Composite Modules are a new type of high-efficiency, energy-saving refractory lining product. They are manufactured by folding and compressing ceramic fiber blankets containing Chromium (Cr₂O₃) and Zirconium (ZrO₂), which are then assembled into modules with a pre-embedded anchoring system.
They combine the excellent thermal insulation properties of ceramic fiber with the easy installation benefits of a modular structure. The addition of chromium and zirconium oxides significantly enhances the material's high-temperature stability, resistance to creep, and resistance to chemical corrosion, making them an ideal lining solution for medium-to-high temperature industrial furnaces operating between 1260°C and 1400°C.
1. Exceptional High-Temperature Performance
· High Maximum Service Temperature: Can withstand continuous use at 1350°C and short-term exposure up to 1500°C.
· Low Thermal Conductivity: The unique micro-porous structure effectively blocks heat transfer, providing excellent insulation and significantly reducing heat loss from the furnace shell.
· Excellent Thermal Stability: Resists severe thermal shock (rapid heating and cooling) without cracking or spalling.
2. Outstanding Chemical Stability
· Strong Corrosion Resistance: The addition of chromium and zirconium oxides provides enhanced resistance to various atmospheres (e.g., reducing, oxidizing) and corrosion from many chemical vapors (e.g., ferrous metals, alkaline vapors).
· Low Impurity Content: Reduces the risk of forming low-melting-point eutectics with furnace atmospheres at high temperatures, extending service life.
3. Stable Structure & Long Service Life
· High Tensile Strength: The folded and compressed structure orients the fibers perpendicular to the hot face, effectively resisting high-temperature shrinkage and sagging under their own weight, preventing roof lining droop.
· Low Thermal Shrinkage: Exhibits dimensional stability at high temperatures with very low permanent linear change after prolonged use, ensuring lining integrity and tightness.
· Resistance to Erosion: The compressed, dense module structure can withstand the scouring effects of high-velocity gases.
4. Modular Design for Easy Installation
· Rapid Installation: Pre-formed modules in the factory allow for on-site installation like "building blocks," drastically reducing construction time and labor costs.
· No Curing/Drying Required: The ceramic fiber lining contains no bound water, allowing for immediate rapid heat-up to operating temperature after installation.
· Design Flexibility: Modules can be designed in various shapes and sizes to fit complex furnace geometries perfectly.
5. Comprehensive Energy Savings
· Low Heat Capacity: The low heat storage of the furnace walls enables faster heat-up times, improving production efficiency, especially for batch-operated furnaces.
· Effective Insulation: Significantly reduces shell temperature, improving the working environment and saving substantial fuel (typically 20%-40% energy savings).
Typical Technical Parameters
| Classification Temperature | 1500° |
| Continuous Use Temperature | 1350°C |
| Bulk Density | 160 ~ 240 kg/m³ |
| Permanent Linear Change (≥1400°C x 24h) | ≤ -2% |
| Thermal Conductivity (Mean Temp. 1000°C) | ≈ 0.28 W/(m·K) |
| Chemical Composition | |
| Al₂O₃ | 35-41% |
| SiO₂ | 45-49% |
| Cr₂O₃ | 5-7% |
| ZrO₂ | 14-16% |
| Shot Content (≥0.25mm) | ≤ 10% |
Due to their superior high-temperature performance, Composite Modules are widely used in demanding industrial applications:
· Iron & Steel Industry: Ladle covers, tundish covers, heat treatment furnaces, annealing furnaces, bell furnaces, soaking pits.
· Petrochemical Industry: Ethylene cracking furnaces, hydrogen reformer furnaces, pipeline heaters.
· Ceramics & Building Materials: Roller hearth kilns, tunnel kilns, shuttle kilns, ceramic sintering furnaces.
· Non-Ferrous Metals: Aluminum melting furnaces, copper processing heat treatment furnaces.
· Others: Waste incinerators, thermal power boiler insulation, aerospace heat treatment equipment.
Installation & Anchoring System
The modules are typically secured to the furnace steel shell (or base structure) via an anchoring system. Common installation methods include:
· Angle-Type: Suitable for walls.
· Slide-On/Speed-Clip: Suitable for roofs, allowing for thermal expansion and contraction.
· Butterfly/Card-Type: Suitable for walls and roofs, easy to install.
Anchor material should be selected based on operating temperature, such as 310S, 330 stainless steel, or RA-series high-temperature alloys.
Comparison vs. Traditional Refractories
| Composite Modules | Traditional Firebrick / Castable | |
| Thermal Conductivity | Low, Excellent Insulation | Higher, Greater Heat Loss |
| Heat Capacity | Low, Fast Heat-up, Saves Energy | High, Slow Heat-up, Consumes Energy |
| Thermal Shock Resistance | Excellent | Poor,Prone to Cracking |
| Installation | Fast & Easy, Modular | Complex,Time-Consuming, Requires Curing |
| Weight | Lightweight, Lighter Support Structure | Heavy, Requires Heavy Support Structure |
| Service Life | Long, Resists Spalling | Long, Resists Spalling |
Summary
Composite Modules represent a high level of modern industrial furnace lining technology. Through advancements in material science (chrome-zirconium composition) and engineering innovation (modular design), they provide users with a comprehensive solution that is energy-efficient, safe, stable, long-lasting, and easy to maintain. Choosing this product means not just selecting a material, but adopting an advanced technology that enhances production efficiency, reduces operating costs, and enables greener manufacturing.
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