High-Performance Ceramic Fiber Modules
Product Introduction
Ceramic fiber modules are high-density, high-strength refractory materials manufactured by cutting, layering, and thermally curing high-performance ceramic fiber blankets or fiber paper. They combine the excellent thermal properties of ceramic fibers with the ease of installation offered by modular structures. Widely used as thermal insulation linings in high-temperature industrial furnaces, heat treatment equipment, boiler linings, and other high-temperature protection applications, ceramic fiber modules are lightweight, exhibit outstanding high-temperature stability, strong thermal shock resistance, and low thermal conductivity. These characteristics make them a key product in modern high-temperature insulation, serving industries such as metallurgy, petrochemicals, power generation, aerospace, and defense.
Product Structure and Composition
Ceramic fiber modules are formed by layering high-quality ceramic fiber blankets or paper, followed by molding and thermal pressing. Their main components include:
Ceramic Fiber Blanket/Paper: Provides thermal insulation and high-temperature stability.
Inorganic Binders: Bond the fiber layers to enhance overall mechanical strength.
Metal or Ceramic Supports (Available in Certain Models): Improve structural stability and installation integrity.
Surface Coatings (Optional): Customizable based on application requirements, such as wear-resistant or corrosion-resistant coatings.
Product Parameter
|
Item |
STD |
HP |
HA |
ZA |
||
|
Classification Temp (℃) |
1260 (2300F) |
1260 (2300F) |
1360 (2480F) |
1360 (2480F) |
||
|
Working Temp (℃) |
≤1050 |
≤1100 |
≤1200 |
≤1200 |
||
|
Color |
Pure White |
Pure White |
Pure White |
Pure White |
||
|
Bulk Density (Kg/m3) |
160-260 |
160-260 |
160-260 |
160-260 |
||
|
Permanent Linear change (%) |
1000℃X 24h≤ -3 |
1100℃x24h≤ -3 |
1200℃ X 24h≤ -3 |
|||
|
Thermal Conductivity(w/m.k) |
400C |
0.09 |
0.09 |
0.101 |
0.101 |
|
|
500C |
0.119 |
0.119 |
0.120 |
0.120 |
||
|
600C |
0.152 |
0.152 |
0.175 |
0.175 |
||
|
Chemical Composition(％) |
AL2O3 |
45-46 |
47-49 |
52-55 |
45-46 |
|
|
AL2O3+SIO2 |
97 |
99 |
99 |
－ |
||
|
AL2O3+SIO2+ZrO2 |
－ |
－ |
－ |
99 |
||
|
ZrO2 |
－ |
－ |
－ |
5-7 |
||
|
Fe2O3 |
≤ 1.0 |
≤0.2 |
≤0.2 |
≤0.2 |
||
|
Na2O+K2O |
≤ 0.5 |
≤ 0.2 |
≤ 0.2 |
≤ 0.2 |
||
|
Size(mm) |
Length:300 – 600; Height:150-300; Thickness:150-300 As customers 'requirements. |
|||||
|
Package |
Cartons |
|||||
|
Certificate |
CE,ISO9001-2008; ISO14001-2004,SGS, ROHS,SASO, REACH |
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Product Specifications and Packaging
Specifications
Module Dimensions: Typically 600×600×50/75/100 mm, customizable based on requirements.
Density Range: 230–450 kg/m³, adjustable according to application needs.
Shapes: Standard square modules, custom shapes (e.g., circular, wedge-shaped) available upon request.
Packaging
Products are packaged with moisture-proof materials, labeled with product and batch information.
Standard packaging includes cartons or wooden crates, suitable for long-distance transportation.
Bulk orders can be palletized to ensure product integrity.
Production Process Flow
Raw Material Preparation
High-purity ceramic fiber blankets or fiber paper are carefully selected to ensure uniform fiber distribution and stable performance.
Cutting and Layering
The ceramic fiber blankets/paper are cut into multiple layers according to the designed module dimensions.
Lamination and Assembly
The cut layers are evenly stacked and bonded with inorganic binding agents.
Molding and Pressing
The assembled layers are placed into specialized molds and formed via thermal pressing to meet dimensional and density requirements.
Heat Treatment and Curing
The modules are cured in high-temperature furnaces to enhance strength and heat resistance.
Surface Treatment
Surface coatings or the addition of support structures are applied based on customer requirements.
Inspection and Packaging
Completed modules undergo multiple tests (dimensions, strength, temperature resistance, etc.) and are packaged for shipment after passing quality checks.
