Introduction
Ceramic fiber modules are derived from ceramic fiber needle-punched blankets and processed using specialized machinery to achieve precise dimensions and fiber compositions. During manufacturing, the modules are compressed to a specific ratio to ensure that, upon installation, each module expands unidirectionally, interlocking seamlessly into a monolithic lining. These modules are directly anchored to industrial furnace shells using various fastening systems, eliminating the need for traditional heavy refractory materials.
This innovative solution streamlines kiln construction, enhances lining integrity, and advances refractory installation technology. Ceramic fiber modules are widely used in lining applications across industries such as metallurgy, machinery, building materials, petrochemicals, and non-ferrous metals.
Standard Specifications
Dimensions: 300 × 300 × 200/250/300 mm (custom sizes available)
Packaging: Woven bags or cartons
Classification
Based on molding methods, ceramic fiber modules are categorized as folded blocks, sliced blocks, Pyro blocks, and vacuum-formed blocks.
Due to their distinct production methods and crystalline structures, polycrystalline mullite fibers are short and have poor flexibility. This limits their use in large modules, restricting large-scale applications. Currently, polycrystalline fibers are primarily applied as patches on the surfaces of furnace walls and roofs made of castables or refractory bricks. These patches effectively reduce the outer wall temperature of furnaces while minimizing heat loss caused by heat storage in the walls.
Advantage
Excellent chemical stability
Superior thermal stability
Outstanding elasticity – Ceramic fiber modules are pre-compressed. After installation in furnace linings, module expansion eliminates gaps and compensates for fiber lining shrinkage, enhancing thermal insulation and overall performance.
Exceptional thermal shock resistance
Rapid installation – Modules feature anchors on the lining's cold surface, reducing the amount of anchor material required.
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Raw Materials
Core Fiber Materials
Aluminosilicate Fibers (Main Raw Material)
Standard Type: Al₂O₃ 45%–55%, SiO₂ 40%–45%, service temperature ≤1260°C.
High-Alumina Type: Al₂O₃ 58%–62%, SiO₂ 35%–40%, service temperature ≤1400°C.
Zirconia-Containing Type: Al₂O₃ 40%–45%, SiO₂ 40%–45%, ZrO₂ 15%–20%, service temperature ≤1600°C.
Reinforcing Fibers (Optional Additives)
Stainless Steel Fibers: 5–10 μm diameter, 10–20 mm length, enhance module thermal shock resistance.
Polycrystalline Mullite Fibers: Al₂O₃ ≥72%, temperature resistance 1600°C, used in ultra-high-temperature zones.
Physical and Chemical Specifications
|
Brand&Properties |
STD Module |
HP Module |
HZ Module |
|
|
ChemicalComposition(%) |
Al₂O₃ |
≥44 |
≥45 |
≥34 |
|
SiO₂ |
≥52 |
≥54 |
≥50 |
|
|
Fe₂O₃+TiO₂ |
≤1.0 |
≤0.5 |
≤0.5 |
|
|
ZrO₂ |
– |
– |
≥15 |
|
|
K₂O+Na₂O+Fe₂O₃ |
≤1.0 |
≤0.2 |
≤0.2 |
|
|
Bulk Density (kg/m3) |
220 |
220 |
220 |
|
|
Specification Temp. (℃) |
1260 |
1350 |
1430 |
|
|
Linear Shrinkage after Heatin(%) |
1000℃X24h≤2.5 |
1000℃X24h≤2.5 |
1000℃X24h≤3.5 |
|
|
Thermal Conductivity(w/m.k) |
400℃ |
0.09 |
0.101 |
0.118 |
|
500℃ |
0.119 |
0.12 |
0.149 |
|
|
600℃ |
0.152 |
0.175 |
0.172 |
|
Process
Raw Material Preparation (ceramic fiber wool, binder, additives) → Opening & Deslagging → Pulping & Mixing (fiber + binder + water) → Molding (needling/pressing) → Drying & Curing (stage-wise heating) → Cutting & Processing → Anchor Installation → Surface Treatment (optional) → Quality Control → Packaging & Storage
Molding Processes
Needle-Punch Molding (Commonly Used)
Fiber pulp is evenly spread in a mold. Through the reciprocating needling action of a needle-punching machine, fibers interlock to form a fiber blanket blank with the specified strength.
The needling density is adjusted according to module strength requirements (typically 20–30 needles/cm²).
Compression Molding (for High-Density Modules)
A hydraulic press applies 0.5–2 MPa pressure to fiber blanks, compressing them to target densities (e.g., 180–280 kg/m³) to form regular blanket or block blanks.
Application
Ceramic fiber modules are widely applied in thermal insulation for kilns and furnaces across various industries, including petrochemical, metallurgy, ceramics, glass and building materials, heat treatment, and other industrial furnace linings.
Typical Application Cases
With the national energy-saving and emission-reduction plan advancing, the transformation of burnt brick tunnel kilns has become urgent. Ceramic fiber modules have been highly praised for their excellent thermal insulation performance in the ceilings of these kilns.
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