Precision-Formed Inorganic Fiber Custom-Shaped Parts
Product Introduction
Custom-shaped inorganic fiber parts combine high-temperature resistance, lightweight properties, high strength, and excellent thermal insulation performance. They are widely used in high-temperature environments such as industrial boilers, metallurgical furnaces, power equipment, petrochemical reactors, and aerospace applications, making them indispensable energy-saving insulation materials in modern industry.
These parts are manufactured using advanced inorganic fiber materials, which are asbestos-free, environmentally safe, and non-toxic. The product's thermal stability and thermal shock resistance are superior to traditional insulation materials, allowing it to maintain structural integrity and stable performance even under repeated thermal cycling.
Core Performance Features
(1) High-Temperature Resistance
Custom-shaped inorganic fiber parts can typically withstand temperatures ranging from 1260°C to 1400°C, with certain special materials capable of even higher temperatures. Their excellent high-temperature resistance ensures long-term stable operation in extreme flame and high-temperature furnace environments, safeguarding equipment safety.
(2) Lightweight and High Strength
Compared to traditional refractory bricks and castables, custom-shaped inorganic fiber parts have a lower density (typically between 100-300 kg/m³), significantly reducing equipment load. Additionally, the product undergoes special processing to achieve high mechanical strength and compressive resistance, ensuring structural stability after installation and minimizing deformation or damage.
(3) Excellent Thermal Insulation Performance
The microporous structure of inorganic fibers results in extremely low thermal conductivity, typically ranging from 0.05 to 0.15 W/m·K, effectively reducing heat loss and conserving energy. Their superior insulation performance helps industrial equipment achieve energy savings, emission reduction, and improved thermal efficiency.
(4) Thermal Shock Stability
Custom-shaped inorganic fiber parts exhibit exceptional thermal shock stability, enabling them to withstand repeated alternating cycles of heating and cooling. This reduces cracking and spalling caused by thermal expansion and contraction, significantly extending their service life.
(5) Environmentally Safe and Non-Toxic
The product is entirely made of inorganic materials, free from asbestos and volatile organic compounds (VOCs). It complies with international environmental standards such as EU RoHS and REACH, ensuring safety for users and the environment.
(6) High Customization Flexibility
Utilizing advanced molds and automated forming technology, these parts can be manufactured into various complex custom shapes to meet the personalized requirements of equipment structures and process workflows.
Product Parameters
|
ITEM |
STD |
HP |
HA |
HTZ |
|
Classification Temperature(C°) |
1260 |
1260 |
1360 |
1430 |
|
Working Temperature(C°) |
≤1000 |
≤1100 |
≤1200 |
≤1300 |
|
Density(KG/m³) |
320-500 |
|||
|
Organic Content% |
≤1.5 |
|||
|
Heating Shrinkage(%) |
1000℃×24h≤ -2 |
1100℃×24h≤ -2 |
1200℃×24h≤ -2 |
1350℃×24h≤ -2 |
|
Thermal Conductivity(500℃) |
≤0.05 |
|||
|
Al₂O₃ |
36-38 |
39-42 |
45-47 |
- |
|
Al₂O₃+SiO₂ |
≥96 |
≥98 |
≥99 |
- |
|
Al₂O3+SiO₂+ZrO₂ |
- |
- |
≥99 |
|
|
ZrO₂ |
- |
- |
≥15 |
|
|
Fe₂O₃ |
<0.5 |
<0.5 |
<0.5 |
<0.5 |
|
Na₂O+K2O+Fe2O₃ |
<0.9 |
<0.9 |
<0.9 |
<0.9 |
Production Process
(1) Raw Material Preparation
High-purity inorganic fiber materials are selected as the base raw materials to ensure product quality and performance stability. Strict screening and pre-processing are conducted to remove impurities and substandard materials.
(2) Formulation and Mixing
Based on product design requirements, binders and other additives are proportionally mixed to ensure a dense structure and high strength after molding.
(3) Mold Forming
Advanced automated molding equipment is used to inject the uniformly mixed fiber slurry into pre-designed molds, creating various custom-shaped structures with precise dimensions.
(4) Sintering and Curing
The molded parts are placed into high-temperature furnaces for sintering and curing, completing the chemical reaction of the binders to enhance mechanical strength and dimensional stability.
(5) Surface Treatment
Some products undergo surface finishing and coating treatment to improve wear resistance and corrosion resistance.
