Category: Ceramic Fiber Insulation

What are the Characteristics of Ceramic Fiber Board?

KilnRefractory

Ceramic fiberboard, also known as aluminosilicate fiberboard, is a type of refractory material board. It is a rigid board product made by adding appropriate amounts of organic binders and inorganic adhesives to loose ceramic fibers, followed by vacuum forming, drying, and finishing. It has advantages such as good thermal stability, high temperature resistance, and low thermal conductivity, and is therefore widely used in many industries.

RS High-Quality Ceramic Fiber Insulation Board
RS High-Quality Ceramic Fiber Insulation Board

Characteristics of Ceramic Fiber Boards

The terminology for refractory ceramic fiber boards is clearly defined in GB/T18930-2002, “Terminology for Refractory Materials.” The definition is as follows: Ceramic fiber boards generally refer to rigid, flat refractory ceramic fiber products containing inorganic or organic binders and produced using a wet process. The binder refers to a substance added to non-plastic granular or fibrous materials to give them workability and green or dry strength. Refractory ceramic fibers refer to man-made mineral fibers suitable for use as insulation materials above 800℃. Rongsheng ceramic fiber board for sale. Ceramic fiber boards possess the following six characteristics:

  1. Grading Temperature

Grading temperature refers to the highest temperature at which the linear shrinkage rate is less than a given value. This temperature is expressed in °C and is in 50℃ increments. According to GB/T17911-2006, the permanent linear shrinkage rate of refractory ceramic fiber products upon heating, when measured according to the permanent linear shrinkage test, is no more than 2% for refractory ceramic fiber boards and irregularly shaped rigid products. This is the grading temperature. In GB/T3003-2006, “Refractory Materials, Ceramic Fibers and Products,” the grading temperature of ceramic fibers and products is divided into 19 levels, starting from 850℃ and ending at 1750℃.

Grading temperature characterizes the heat resistance of refractory ceramic fiber boards and is the most basic performance indicator to ensure the correct use of refractory ceramic fiber boards.

  1. Bulk Density

Bulk density refers to the ratio of the dry mass of a ceramic fiber board to its total volume. Generally, the bulk density of ceramic fiber boards ranges from 260 to 480 kg/m³. GB/T3003-2006, “Refractory Materials, Ceramic Fibers and Products,” specifies eight nominal bulk density values ​​for ceramic fiber boards: 260, 280, 300, 320, 330, 360, 400, and 450 kg/m³.

  1. Compressive Strength

This refers to the ultimate load that a rigid ceramic fiber product can withstand per unit area at room temperature. Compressive strength is one of the important performance indicators for evaluating the quality of rigid ceramic fiber products. It can indirectly reflect the product’s microstructure, such as density, uniformity, and sinterability.

  1. Permanent Linear Changes Due to Heating

The linear expansion or contraction of refractory materials after heating to a specified temperature, holding for a certain time, and cooling to room temperature without external force is considered. Domestic and international research results indicate that the linear shrinkage test for ceramic fiber products requires a 24-hour holding period. After 24 hours of holding, the linear shrinkage rate of ceramic fiber products reaches over 75% of the long-term shrinkage rate. The results of the 24-hour holding period linear shrinkage test can characterize the permanent linear changes due to heating during long-term use.

The linear shrinkage of ceramic fibers due to heating is meaningless for individual fibers; it only relates to the ceramic fiber product and is directly related to fiber crystallization and grain growth. Before crystallization begins, when the fibers remain in their original glassy state and there is no significant creep, the ceramic fiber product does not shrink. As the glassy fibers begin to crystallize, individual fibers curl, leading to shrinkage in the ceramic fiber product. Internationally, the test temperature at which the linear shrinkage rate after holding the sample for 24 hours does not exceed 2% is the permissible long-term service temperature for ceramic fiber boards. At this temperature, the crystallization of glassy fibers, the transformation of polycrystalline fibers, and the growth rate of grains are slow, resulting in stable fiber properties and soft, elastic fibers.

  1. Thermal Conductivity

Thermal conductivity characterizes a material’s ability to conduct heat. Its value refers to the amount of heat passing through each unit area per unit length per unit time when the temperature difference is 1°C. Its unit is W/(m·K).

  1. Combustion Performance

Combustion refers to the exothermic reaction of a substance under the action of an oxidant, usually accompanied by the generation of flame or visible light. GB/T16400-2003, “Aluminum Silicate Wool and Its Products for Thermal Insulation,” stipulates that products with binders should achieve a combustion performance rating of Class A (non-combustible material).

