In the field of modern high-temperature industry, the performance and efficiency of refractories are very important to ensure the safety, stability and economy of the production process. As a new type of refractory material, ceramic fiber module has gradually become one of the first choice materials for industrial furnace lining and high-temperature equipment insulation due to its excellent thermal insulation performance, high-temperature stability and convenient installation method. This paper will introduce the characteristics, technical parameters, application fields and advantages of ceramic fiber module in high temperature industry in detail.

I. Characteristics of ceramic fiber modules

Ceramic fiber module is a kind of modular refractory material based on ceramic fiber and specially processed. It has the following remarkable characteristics:

(1) Low thermal conductivity and low thermal capacity

The thermal conductivity of ceramic fiber modules is extremely low, which is only a fraction or even lower than that of traditional refractories. For example, when the density is 190-240 kg/m, its thermal conductivity is only 0.068-0.07 w/m k (at 400℃). This means that in high temperature environment, ceramic fiber module can effectively block heat transfer and reduce heat loss, thus reducing energy consumption. At the same time, the low heat capacity makes the module respond quickly when the temperature changes, reducing thermal inertia and further improving the heat insulation effect.

(2) High temperature stability and thermal shock resistance

Ceramic fiber module can maintain stable performance at extremely high temperature, and its maximum service temperature can reach 1350℃. For example, the highest service temperature of ZYC-HZ ceramic fiber module can reach 1350℃, and even at such a high temperature, the chemical composition and physical structure of the module remain stable. In addition, ceramic fiber modules have excellent thermal shock resistance, and can withstand rapid temperature changes without cracking or peeling. This makes the module still work reliably under the conditions of frequent start-stop and temperature fluctuation.

(3) Good mechanical properties

Ceramic fiber module has high mechanical strength and can withstand certain mechanical pressure and impact. Its tensile strength can reach 0.5-0.75 MPa, which can meet the use requirements of most industrial furnace linings. At the same time, the flexibility of the module is good, and it can be installed flexibly according to the shape and size of the equipment, with strong adaptability.

(4) chemical stability

The main components of ceramic fiber module are alumina and silica, which have good chemical stability. It can resist the corrosion of most chemical media, including acidic and alkaline gases and liquids. For example, when the high-temperature furnace gas contains a certain amount of corrosive gases (such as SO, NO, etc.), the ceramic fiber module can still maintain good performance and long service life.

II. Technical parameters of ceramic fiber module

The technical parameters of ceramic fiber module are different due to different models and uses. With the upgrading of models, the maximum service temperature and tensile strength of ceramic fiber module are gradually improved, which can meet the use requirements in different high-temperature environments.

III. Application fields of ceramic fiber modules

Ceramic fiber modules are widely used in metallurgy, machinery, petrochemical, ceramics, environmental protection and other industries. The following are their main application fields:

(1) Metallurgical industry

In metallurgical industry, ceramic fiber modules are widely used in heating furnace, heat treatment furnace, ladle cover, continuous annealing furnace, rotary furnace, bell jar furnace, coating furnace, walking beam heating furnace, hot air pipeline and flue. For example, using ceramic fiber module on ladle cover can effectively reduce heat loss, improve the stability of molten steel temperature and prolong the service life of ladle. In heating furnace and heat treatment furnace, ceramic fiber module as furnace lining material can significantly reduce the furnace wall temperature, reduce energy consumption and improve the thermal efficiency of the furnace.

(2) Machinery industry

In the mechanical industry, ceramic fiber modules are mainly used as thermal insulation materials for electric boilers, gas turbines and nuclear power plants. For example, in the combustion chamber and exhaust pipe of gas turbine, ceramic fiber module can withstand the erosion of high-temperature gas, and at the same time effectively insulate heat, protect the structural parts of equipment from high-temperature damage, and improve the operating efficiency and safety of equipment.

(3) Petrochemical industry

In petrochemical industry, ceramic fiber modules are used for lining of high-temperature reaction equipment and heating equipment, such as reforming furnace, atmospheric and vacuum furnace, cracking furnace and flue lining. These equipments operate in high temperature, high pressure and corrosive environment. The high temperature stability and chemical stability of ceramic fiber module make it an ideal thermal insulation material. For example, in the cracking furnace, the ceramic fiber module can withstand the heat generated by the high-temperature cracking reaction, and at the same time resist the corrosion of corrosive gases in the furnace, thus prolonging the service life of the equipment.

(4) Ceramics and electric ceramics industry

In the ceramic and electro-ceramic industries, ceramic fiber modules are used for lining of roller kilns, tunnel kilns, shuttle kilns and other kilns. These kilns need good thermal insulation and temperature uniformity during high-temperature firing, and ceramic fiber modules can meet these requirements. At the same time, their low heat capacity makes the temperature rise faster and the energy-saving effect is remarkable.

(5) Environmental protection industry

In the field of environmental protection, ceramic fiber modules are used as linings of waste incinerators and RTO (regenerative thermal oxidation) waste gas treatment furnaces. These equipments need to treat harmful gases and wastes at high temperature. The high temperature stability and corrosion resistance of ceramic fiber modules enable them to operate reliably under harsh working conditions, reduce heat loss and improve energy utilization efficiency.

IV. Advantages of Ceramic Fiber Module

Compared with traditional refractory materials such as refractory bricks and castables, ceramic fiber modules have the following obvious advantages:

(1) Convenient installation

Ceramic fiber module adopts modular design, which can be cut and assembled according to the shape and size of the equipment, and the installation is very convenient. The modules are fixed on the steel structure of the equipment through anchors, and complicated masonry process is not needed, which greatly shortens the installation time and cost. For example, in the lining installation of large industrial furnaces, ceramic fiber modules can be used to complete the installation in a short time, reducing the downtime of equipment and improving production efficiency.

(2) remarkable energy-saving effect

The low thermal conductivity and low thermal capacity of ceramic fiber module make it perform well in thermal insulation. Compared with traditional refractory materials, the use of ceramic fiber modules can reduce the heat loss by 30%-50%, thus reducing energy consumption and saving production costs. For example, in the heating furnace of metallurgical industry, after using ceramic fiber module, the furnace wall temperature is significantly reduced, the energy consumption is greatly reduced, and the thermal efficiency of the furnace is improved.

(3) Long service life

Ceramic fiber module has excellent high temperature stability and thermal shock resistance, and can run stably for a long time in harsh high temperature environment. It has strong chemical stability, can resist the corrosion of most chemical media and has long service life. For example, in the cracking furnace of petrochemical industry, the service life of ceramic fiber module can reach 5-8 years, which is much higher than that of traditional refractories.

(4) Low maintenance cost

Due to the stable performance and long service life of ceramic fiber module, the maintenance cost is low during use. Modular design makes it easy to replace the partially damaged modules without overhauling the whole furnace lining, thus reducing the maintenance time and cost.

V. Conclusion

Ceramic fiber module, as a new type of refractory material, has been widely used in high temperature industry because of its excellent characteristics such as low thermal conductivity, low thermal capacity, high temperature stability, thermal shock resistance, good mechanical properties and chemical stability. It can not only significantly improve the thermal insulation performance and energy utilization efficiency of the equipment, but also prolong the service life of the equipment and reduce the maintenance cost. With the continuous development of high-temperature industry, the application prospect of ceramic fiber module will be broader, which will provide a strong guarantee for the safety, efficiency and energy saving of industrial production.