Types of Insulation – Optimize Furnace and Kiln Efficiency, Avoid Costly Issues

Insulation is one of the components with the greatest influence on furnace performance.

A good or poor choice between the different types of insulation can be game-changing in terms of efficient production and significant resource waste.

Learn more about the importance of insulation and what to consider when choosing or substituting your equipment's insulation.

How does the material used influence the insulation?

The two most common insulation materials for furnaces and kilns are:

A) Ceramic fiber

This low density insulation offers a significant advantage in shuttle kilns by minimizing heat waste and lowering fuel consumption.

• Enables faster heating and cooling due to lower heat storage, resulting in a better response.
• Ceramic fiber requires less maintenance when the fibers remain undamaged.

For these reasons, at NUTEC Bickley, we use ceramic fiber in our furnace and kiln insulation in feasible applications that deliver or will deliver an operational advantage. This material is sourced from our sister company, which specializes in fiber products.

Consult with our team today to optimize your furnace insulation.

Ceramic Fiber Installation by NUTEC Bickley

B) Refractory brick

A high-density and hard insulating material with greater mechanical strength.

• Stores more heat, leading to a slower response to temperature changes.
• Consumes more fuel in intermittent furnaces due to slower heating and cooling cycles.
  
  

Refractory Brick Installation for a NUTEC Bickley Furnace

When to change your furnace or kiln insulation for optimal performance

The primary factor influencing the decision to replace your furnace insulation is whether its deterioration negatively affects production or equipment. Here are some key indicators:

1. Risk of product contamination

As fiber ages, it crystallizes, deforms, and sheds particles.

• This can contaminate products requiring a flawless finish, such as sanitaryware or porcelain.
• In such cases, replacing the ceramic fiber insulation becomes necessary. Steel products are generally less susceptible to contamination from fiber degradation.

2. Detection of hot spots

The presence of hot spots is a concern not only because it can cause energy loss but also because it can damage critical equipment components.

Signs of heat leakage requiring insulation replacement:

• Overheated or damaged valves
• Burned-out wires or thermocouples
• Jammed wheels in Car-bottom Furnaces hinder product movement

When replacing furnace insulation, we recommend a complete overhaul rather than patching. Patching is not advisable because the fiber shrinks with temperature, creating gaps and potentially worsening the situation.

At NUTEC Bickley, we specialize in industrial furnaces and their various components.

Contact our expert advisors to learn more about our comprehensive furnace insulation solutions and optimize your furnace performance.