Although we might think that the installation of insulation in an industrial furnace is a simple matter, the reality is that when it is carried out without the appropriate engineering studies, it is most likely that we will later encounter some common problems, such as:
- Heat leaks that are generated by not having the necessary precautions to protect the areas where the material shrinks.
- Degradation due to poor quality or poor choice of fiber.
- Furnace roofs that partially detach or fall, resulting in heat leakage.
Advantages of ceramic fiber over refractory brick
In the following section, we will describe the substantial benefits of using ceramic fiber insulation in your furnaces:
1. Avoiding thermal shock
When working with high temperatures of 1100°C (2010°F) and opening the furnace in operation, the thermal shock from cooling can cause refractory material to break or for fractures to appear, affecting its operation and significantly reducing its useful life.
With our ceramic insulation there is no danger when opening the furnace, this being especially useful when it comes to the operation of shuttle furnaces.
2. Optimized gas consumption
To heat refractory brick until the desired furnace temperature is achieved, a large amount of energy is required due to its higher density, unlike ceramic fiber which does not require as much energy in order to reach the desired temperature levels.
3. Faster installation on wide roofs
The installation of traditional refractory material in furnace roofs needs a considerable reinforcement in the structure to support the brick arch. This installation is faster with ceramic fiber thanks to its lightness and versatility.
4. Virtually maintenance free
Our ceramic insulation material is extremely resistant, hence any possible damage to the fiber will not affect production as it would in the case of refractory brick.
Various types of furnace insulation
- LTS fiber insulation: for temperatures up to 1093°C (2000°F)
- HPS fiber insulation: for temperatures up to 1316°C (2400°F)
- HTZ fiber insulation: for temperatures up to 1425°C (2600°F)
Fiber installation methods
1. Insulation with ceramic modules
This method is suitable for furnaces that will operate at temperatures between 500°C and 1100°C (930°F to 2010°F). We have different subdivisions according to the length of the module:
In the case of heights up to 200in (508cm), we join one module with another to provide greater stability.
2. Insulation with Macro-modules
Macro-modules comprise a single monolithic piece without joints, custom made to the size required by the user for the insulation of walls, roofs and doors in furnaces with operating temperatures greater than 1100°C (2010°F).