Ceramic Fiber Insulation Board
Ceramic Fiber Insulation Board

Main Applications of Ceramic Fiber Boards

  • Steel Industry: Expansion joints, backing insulation, insulation sheets, and mold insulation.
  • Non-ferrous Metals Industry: Backing insulation material, tundish and runner covers for casting copper and copper alloys.
  • Ceramic Industry: Lightweight kiln car structures and kiln hot face linings, kiln temperature zone separation, and fire baffles.
  • Glass Industry: Molten pool backing insulation, burner blocks.
  • Kiln Construction: Hot face refractory material (replaces fiber blankets), backing for heavy refractory materials, expansion joints.
  • Light Industry: Linings for combustion chambers of industrial and domestic boilers.
  • Petrochemical Industry: Hot face material for high-temperature heating furnace linings.
  • Building Materials Industry: Thermal insulation for equipment such as cement rotary kilns.

Ceramic fiber boards can be further categorized based on their high-temperature resistance range. Therefore, users should choose the appropriate type based on the specific application and temperature resistance requirements.

The Difference between Heat Insulation Materials and Thermal Insulation Materials

KilnRefractory

Strictly speaking, the concept of thermal insulation refers to the change of thermal energy of the object of concern (such as equipment, buildings, etc.), while the concept of thermal insulation, heat insulation, or thermal insulation refers to the heat flow or heat transfer of the heat source. Thermal insulation materials refer to materials that can block the transfer of heat flow, also known as thermal insulation materials (but not the same as thermal insulation materials). Thermal insulation materials can be divided into three categories: void heat insulation materials, heat reflective materials, and materials with both void heat insulation and heat reflective properties.

RS Ceramic Fiber Insulation Materials
RS Ceramic Fiber Insulation Materials

Insulation Materials

Insulation materials are materials or material complexes that are not easy to conduct heat and have significant resistance to heat flow. Their characteristics are: light weight, looseness, porosity, heat preservation, cold preservation, heat insulation, sound absorption, and sound elimination. Generally speaking, insulation materials include the first and third categories of materials mentioned above. Insulation materials can be divided into organic insulation materials (or organic thermal insulation materials) and inorganic insulation materials (or inorganic thermal insulation materials).

In industry idioms, insulation materials often refer to insulation materials suitable for temperatures below 600-700℃. In addition, the industry also refers to insulation materials suitable for low-temperature environments as “cold insulation materials”. Insulation materials suitable for high-temperature environments above 600-800℃ are called “refractory insulation materials“. Insulation materials have lower requirements for thermal conductivity values.

Insulation materials are often referred to as “thermal insulation materials” by people. Here, people do not strictly distinguish the subtle differences between different concepts.

The refractory industry and other industries often use the words “insulation” and “thermal insulation” to refer to lightweight and poorly conductive materials. However, the two are not used consistently and deserve to be reconsidered and unified. In the refractory industry, before the mid-1980s, “insulation materials” and “thermal insulation materials” were used interchangeably. Since then, the term “thermal insulation materials” has been gradually unified, so RS Kiln Refractory Factory will focus on the difference between thermal insulation and heat preservation below.

What is the Difference between Thermal Insulation and Heat Insulation?

  1. The concept of thermal insulation board and heat preservation board

Thermal insulation board refers to a board used to isolate heat transfer, generally referring to a board with a thermal conductivity of less than or equal to 0.065W/m•k, such as foam glass, polystyrene board, etc.

Thermal insulation board refers to a reasonable engineering material used to maintain the temperature inside and outside the building. It is usually made of materials with a thermal conductivity of less than or equal to 0.12W/m•k, such as extruded board, mineral wool board, etc.

  1. Differences between insulation board and heat preservation board

(1) Material properties

The thermal conductivity of insulation board is lower than that of heat preservation board, and the density of heat preservation board is higher than that of heat preservation board. Heat preservation board is generally a porous material with good air tightness, which can block water vapor penetration to a certain extent, but its bearing capacity for gravity load and wind pressure load is poor. The material used for heat preservation board is relatively hard, with high strength, and can withstand greater pressure.

(2) Application

Thermal insulation board is mainly used for moisture-proof, mildew-proof, anti-corrosion, fire-proof and sound-proof, and is also suitable for roof and wall insulation of industrial buildings and high-end residential buildings. The role of heat preservation board is more to improve the living environment of residential buildings, and is mainly used in the fields of exterior wall insulation, roof insulation, cold storage insulation, etc.