(6) Inspection and Packaging
After strict quality inspections, the products are packaged with moisture-proof materials to ensure they remain undamaged during transportation and storage.
Main Application Areas
Industrial Boilers and Furnace Linings
Inorganic fiber custom-shaped parts are used for high-temperature insulation in boiler combustion chambers, flame ducts, and furnace walls, effectively preventing heat loss and ensuring safe operation.
Power Industry
Widely applied in thermal power units, steam turbines, waste heat boilers, and other equipment as refractory insulation layers to improve energy efficiency.
Metallurgical Industry
Used in steelmaking furnaces, high-temperature processing equipment, hot blast stoves, and other high-temperature processes to meet demanding insulation and wear resistance requirements.
Petrochemical Industry
Provides thermal insulation protection for critical equipment such as refining units, high-temperature reactors, and cracking furnaces, ensuring safe production.
Aerospace Field
Used as insulation materials for extreme high-temperature components such as aircraft engines and combustion chambers, meeting the stringent requirements of high-tech industries.
Other Emerging Fields
Applied in new energy equipment, high-temperature experimental setups, and specialized machinery, demonstrating the broad adaptability of inorganic fiber custom-shaped parts.
Product Advantages
Advanced Technology: Utilizes internationally leading production processes to ensure stable product quality and performance.
Rich Experience: Years of industry expertise, providing a wealth of design and application solutions.
Customization: Can be designed in custom shapes and sizes to meet the needs of complex equipment.
Eco-Friendly and Energy-Saving: Emits no harmful substances, helping enterprises achieve green production.
High-Performance Assurance: Excellent thermal stability and mechanical strength ensure safe and reliable equipment operation.
Selection Recommendations
✅ Based on Temperature Requirements
For low-temperature applications (≤1260°C), standard inorganic fiber custom-shaped parts are recommended.
For high-temperature applications (above 1260°C), high-purity, high-density refractory inorganic fiber materials are suggested.
✅ Based on Mechanical Strength Requirements
For applications requiring higher structural strength, products with greater density and compressive strength should be selected.
For lightweight insulation needs, low-density products are recommended.
✅ Shape and Dimensions
The shape and dimensions of the custom-shaped parts should be determined based on the equipment's structural design drawings.
Detailed design information should be provided to ensure precise product fit.
Packaging and Transportation
Packaging Methods
Products are packaged with moisture-proof and shock-resistant materials and palletized to ensure safety during transportation.
Custom packaging solutions and brand labeling are available upon request.
Transportation Precautions
Avoid moisture; storage environments should be dry and well-ventilated.
Prevent heavy pressure and severe vibrations during transportation to avoid damaging the products.
Installation Guide
(1) Installation Preparation
Confirm that the product model matches the equipment design requirements.
Prepare professional tools and ensure the installation environment is clean and free of debris.
(2) Installation Steps
Precisely position the custom-shaped part in the designed location to avoid gaps that could create thermal bridges.
Use appropriate fixing methods (anchoring, adhesive bonding, etc.) to ensure secure installation.
Seal all joints to prevent heat leakage.
(3) Maintenance Recommendations
Regularly inspect the installation stability and insulation performance.
Repair or replace parts promptly in case of abnormalities.
FAQ
Q1: What is the maximum temperature resistance of inorganic fiber custom-shaped parts?
A1: The typical temperature resistance ranges from 1260°C to 1400°C, depending on the product model and manufacturing process.
Q2: Can the product be customized in size?
A2: Yes, precise customization is available based on customer design drawings.
Q3: What is the service life of inorganic fiber custom-shaped parts?
A3: Under normal operating conditions, the product's service life can exceed 5 to 10 years.
Q4: What should be noted during installation?
A4: Ensure tight fitting and secure fixing of the custom-shaped parts, and avoid thermal bridges and gaps during installation.
Q5: Is the product environmentally friendly?
A5: Inorganic fiber custom-shaped parts are made entirely from inorganic materials, free of asbestos and harmful volatile substances, and comply with international environmental standards.
As a high-performance refractory and thermal insulation material, inorganic fiber custom-shaped parts have become an ideal choice for modern high-temperature industrial equipment insulation, thanks to their excellent thermal stability, lightweight and high-strength properties, and environmentally safe attributes. Leveraging advanced production processes and personalized customization capabilities, SUNTHERM Group is committed to providing the most reliable and efficient inorganic fiber custom-shaped parts and solutions for global customers.
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