How many temperature zones can a customized tube furnace be made into?

The number of temperature zones for customized tube furnaces can be flexibly designed according to experimental needs, usually supporting 1 to 5 temperature zones, or even more, depending on process complexity, equipment size, and budget.

1. Number of common temperature zones and applicable scenarios
Single temperature zone tube furnace
Structure: The entire furnace body is a continuous heating zone with uniform temperature distribution.
Applicable scenarios:
Simple heat treatment (such as annealing, drying).
The sample size is small or there are no special requirements for temperature gradient.
Case: A laboratory used a single temperature zone tube furnace for preliminary sintering of metal powder, with a temperature uniformity of ± 2 ℃, meeting the needs of basic research.
Dual temperature zone tube furnace
Structure: Divided into two independent heating zones (such as heating zone+constant temperature zone), with a transition section in between.
Applicable scenarios:
The material undergoes a staged reaction (such as activation by heating first, followed by a constant temperature reaction).
Reduce sample transfer steps and improve experimental efficiency.
Case: A certain enterprise customized a dual temperature zone tube furnace for pre firing and final firing of lithium battery cathode materials, optimizing material crystallinity through independent temperature control.
Three temperature zone tube furnace
Structure: heating zone+reaction zone+cooling zone, simulating continuous process flow.
Applicable scenarios:
Complex heat treatment (such as semiconductor epitaxial growth, catalyst support activation).
Processes that require precise control of temperature gradients, such as nanomaterial synthesis.
Case: A university customized a three temperature zone vertical tube furnace for CVD growth of graphene films. By independently controlling the temperature of each temperature zone, uniform film formation was achieved.
Four temperature zone and above tubular furnace
Structure: Divide more independent heating zones (such as four temperature zones and five temperature zones) according to demand, supporting more complex temperature curves.
Applicable scenarios:
Multi step continuous process (such as quenching tempering aging treatment of metals).
Development of new materials in scientific research (such as preparation of gradient functional materials).
Case: A research institute customized a five temperature zone tube furnace for staged sintering of high-temperature superconducting materials, and improved the critical current density through precise temperature control.

2. Core considerations for customizing multi zone tube furnaces
Process requirements
Temperature curve complexity: If the process requires multi-step temperature changes (such as rapid heating constant temperature gradient cooling), three temperature zones or above should be selected.
Sample characteristics: Large size samples or materials sensitive to temperature uniformity (such as semiconductor wafers) require more temperature zones to ensure uniform heating.
Equipment size and cost
Furnace body length: An increase in the number of temperature zones will prolong the furnace body length, and it is necessary to ensure sufficient laboratory space.
Budget: The cost of equipment in multiple temperature zones is higher (for example, three temperature zones are 30% -50% more expensive than single temperature zones), and a balance between performance and cost is needed.
Temperature control accuracy and uniformity
Independent temperature control system: Each temperature zone needs to be equipped with an independent temperature controller (such as a PID controller) to ensure temperature accuracy within ± 1 ℃.
Transition zone design: A transition section should be set between adjacent temperature zones to avoid sample cracking or performance degradation caused by sudden temperature changes.

3. Customization process of multi temperature zone tube furnace
Requirement communication
Provide detailed parameters such as experimental objectives, temperature curves, sample size, and atmosphere requirements.
Example: The user needs to customize a three temperature zone tube furnace for gradient activation of catalyst supports. The heating rate is required to be 10 ℃/min, the reaction zone should be kept at a constant temperature for 12 hours, and the cooling zone should be naturally cooled.
scheme design
The manufacturer designs the temperature zone layout, heating element type (such as silicon carbon rod, silicon molybdenum rod), furnace tube material (quartz or corundum), etc. according to the requirements.
Key points: It is necessary to clarify the temperature range, overlapping areas, and atmosphere sealing of each temperature zone.
Production and Testing
The manufacturer produces equipment according to the design plan and conducts no-load testing (temperature uniformity, atmosphere leakage rate) and load testing (simulating actual process conditions).
Standard: Temperature uniformity ≤ ± 3 ℃, atmosphere leakage rate ≤ 0.5% vol/h.
Delivery and Training
The manufacturer provides on-site installation and debugging, and trains operators on the use of temperature control systems, air circuit control, safety protection, and other functions.
Services: including 24-hour hotline, 48 hour on-site maintenance, lifelong technical support, etc.