(3) Construction method

Thermal insulation board is mostly constructed by pasting, such as binding with polyurethane foam adhesive. It is generally more convenient to directly paste it with brick wall to achieve insulation. The insulation board needs to be installed by hanging, which is more troublesome, especially in high-rise buildings where construction safety issues need to be considered.

  1. Applicable situations

If the building needs to be moisture-proof, mildew-proof, anti-corrosion, fire-proof, sound-proof, etc., it is suitable to use insulation boards. Such as industrial buildings and high-end residences such as pharmaceutical factories, chemical plants, and food factories. If you need to improve the residential living environment, insulation boards are the first choice. It can effectively increase the temperature of the room and keep the indoor temperature stable, thereby reducing energy consumption.

What are the Advantages of Applying Ceramic Fiberboard to Industrial Furnaces?

KilnRefractory

The main raw material of ceramic fiberboard is aluminum silicate, which is one of the important guarantee factors for the kiln to save energy, reduce consumption, and optimize high production. According to the temperature division, fiberboard can be widely used in the backing of industrial kilns or the hot surface of low-temperature kilns. If you want to ask, what advantages does ceramic fiberboard have in industrial furnaces? Then its advantages are still obvious.

Ceramic Fiber Insulation Board
Ceramic Fiber Insulation Board
  1. The specific heat capacity (storage heat) is small. One of the reasons why ceramic fiberboard can reduce the maintenance cost of industrial kilns is its small specific heat capacity, which can save energy during the shutdown and start-up of the heating furnace.
  2. Low thermal conductivity. The ceramic fiberboard furnace lining has low thermal conductivity and a good heat insulation effect.
  3. Good thermal shock resistance. The porosity of the ceramic fiber board is high, and the ceramic fiber lining can meet various rates of heating or cooling without damage (under the premise that the kiln body can bear it).
  4. Good sound insulation performance. Ceramic fiber board has good sound insulation ability, can reduce noise pollution, can be used as sound insulation material, and can also be used as wall insulation and sound insulation material in buildings (such as structural insulation integrated ceramic wool composite insulation board).
  5. Stable chemical properties. The main chemical composition of ceramic fiberboard is aluminum silicate, which does not easy to be corroded except for the reaction with strong acids and alkalis.
  6. Wide application range. Refractory ceramic fiberboard can meet the requirements of different operating temperature ranges (such as between 600°C and 1300°C). Different industrial furnaces that can be applied to different industries require the use of refractory ceramic fiber boards.

What is the Insulation Effect of Ceramic Fiberboard?

What kind of insulation effect does the ceramic fiber board play? Ceramic fiber board is also called ceramic cotton board, which has good characteristics of high-temperature resistance, heat preservation, and heat insulation, and is widely used. Ceramic fiber boards can be used for the lining of highly heat-sensitive furnaces. So what is the so-called high heat-sensitive stove?

The so-called high heat sensitive furnace means that the furnace can effectively control the heating or cooling speed. In contrast, what is thermal inertia? This means that when the furnace is heated, the heat is almost absorbed by the furnace lining, the furnace temperature is almost synchronized with the furnace wall temperature, and the heat rises slowly. When cooling, almost all the heat is from the furnace wall, and the furnace temperature drops slowly. If the cooling or heating time is too long, it will waste a lot of fuel, and reduce production efficiency and product quality.

The lining material determines how to increase the heat sensitivity of the furnace.

Different from the traditional refractory brick lining, ceramic fiber boards can effectively improve this problem. The ceramic fiber material has a low thermal conductivity and hardly absorbs the heat of the furnace, effectively reducing heat loss and shortening the heating time. When the temperature is lowered, the heat storage capacity of the furnace is reduced, and the heat sensitivity of the furnace is increased.

RS High-Quality Ceramic Fiber Insulation Board
RS High-Quality Ceramic Fiber Insulation Board

Application of Ceramic Fiber Products in the Steel Industry

The refractory lining of traditional industrial kilns has a large weight, the waste of heat storage in the furnace body is serious, and the heat preservation effect is poor. The temperature of the cold surface of the furnace body exceeds 100°C, and it is difficult to precisely control the temperature of the furnace. In recent years, the ceramic fiber module refractory lining of the furnace wall and roof of the industrial furnace has been designed with a full fiber lining. Due to the low thermal conductivity, low density, and light weight of fibers, lighter steel frame support structures are used in the design and construction of kilns. As a result, the development of industrial furnaces has entered the era of “kiln lightweight”. The heat storage of fibers is small, which is suitable for the operation mode of rapid heating and cooling. In addition, the ceramic fiber module can be processed into special-shaped products to adapt to various shapes of the inner wall of the furnace shell. The fiber module has good resistance to mechanical vibration and shock and has good chemical stability. These advantages have played an important role in promoting the development of new kilns.

