Ceramic Fiber Blanket

Introduction

 

Refractory fiber blanket is a lightweight thermal insulation material made from refractory fibers (such as alumina, silica, etc.) through processes like fiber formation, carding, and needling. It features low thermal conductivity, thermal shock resistance, and ease of processing.

With comprehensive advantages such as being lightweight, thin, strong, and cost-effective, refractory fiber blankets have become core materials for energy-saving upgrades in high-temperature industries. Technological innovations continue to drive green and intelligent transformation in sectors like steel, glass, and energy.

High-Efficiency Thermal Insulation and Lightweight

Thermal conductivity is only 1/5 to 1/10 that of traditional refractory bricks (e.g., ceramic fiber blanket has a thermal conductivity of 0.2 W/(m·K) at 800°C, while high-alumina bricks reach 1.5 W/(m·K)). This can lower furnace wall temperatures by 50–100°C and reduce heat loss by over 30%.

With a density of 80–300 kg/m³ (refractory bricks: 2000–2800 kg/m³), equipment weight is reduced by 70–80%, minimizing the load on steel structures.

Thermal Shock Resistance and Chemical Stability

Can withstand sudden temperature changes up to 1000°C without cracking (conventional refractories typically withstand only 300–500°C), making it suitable for kilns with frequent start-stops.

Resistant to acidic and alkaline gases (e.g., SO₂, HCl), and lasts 2–3 times longer than refractory bricks in waste incinerators.

Ease of Construction and Expanded Functionality

Can be installed via pasting, sewing, or anchoring, with construction efficiency more than 5 times higher than refractory brick masonry.

With a surface antioxidant coating (e.g., ZrO₂), its service life exceeds 5 years in 1400°C oxidizing atmospheres.

 

Zinfon Refractory Technology Co.,Ltd.

 

We provide one-stop services from technical consultation to design, production, and after-sales support.

Manufacturer Direct

Factory Prices

Premium Service

Customization Available

Raw Materials

Ordinary Type (Al₂O₃ + SiO₂ content >96%): Primarily made from bauxite and silica, with a maximum service temperature of 1000°C.

High-Purity Type (Al₂O₃ >45%, SiO₂ >50%): Uses high-purity raw materials, suitable for clean high-temperature applications like precision ceramic sintering furnaces.

Raw material preparation→melt fiber formation→fiber collection→needling molding→post-treatment→cutting and packaging

I. Raw Material Preparation

Raw Material Selection and Proportioning

Main Materials: High-alumina bauxite (Al₂O₃ 45%–60%), silica (SiO₂ 30%–50%), zircon sand (ZrO₂ 10%–20% for high-end products).

Additives: Borax (flux), starch/silica sol (binder), and water repellent (for moisture-resistant products).

Raw Material Pretreatment

Crushing: Raw materials are crushed to particles <5 mm using jaw and hammer crushers.

Grinding: Ground using a ball mill to ≥200 mesh for uniform composition (ingredient deviation <±0.5%).

 

 

II. Melt-to-Fiber Process

High-Temperature Melting

Raw materials are heated to 1800–2200°C in electric melting furnaces (e.g., three-phase arc or plasma furnaces) to form a uniform molten phase.

Fiber Formation (Two Main Methods)

Blowing Method: High-pressure air (0.5–1.0 MPa) is sprayed onto the molten stream to split it into 2–5 μm diameter fibers.

Advantages: Simple equipment, low cost; fiber length 0.5–10 cm; suitable for standard industrial blankets.

Centrifugal Spinning Method: The molten material enters a high-speed spinning disc (10,000–15,000 rpm) and is ejected by centrifugal force.

Advantages: Produces finer fibers (1–3 μm) with a high aspect ratio (>1000), resulting in 30% higher blanket strength-ideal for high-end products.

Process Parameter Comparison

III. Fiber Collection and Settlement

Cotton Collection Chamber

Formed fibers are carried by airflow into the chamber and deposited onto a mesh belt under negative pressure (-500 to -1000 Pa), forming a cotton layer.

Key Controls: Airflow speed of 0.5–1.5 m/s ensures random fiber distribution (orientation <15%) to avoid anisotropy.

