Installation methods and application areas of ceramic fiber modules
Ceramic fiber modules are made of ceramic fiber (mainly composed of alumina, silica, etc.) and processed into prefabricated block structures through special processes. They are usually installed with anchors to form a continuous, seamless insulation layer with the characteristics of light weight, high temperature resistance, and low thermal conductivity. They are widely used in thermal insulation in industrial furnaces, high-temperature equipment and other fields.
Preparation before installation
Base inspection:
Ensure that the furnace wall or equipment surface is flat and free of debris, and the steel structure needs to be treated with anti-corrosion.
Check the welding quality of anchors (such as "V" nails, "Y" nails or bolts) to ensure that the spacing and arrangement meet the design requirements (usually 1/2~2/3 of the module size).
Module pre-compression:
The new module is usually in a compressed state when packaged. The packaging must be kept intact before installation to avoid premature loosening.
Safety protection:
Wear dust masks, goggles, gloves, etc. to avoid inhaling ceramic fiber dust.
2. Installation process
1. Anchor installation
Weld anchor nails (usually made of 304/310 stainless steel or heat-resistant steel) according to the design drawings, with a spacing of 300~400mm.
The direction of the anchor nails must be perpendicular to the compression direction of the module to ensure uniform force.
2. Module installation
Folding module:
Unfolding and positioning: tear open the package and slowly unfold the folded module to the designed thickness.
Fixing with nails: align the center of the module with the anchor nail, pass through the reserved hole of the module, and fix it with a quick card or nut.
Compression adjustment: The module needs to be slightly pre-compressed (about 10%~15%) when installed, and it can expand after heating to fill the gap.
Layering module:
Layering: stack multiple layers of ceramic fiber blankets and fix them layer by layer with anchor nails.
Compacting treatment: Each layer needs to be compacted with a special tool to ensure uniform density.
3. Joint treatment
Gap between modules: adjacent modules are naturally filled by self-expansion, or ceramic fiber blanket strips are inserted to seal.
Corners: Use ceramic fiber special-shaped modules or on-site cut fiber blankets to fill to avoid thermal bridge effect.
4. Surface treatment (optional)
Spray curing agent: spray high-temperature coating (such as alumina coating) on the surface of the module to enhance the ability to resist airflow scouring.
Covering fiber blanket: Add a layer of ceramic fiber blanket on the outer layer to improve the overall sealing.
Application areas:
Metallurgical industry: ladle, aluminum melting furnace, heat treatment furnace.
Petrochemical industry: cracking furnace, converter, pipeline insulation.
Ceramic and glass industry: kiln, annealing furnace.
Power industry: boiler, flue insulation.
Others: waste incinerator, experimental electric furnace, etc.