Taking heating furnaces in the steel industry as an example, ceramic fiber modules are mainly used for ladle covers, billet carriers, furnace walls of heat treatment furnaces, etc. At present, a large number of ceramic fiber modules are used as linings in heat treatment furnaces that require high furnace cleanliness. In the annealing furnace for cold-rolled strip steel, from the heating section to the cooling section, from the top to the bottom of the furnace, ceramic fiber modules are used as linings. In the direct fire heating part of the preheating section, the hollow module is convenient for direct installation of the burner. On the furnace wall of the heating section, in order to cooperate with the installation of the radiant tube, the entire furnace wall module adopts the form of B, and at the journal of the furnace roller, the module can be made into a bell shape. Very convenient for furnace lining installation. In order to prevent fiber shedding from polluting the steel strip, aluminum cloth can also be sewn on the module as an inner lining. Special-shaped modules can be used in some special-shaped parts such as the furnace throat and the bottom chamber.

The good thermal insulation performance of the ceramic fiber module makes it widely used in the thermal insulation layer of high-temperature industrial furnaces. RS Kiln Refractory Material Manufacturer is a powerful refractory material manufacturer. Our refractory products have been sold to more than 100 countries and regions all over the world. Moreover, our technical team is committed to the R&D, design, and construction of refractory materials for the insulation layer. Our new thermal insulation material products can achieve a body density of less than 0.4g/cm3. Contact us for free samples and quotes.

Ceramic Fiber Insulation Zr-Al Insulation Blanket Furnace Insulation Blanket

KilnRefractory

In the modern steel industry, in order to improve the thermal insulation performance of ladle, increase the service life of lining and reduce the consumption of refractory materials, new ladle has appeared. The so-called new ladle is a widely used ladle calcium silicate plate and aluminum silicate fiber blanket. furnace insulation blanket, there are a lot of different kinds, there are a lot of different names, zr-al insulation blanket, furnace insulation blanket, ceramic fiber insulation, ceramic insulation blanket, ceramic fiber blanket insulation, furnace blanket insulation, etc. Ceramic insulation blanket, ceramic fiber blanket insulation, furnace blanket insulation, etc. Contact us to purchase a high-quality furnace zr-al insulation blanket.

Ceramic Fiber Insulation Aluminum Silicate Fiber Blanket
Ceramic Fiber Insulation Aluminum Silicate Fiber Blanket

What is an Aluminum Silicate Fiber Blanket?

An aluminum silicate fiber blanket is a kind of refractory insulation material. Aluminum silicate fiber blanket is mainly divided into aluminum silicate fiber blowing blanket and aluminum silicate fiber spinning blanket. Aluminum silicate casting blanket because of the long fiber, small thermal conductivity, and thermal insulation performance is better than aluminum silicate blowing blanket. Most insulation pipe construction uses ceramic fiber swing silk blankets.

Common sizes for aluminum silicate fiber blankets (mm)

  • 10*610*15000
  • 20*610*7200
  • 30*610*5000
  • 40*610*3600
  • 50*610*3600
  • 60*610*3000

Aluminum silicate fiber blanket density: 55kg/m3-160kg/m3

Classification and service temperature of aluminum silicate fiber blanket

  • Ordinary type aluminum silicate fiber blanket 1100℃
  • Standard type aluminum silicate fiber blanket 1260℃
  • High purity aluminum silicate fiber blanket 1260℃
  • High aluminum type aluminum silicate fiber blanket 1360℃
  • Zirconium aluminum type aluminum silicate fiber blanket 1360℃
  • Zirconium-containing aluminum silicate fiber blanket 1430℃

Characteristics of aluminum silicate fiber blanket products

  • 1, high-temperature resistance, low volume weight, and small thermal conductivity.
  • 2, corrosion resistance, oxidation resistance, thermal shock resistance, etc.
  • 3, high-temperature condition fiber elasticity is good, shrink.
  • 4, good sound absorption.
  • 5, easy to secondary processing and installation.

In summary, combined with the physical and chemical properties of aluminum silicate fiber blanket has a good thermal conductivity of 0.03 at 200℃. 400℃ is 0.06. 600℃ is 0.09. 800℃ is 0.1. It is widely used in furnace lining, boiler, gas turbine, and nuclear power heat insulation welding to eliminate stress heat insulation, fire insulation, sound absorption, insulation, high-temperature filter medium, and kiln door seal.

