ceramic fiber module

Scope of application

Ceramic fiber heating module is a high-efficiency thermal insulation heating integrated component that integrates ceramic fiber and electric heating elements. It is widely used in various muffle furnaces, tube furnaces, and industrial electric furnaces.

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ceramic fiber module is a refractory insulation lining unit made from alumina-silica ceramic fiber, folded or stacked, and integrated with anchoring systems. It features low thermal conductivity, low heat storage, fast installation, and easy maintenance, making it an ideal choice for heat treatment furnaces, reheating furnaces, annealing furnaces, ceramic kilns, petrochemical cracking furnaces, glass furnaces, and electric furnaces.

Key Features

Low Thermal Conductivity: Ensures excellent insulation between 800–1200°C, reducing energy consumption (keywords: energy saving insulation, thermal efficiency).
Low Heat Storage: Faster heating and cooling cycles, minimizing energy loss (keywords: fast heat-up, low heat storage).
Modular Installation: Pre-assembled modules with L / Y / T-type anchors, easy to replace or repair (keywords: anchor system, modular lining).
Excellent Thermal Shock Resistance: Stable under harsh atmospheres (keywords: thermal shock resistance, chemical stability).
Lightweight: Typical density 96–160 kg/m³, reducing structural load (keywords: lightweight refractory, 128 kg/m³).
Temperature Grades: 1260°C / 1360°C / 1400°C / 1430°C (keywords: 1260C module, 1400C high alumina).

Structure & Materials

Fiber Composition: Al₂O₃–SiO₂ based (standard, high-alumina, or zirconia-reinforced for higher service temperature).
Forming Method: Folded (accordion type) or stacked, ensuring fibers are perpendicular to the hot face, resisting gas flow erosion.
Anchoring System: Built-in stainless steel or heat-resistant alloy (304, 310S, Incoloy, Inconel).
Surface Treatment: Optional ceramic coating or hardener for improved anti-dusting performance.

Typical Technical Data

Classification Temp.: 1260°C / 1400°C / 1430°C
Continuous Service Temp.: ≤ 1100–1300°C (depending on grade)
Density: 96 / 128 / 160 kg/m³
Thermal Conductivity (W/m·K): 0.08–0.22 (200–1000°C)
Linear Shrinkage: ≤ 1.5% after 24h at classification temperature
Shot Content: ≤ 15%
Standard Size: 300×300 / 300×600 / 600×600 mm, thickness 100–300 mm
Anchors: 304 / 310S / Incoloy 800 / Inconel 601

Applications (Industries & Furnaces)

Metallurgy: Heat treatment furnaces (quenching, tempering, annealing)
Steel & Non-ferrous: Reheating furnaces, holding furnaces, aluminum melting/holding
Ceramics & Building Materials: Tunnel kilns, shuttle kilns, roller kilns
Petrochemical & Chemical: Cracking furnaces, reformers, incinerators
Glass Industry: Annealing kilns, decorating kilns, forehearth insulation

Selection Guide

Operating Temperature & Atmosphere – Select standard, high-alumina, or zirconia fiber depending on furnace environment.
Thermal Gradient – Adjust thickness to ensure safe backing temperature.
Gas Velocity & Erosion – Choose folded modules or apply surface coating.
Anchoring Material – 304 for <1000°C, 310S / 601 for >1000°C.
Maintenance Plan – Keep spare modules of the same specification for quick replacement.

Installation Guidelines

Prepare furnace shell and weld studs or rails.
Install modules with staggered joints (≥50% overlap).
Ensure fiber direction is perpendicular to the hot face.
Fill gaps with ceramic fiber blanket or board.
Apply ceramic coating if needed for anti-dust and erosion resistance.
Follow recommended heating curve (bake-out) to avoid thermal shock.

FAQ (Frequently Asked Questions)

Q1: Is “ceramic fiber module” the same as “ceramic fibre module”?
Yes, only spelling difference (US vs UK).

Q2: Can modules be used above 1400°C?
Yes, zirconia-containing fiber modules are available, but continuous temperature should stay below classification temp.

Q3: Can modules be combined with castables or bricks?
Yes, often used as backing insulation with castable or brick hot-face layers.

Q4: Do ceramic fiber modules generate dust?
Slight dust may occur during installation or first heating. Surface coatings and bio-soluble fibers (AES) can reduce it.

Q5: How much energy can be saved?
Typically 10–30% savings, depending on furnace design and operation cycle.