Pre-Needling Pretreatment

Pleating: Mechanically pleated to increase fluffiness (reducing bulk density by 10–20%) and improve insulation.

Pre-Compaction: Cotton layer is compacted to 50–70% of the target density in preparation for needling.

 

IV. Needling Molding

Needling Process

Needling Density: 20–50 needles/cm²

(20–30 for ordinary blankets; 40–50 for high-strength blankets)

Needling Depth: 10–20 mm

(Too deep can break fibers; too shallow reduces bonding strength)

Equipment: Multi-channel needling machines (3–5 stages), with gradually increasing needle density to enhance blanket strength.

Performance Optimization

Transverse Reinforcement: Cross-needling or adding transverse fibers increases tensile strength by 50% (longitudinal >80 N/50 mm; transverse >40 N/50 mm).

Thickness Control: Accuracy of ±0.5 mm is achieved by adjusting needling pressure and belt speed (standard thickness: 5–50 mm).

 

V. Post-Treatment

High-Temperature Sintering (Optional)

Heated at 900–1100°C for 2–4 hours to burn off organic binders (e.g., starch) and induce mullite crystallization, improving high-temperature stability.

Surface Treatment

Coating: Sprayed with high-temperature-resistant coatings (e.g., ZrO₂, Al₂O₃) to form an oxidation-resistant layer, increasing temperature tolerance by 100–200°C.

Composite Layer: Laminated with aluminum foil or stainless steel mesh to enhance reflectivity (>85%) or mechanical strength.

 

VI. Cutting and Packaging

Cut to Size

Automated cutting machines (laser or mechanical knives) provide ±1 mm accuracy.

Standard widths: 610 mm / 1220 mm

Standard lengths: 10–50 m

Packaging and Storage

Moisture-Proof Packaging: PE film + woven bag; moisture content <1%

(Store in dry environments with relative humidity <60%)

Compression Packaging: Volume compressed to 30–50% of original size

(Rebound rate >95%, recovers within 24 hours after unpacking)

Metallurgical Industry

Thermal insulation of furnace walls in blast furnaces, hot blast furnaces, and reheating furnaces reduces heat loss and improves efficiency.

Applied in ladles and tundishes to maintain molten steel temperature and improve casting quality.

Petrochemical and Chemical Industry

Used in cracking furnaces, reactors, and pipelines to block heat transfer and protect against high-temperature media.

Insulates chemical kilns and incinerators against corrosive gases, extending equipment life.

Power Industry

Insulates boiler walls and flues in power plants to reduce heat dissipation and equipment weight.

Wraps turbines and high-temperature pipelines to reduce energy loss and improve safety.

Kilns and Heat Treatment Equipment

Used behind refractory bricks in ceramic and refractory kilns, reducing external wall temperatures by 50–80°C and energy use by 15–20%.

Insulates glass kiln roofs and walls, preventing heat loss and cracking in fluctuating temperature environments.

Building Fire Prevention and Thermal Insulation

Used in fire barriers and cable shafts in high-rise buildings due to its non-combustibility (fire-resistant up to 1000–1400°C).

Provides lightweight insulation for industrial buildings and cold storage.

Machinery Manufacturing

Insulates high-temperature engine components (e.g., exhaust pipes) to improve thermal stability.

Reduces heat loss in forging and die-casting molds, extending service life.

Aerospace and Military

Provides thermal protection for rocket engines and missile warheads during high-speed flight.

Fireproofs aircraft engine compartments to ensure flight safety.

Environmental Protection Equipment

Used in linings of incinerators and hazardous waste treatment furnaces for thermal insulation and corrosion resistance.

Insulates high-temperature pipes in desulfurization and denitrification systems.

New Energy Sector

Insulates solar collectors and high-temperature energy storage systems, improving thermal efficiency.

Provides insulation for fuel cell stacks, ensuring stable reaction conditions.

Ship and Marine Engineering

Insulates ship boilers and steam pipes to reduce weight and protect cabin structures from high temperatures.

Electronics and Semiconductors

Used in semiconductor processing equipment (e.g., diffusion and annealing furnaces) to maintain precise temperature control.

Fire Protection Supplies

Serves as core material in high-temperature protective clothing and fire curtains for firefighters and metallurgical workers.

 

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