Ceramic Fiber Blanket with Zirconium
Ceramic Fiber Blanket with Zirconium

1400 Model Ceramic fiber blanket with zirconium

1400 ceramic fiber blanket model meaning, that is, 1400 belongs to the classification temperature, also known as the classification temperature.

Ceramic fiber blanket material classification, according to the long-term working temperature from low to high divided into ordinary, standard, high purity, high aluminum, zirconium aluminum, and zirconium containing 6 grades. The zirconium ceramic fiber blanket corresponding long-term operating temperature is 1280℃.

Application of ceramic fiber blanket containing zirconium. Zirconium ceramic fiber blanket is generally used in the long-term working temperature between 1150℃-1300℃ industrial kiln wall lining, and backing material. Industrial kiln masonry expansion joint material, furnace door, top cover insulation seal. Thermal insulation sealing material for high-temperature pipelines. High-temperature insulation gasket with long-term operating temperature below 1280℃. Raw materials for processing zirconium ceramic fiber modules/folding blocks.

Characteristics of zirconium-containing (zircon-quartz) aluminum silicate fiber blanket

Zirconium-containing aluminum silicate fiber blanket is a high-temperature resistance grade of ceramic fiber conventional models. Strictly speaking, a zirconia-containing aluminum silicate fiber blanket is divided into low zirconium type and high zirconium type.

  • Low zirconium type, theoretical classification temperature 1400 degrees, 24-hour operating temperature 1200 degrees. The content of zirconia is 5%-7%.
  • High zirconium type, theoretical classification temperature 1430 degrees, 24-hour operating temperature 1260 degrees. The content of zirconia is 15%-17%.

Properties of zirconium containing refractories

Zircon refractory products are made of natural zircon sand and are acidic materials. Zirconium refractory has good slag resistance, low thermal expansion rate, and thermal conductivity decreases with increasing temperature. High softening temperature under load, high wear resistance, and good thermal shock resistance have become important materials in various industrial fields.

Zircon refractory has high resistance to acid slag and glass but also has the property of non-penetration of aluminum, and aluminum oxide slag. Therefore, good results have been obtained on the bottom of the aluminum smelting furnace.

Zirconium-containing Aluminum Silicate Fiber Blanket
Zirconium-containing Aluminum Silicate Fiber Blanket

1430℃ Zirconium Aluminum Silicate Blown Fiber Blanket

The production process of zirconium-containing aluminum silicate-blown fiber blanket. Zirconium-containing aluminum silicate fiber blanket is made of fiber cotton through needling, heat setting, cross – and – cross-cutting, winding, and other processes. All kinds of needled blankets have the same excellent properties as the corresponding loose aluminum silicate fiber cotton and have excellent tensile strength. The needled blanket has a uniform texture and a flat surface.

The needled blanket with different bulk densities and thickness provides users with a wide range of materials to obtain the best heat insulation structure and energy-saving benefits.

The working temperature of a zirconium-containing aluminum silicate blown fiber blanket depends on the material use condition, the type of heat source, and the environment atmosphere.

Technical characteristics of zirconium-containing aluminum silicate-blown fiber blanket

  • Low thermal conductivity and low heat capacity
  • Excellent thermal stability and thermal shock resistance
  • Excellent tensile strength
  • Excellent heat insulation, fire prevention, and sound absorption

Application of zirconium-containing aluminum silicate-blown fiber blanket

  • Industrial building materials kiln, heating device, high-temperature pipelining
  • Electric boiler, gas turbine, and nuclear heat insulation
  • Wall lining of high-temperature reaction equipment and heating equipment for the chemical industry
  • Fire prevention and heat insulation of high-rise buildings
  • Heat insulation of furnace door and top cover
  • High-temperature filter material

Zirconium-containing Aluminum Silicate Fiber Blanket Price

Aluminum silicate needled blanket adopts advanced equipment, a double-sided needled blanket assembly line. Its equipment and production technology are at a higher level. All kinds of aluminum silicate fiber blankets, using different materials of raw materials (such as coke gems, SiO2, Al2O3, zirconium sand, etc.) into the fiber by settling acupuncture, heat setting, cross and cross-cutting, roll, and other processes made. Uniform texture, flat surface, excellent tensile strength, solid aluminum silicate needled blanket itself does not contain a binder, so greatly improves the degree of heat resistance. For free zirconium-containing aluminum silicate fiber blanket prices, please contact Rongsheng refractory manufacturers.