Application Areas
Metallurgical Industry
Lining for blast furnaces and steel ladles
Insulation lining for preheating furnaces, soaking pits, and heating furnaces
Thermal protection for continuous casting machine coatings
Heat Treatment Equipment
Lining for various high-temperature heat treatment furnaces
Insulation layers for metal surface treatment equipment
Power Industry
Boiler lining and thermal insulation layers
Heat exchanger insulation
Chemical and Petroleum Industries
Thermal insulation for high-temperature reactors and pipelines
Lining for catalytic cracking units
Aerospace and Defense
Thermal insulation for aircraft engines
Protective insulation for missile launch tubes
Other High-Temperature Equipment
Lining for kilns and furnace chambers
Thermal insulation for ceramic manufacturing equipment
Product Advantages Analysis
Lightweight and High Strength: Low density with high mechanical strength, easy to handle and install.
Excellent High-Temperature Resistance: Suitable for applications up to 1600°C.
Thermal Shock Stability: Resistant to thermal cycling, extending service life.
Significant Energy Efficiency: Low thermal conductivity reduces heat loss and improves energy efficiency.
Eco-Friendly and Safe: Asbestos-free and compliant with international environmental standards.
Easy Installation: Modular design allows for quick assembly, reducing construction time.
Installation and Usage Guidelines
Preparation for Installation
Ensure the installation site is clean and dry.
Workers must wear protective gear to avoid inhaling dust.
Installation Process
Pre-check module dimensions according to design specifications.
Assemble modules sequentially, ensuring tight joints to prevent thermal bridging.
Secure modules using high-temperature anchors, supports, or refractory adhesives.
Perform sealing treatment after installation.
Maintenance and Care
Regularly inspect module surfaces and joints to ensure no loosening.
Clean accumulated dust and debris to maintain insulation effectiveness.
Replace damaged modules promptly to prevent further deterioration.
Quality Control System
The company maintains a comprehensive quality management system, implementing strict inspections from raw material procurement to finished product delivery, including:
Chemical composition analysis of raw materials
Testing of module dimensions, density, and strength
Thermal conductivity performance tests
Temperature resistance and thermal cycling tests
Validation of surface treatment effects
Compliance with ISO9001 and ISO14001 quality and environmental management systems
Each batch of products is accompanied by a test report to ensure customer confidence.
Packaging and Logistics
Standard packaging includes moisture-proof, pressure-resistant cartons or wooden crates suitable for long-distance transport.
Palletized packaging is available upon customer request.
Ensure waterproofing, moisture resistance, and shockproof measures during transportation.
Multiple domestic and international shipping options are supported to guarantee safe product arrival.
Customer Case Studies
A steel group replaced traditional brick linings with ceramic fiber modules, achieving 15% energy savings and extending furnace lining life by 30%.
A heat treatment plant utilized high-density ceramic fiber modules to enhance furnace insulation and reduce preheating time.
An aerospace research institute customized high-temperature ceramic fiber modules for successful application in rocket engine insulation systems.
FAQ
Q1: What temperature range is suitable for ceramic fiber modules?
A1: They are generally suitable for continuous operating temperatures ranging from 1260°C to 1600°C, with short-term tolerance up to 1650°C.
Q2: How does module density affect performance?
A2: Higher density improves mechanical strength and wear resistance, though thermal conductivity may slightly increase. Customization is available based on specific requirements.
Q3: How are ceramic fiber modules installed?
A3: Modules can be installed using mechanical fasteners or high-temperature-resistant adhesives, ensuring quick assembly and excellent sealing performance.
Q4: How environmentally friendly are ceramic fiber modules?
A4: The modules contain no harmful substances such as asbestos and comply with environmental standards like RoHS and REACH.
Q5: What is the typical lifespan of the product?
A5: Under normal operating conditions, the service life is generally 3–5 years, depending on the specific application environment and maintenance practices.
Q6: Can custom-shaped modules be ordered?
A6: Yes, custom-shaped modules in various specifications can be produced based on customer drawings or requirements.
Q7: Does the company provide technical support?
A7: We offer professional technical consultation, installation guidance, and after-sales services to ensure customer satisfaction.
Ceramic fiber modules, with their outstanding high-temperature performance, excellent thermal insulation, and environmentally safe characteristics, have become the ideal insulation material for modern industrial high-temperature equipment. Their modular design enhances installation efficiency and maintenance convenience, effectively reducing energy consumption and equipment maintenance costs. Upholding the principle of "Quality First, Customer Foremost," we are committed to providing global customers with high-quality, high-performance ceramic fiber modules and comprehensive technical support.
For detailed technical information and product samples, please feel free to contact us. Let us work together to create an energy-efficient and environmentally friendly future.
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