced its reactor lining with stainless steel Al₂O₃ ceramic, extending equipment downtime and maintenance intervals from 6 months to 18 months, significantly reducing operating and maintenance costs.

Seals and Valve Seats

Challenge: Traditional metal seals wear rapidly in high-temperature, high-pressure, and corrosive environments.
Solution: Aluminum nitride (AlN) ceramic seals offer high-temperature resistance (up to 1,400°C) and chemical resistance.
Advantages: Stable sealing performance, reduced leakage risk, and improved production safety.

Sensors and Measuring Elements

Application: Ceramic sensor probes for chemical online monitoring instruments offer the dual advantages of high-temperature insulation and chemical resistance, making them suitable for smart manufacturing and Industry 4.0.

in the Plastics Industry

Extruder Screw and Barrel

Challenge: High-viscosity plastics create high friction between the screw and barrel, easily leading to equipment wear and production line downtime.
Solution: Spraying a silicon carbide (SiC) or boron carbide (B₄C) ceramic coating on the inner wall of the screw barrel reduces friction and extends equipment life.
Result: Screw wear is reduced by 60%, and routine maintenance costs are reduced by 40%.

Mold and Runner Components

Advantage: Using silicon nitride ceramic molds, with their high thermal conductivity and wear resistance, significantly improves the surface quality of plastic parts and production stability.
Case Study: An automotive interior parts manufacturer adopted Si₃N₄ ceramic molds, achieving a 15% reduction in molding cycle time and a 30% drop in defective product rates.

Hot Runner System

Requirement: Precise temperature control and fast response.
Solution: Aluminum nitride (AlN) ceramic heater rods offer high thermal conductivity (>140 W/m·K) and excellent electrical insulation, enabling rapid temperature ramping and stable temperature control.

in the Rubber Industry

Rubber Seals and Wear-Resistant Bushings

Scenario: In oil and natural gas transportation, seals are subject to high pressure and chemical corrosion.
Solution: Ceramic/elastomer composite seals leverage the ceramic surface hardness and corrosion resistance to extend seal life by 2–3 times.

Autoclave Liners and Molds

Requirement: Resist corrosion and wear from vulcanizing agents during high-temperature vulcanization.
Solution: Silicon nitride (Si₃N₄) or silicon carbide (SiC) linings improve wear resistance and anti-stick properties, ensuring product consistency.

Mixing Rollers and Cutting Tools

Advantages: SiC ceramic rollers offer high surface hardness and excellent wear resistance, making them suitable for high-intensity mixing and reducing downtime for roll changes.
Case Study: After upgrading to ceramic rollers, a rubber products factory saw a 20% increase in production capacity and a reduction in maintenance intervals from 20 days to 60 days.

Most Common Ceramic Materials Used

At Great Ceramic, we help our customers in the chemical, plastics, and rubber industries achieve unprecedented levels of performance, reliability, and sustainability by utilizing advanced ceramics such as alumina (Al₂O₃), silicon carbide (SiC), silicon nitride (Si₃N₄), and zirconium oxide toughened alumina (ZTA20).

세라믹 소재	Properties & Benefits	Typical Applications
알루미나(Al₂O₃)	High hardness, good chemical resistance, cost-effective	Seals, bushings, guides, valves
지르코니아(ZrO₂)	Tough, wear-resistant, corrosion-resistant	Pump shafts, plungers, grinding media
실리콘 카바이드(SiC)	Extreme hardness, thermal shock resistance, excellent corrosion resistance	Nozzles, reactor linings, extrusion tools
질화규소(Si₃N₄)	Lightweight, high strength, thermal shock resistance	Bearings, mixers, high-temp valve components
질화 알루미늄(AlN)	높은 열 전도성, 전기 절연성	High-temp electronics, heaters, process monitoring devices
질화붕소(BN)	Chemically inert, excellent lubricity and insulation	Lubricating coatings, insulators, crucibles
ZTA(지르코니아 강화 알루미나)	Balanced toughness and hardness	Die inserts, guides, wear plates
MGC(가공 가능한 유리 세라믹)	Easily machinable, good thermal/electrical insulation	Insulating components, spacers, custom lab parts

Great Ceramic’s Capabilities

At Great Ceramic, we provide custom precision ceramic parts tailored for demanding chemical and plastic processing environments. From zirconia plungers to alumina nozzles and silicon carbide wear-resistant liners, our materials and manufacturing capabilities ensure longevity, precision, and performance.

Material Selection Support: Alumina, zirconia, silicon nitride, aluminum nitride, SiC, ZTA, BN, MGC, and more
Custom Component Design: Based on drawings, 3D models, or customer application needs
Advanced Machining: CNC grinding, polishing, hole drilling, slotting, and surface treatment
Tight Tolerances: Precision up to ±0.001mm
Prototyping and Small Batch Production: Rapid delivery for development and testing
Surface Metallization & Brazing Services: For ceramic-to-metal assemblies
Substrate Preparation: AlN and alumina ceramic boards with laser cutting and metallization