SUNTHERM High Temperature Refractory Ceramic Fiber Blanket Manufacturing Equipment

Product Overview

SUNTHERM Ceramic Fiber Blanket Production Line is widely used in refractory material plants, insulation product manufacturers, and enterprises in industries such as steel, petrochemicals, building materials, metallurgy, and power generation. It plays a key role in enhancing both the production efficiency and product quality of high-temperature insulation materials.

Utilizing high-purity aluminum oxide and silicon dioxide as primary feedstocks, this production line integrates advanced process stages-including electric or gas-fired furnace melting, centrifugal fiberizing, needle-punch blanket forming, precision shaping and cutting, and automatic winding. The resulting ceramic fiber blankets are eco-friendly, asbestos-free, and exhibit outstanding high-temperature resistance, low thermal conductivity, and excellent flexibility.

Equipment Structure & Components

A complete ceramic fiber blanket production line generally includes the following core sections:

(1) Raw Material Feeding System

Bucket elevators and batching weigh systems

Automated feeding into the melting furnace to ensure precise composition ratios

(2) High-Temperature Melting System

Electric arc or natural gas melting furnace with refractory lining

Temperature control system accurately maintains melting temperatures between 1700°C and 1850°C

(3) Fiber Forming System

Fiberizing machine equipped with multi-disc high-speed centrifugal rotors

Hot air assist system for efficient blowing and spinning

Produces uniform fibers with diameters controlled within 2–5 μm

(4) Web Formation & Layering System

Negative pressure suction chamber and conveyor belt for even fiber deposition

Adjustable parameters for thickness and density during forming

(5) Double-Side Needle-Punching System

Upper and lower needle looms with adjustable punching density

Enhances blanket strength, structural stability, and flexibility

(6) Drying & Curing System (Optional)

Thermal setting for hydrophobic or surface-bonded fiber blankets

Gas or electric heating options available

(7) Edge Trimming & Cutting System

High-speed precision cutting machines

Ensures consistent product dimensions and neat edges

(8) Winding & Packaging System

Automatic winding machine with length control

Configurable roll diameter and weight, supports online packing

(9) Electrical Control System

Automated PLC and HMI-based control

Integrated management of parameter setting, data logging, and fault alarms

Process Flow Diagram

Batching → Melting → Fiberizing → Web Formation → Needle Punching → Drying & Curing → Cutting → Winding → Packaging

Main Technical Parameters

Product Features & Advantages

(1) High Production Efficiency

The fully automated production line operates continuously from raw material melting to finished product, achieving a maximum daily output exceeding 20 tons.

(2) Stable Product Quality

The process ensures uniform fiber fineness and consistent blanket density, delivering excellent flexibility, thermal shock resistance, low thermal conductivity, and high performance uniformity.

(3) Multi-Product Compatibility

The line supports production of various ceramic fiber blanket types, including standard, high-purity, hydrophobic, and zirconium-enhanced grades.

(4) Energy-Saving & Eco-Friendly Design

Featuring optimized furnace insulation and energy recovery systems, the line significantly reduces energy consumption and complies with environmental standards.

(5) Remote Monitoring & Smart Diagnostics

Optional Industrial IoT modules enable real-time remote monitoring of equipment operation and proactive maintenance diagnostics.

Typical Application Scenarios

Ceramic fiber blankets produced by the line are widely used in high-temperature applications including:

✓ Industrial kiln linings (tunnel kilns, electric furnaces, heat treatment furnaces)

✓ Insulation wrapping for high-temperature pipelines, elbows, and flanges

✓ Thermal insulation for metallurgical hot blast stoves, ladles, and electrode covers

✓ Insulation linings for petrochemical reactors and heat exchangers

✓ Power generation boiler walls and hot air ducts

✓ Automotive exhaust system heat shields

✓ Aerospace engine thermal protection components

Production Line Configuration Proposal

Investment and Return Analysis

Initial Investment: Approximately RMB 3-8 million, depending on scale, process requirements, and the degree of supporting automation;

Operating Costs: Primarily energy, labor, and maintenance costs;

Payback Period: Approximately 12-24 months under normal operation;

Profitability: Flexible adjustment of output specifications based on market demand to increase gross profit margin;

Scalability: Modular design facilitates future production increases or product line expansions.

After-Sales and Technical Services

Free technical training and equipment installation guidance;

One-year warranty and lifetime technical support;

Equipment operation optimization recommendations and process upgrade services;

24/7 after-sales response system;

Spare parts supply and customized maintenance plans available.

FAQ

Q1: Which types of ceramic fiber blankets can this production line process?

A1: The line is compatible with standard, high-purity, zirconium-containing, and hydrophobic ceramic fiber blankets. It also supports fast changeovers between varying densities and thicknesses.

Q2: What is the staffing requirement per shift?

A2: Thanks to a high level of automation, only 4–6 operators are needed per shift. Roles typically include control system monitoring, furnace operation, quality inspection, and packaging.

Q3: How is fiber dust managed to meet environmental standards?

A3: An integrated high-efficiency dust collection system, sealed exhaust hoods, and dust bag filters ensure a high dust recovery rate, keeping the operation fully compliant with environmental regulations.

Q4: What is the typical installation and commissioning timeline?

A4: Depending on system scale, installation and commissioning generally require 30 to 60 days. This period includes operator training and pre-production trial runs.

Q5: Can this production line be exported?

A5: Yes. We have successfully exported and commissioned similar lines to multiple countries, including Russia, Turkey, India, Vietnam, and Brazil.

Q6: Do you offer customized solutions?

A6: Absolutely. We provide tailored system designs and complete production line layouts based on customer-specific needs, including production capacity, process requirements, budget, and site conditions.

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