Manufacturing Ceramic Fiber Insulation
The primary component of ceramic fiber insulation is high-temperature insulation wool made from synthetic minerals capable of withstanding consistent temperatures exceeding 1200°C (2192°F). Before application however, this synthetic material must be densified, treated, and machined for various purposes.
This post will explore the process of manufacturing ceramic fiber insulation in more detail:
Forming Alumina Silicate Wool
Thermcraft’s ceramic fiber insulation products are formed using industry-leading refractory ceramic fibers made from alumina silicate. These are manufactured by melting varying ratios of pure aluminum (AL2O3) and silicon (SiO2) in an industrial furnace. The melt is made to flow through an aperture at the bottom of a furnace where constant streams of air will cool and separate the molten material into thin strands or fibers. This is known as the blowing process. Other methodologies include a spinning process, in which the molten mixture is dripped from the furnace aperture through arrays of rapidly spinning wheels.
Both processes result in loose conglomerations of ceramic fibers that will be collected into a tough fleecy mass to be further treated and manufactured.
Vacuum Formed Ceramic Fiber Insulation
Vacuum forming of ceramic fiber insulation allows manufacturers to create insulation products of varying densities to unique dimensions. The process involves directing a mixture of ceramic fibers, water, and an inorganic binder through a mold and drying the end-product in a vacuum oven. Multiple ceramic fiber products can be formed using this methodology.
Ceramic fiber blankets are generally supplied in rolls that can be cut to specification on-site. The high formability of ceramic fiber blankets grants them a high suitability for insulating refractory machinery, either by filling voids, encapsulating machinery, or by integrating them into heating components.
This formability can be dramatically increased by treating ceramic fiber blankets with inorganic bonding agents and packing them in plastic to maintain high moisture levels prior to application. It can be accurately molded to a ceramic component, exhibiting exceptional resistances after the bonding agent has dried.
Conversely, it is possible to rigidify ceramic fibers for the formation of ceramic fiber board insulation by tightly compressing them into flat panels and machining them for eventual application.
Vacuum formed ceramic fiber products can be made to bespoke specifications with thermal resistances upwards of 1200°C and exceptional degrees of versatility for integration with an enormous range of industrial heating elements and instruments.
Ceramic Fiber Insulation from Thermcraft
Thermcraft are leading developers of industrial insulation and heating elements, with a catalogue of high-quality thermal processing components and equipment for various industries and sectors.
Our ceramic fiber insulation products are available to a range of specifications, including board insulation products exhibiting continuous thermal resistances of up to 1538°C (2800°F). If you would like any more information about our ceramic fiber insulation products, please do not hesitate to contact us.