Refractory Products
Ceramic Fiber Modules
Ceramic fiber products are a staple of the refractory industry. At RSI, we carry an array of ceramic fiber products, including ceramic fiber modules. If you’re looking for an ideal insulating solution for your refractory equipment, ceramic fiber modules can get the job done.
The Most Insulating Class of Refractories
Ceramic fiber products are the most insulating class of refractories. Fiber products are the go-to answer if you’re looking for effective insulation.
What makes ceramic fiber the right choice for many high-temperature applications? It’s made from a mixture of alumina and silica sand. When these materials are spun into fibers, you get a great insulator with extremely low density and low thermal conductivity. Ceramic fiber protects your furnace lining from the thermal shock of rapid heating and cooling.
Ceramic fiber is used throughout refractory for applications such as pollution control, heat treating, and high-temperature dryers. Fiber modules are made up of ceramic fiber—the same material used in ceramic fiber blanket composition. They offer high-temperature insulation for all your needs.
One great aspect of modules is that they’re offered in multiple configurations and styles. These modules offer insulation in high temperature furnaces, even when heat reaches an astonishing 3000° F.
How Ceramic Fiber Modules are Used in Refractory
Modules are often installed on a surface’s hot face or working lining. These thick blocks of ceramic fiber include attached hardware, allowing users to weld them to the furnace’s internal metal.
You can use fiber modules as an insulation product for an entire furnace lining. These refractory tools are easy to use, easy to install, and highly insulating. How insulating? A lining with 6 inches of fiber can accomplish as much as 18-20 inches of hard refractory like brick or castable.
Similarly, ceramic fiber cools down quickly. If that same furnace has an issue your team needs to access, you may have to shut it down for several days with a hard lining. The hard refractory materials hold the heat because they have so much mass. With modules, the same unit takes just a fraction of the time to reach safe temperatures.
This versatility makes modules a go-to choice for industrial furnaces (under applicable conditions). They reduce the need for downtime, allowing you to make repairs and gain access quickly.
Hard refractory is sensitive to temperature changes and can experience thermal shock, damaging the integrity of furnaces. Ceramic fiber linings can take the heat—they won’t crack even if you quickly go from 0 to 2000°.
It’s this reliability and versatile nature that make ceramic fiber modules a great choice. Because the material is softer, it can be more sensitive to mechanical damage, but modules are also highly affordable and easy to replace. They lower maintenance costs for your overall equipment.
The Unique Properties of Ceramic Fiber Modules
Many ceramic fiber products, like boards, contain binders. These binders can start to lose strength at temperatures above 500°. Blankets, the base of modules, don’t contain the same binding agent. Instead, the fibers are felted together in manufacturing.
The result is an extremely strong ceramic fiber product that holds up to high temperatures. Even head-to-head, a fiber module rated at 2200° will function completely differently than a ceramic fiber board rated at 2200°.
Boards are often used as a backup to hard refractory. Ceramic fiber modules, which can tolerate heat, are often used on the furnace surface as furnace linings.
Most modules have a built-in anchoring system that’s easy to weld in place. Place the module against the steel and put the weld gun through the tube in the front of the module. You can quickly wield the stud to the shell. The tube pops off, indicating the module is correctly attached.
Any process that needs heat needs ceramic fiber. Modules are the ideal lining for high temperatures. With easy installation and light weight handling, refractory ceramic fiber lining is an effective solution.
Ceramic Fiber Modules for Every Industry
Ceramic fiber modules are used in many different industries—nearly any job that requires heat-treating, forging, or furnace heating.
Modules are especially preferred in pollution control equipment, where gases and chemicals such as ethanol are produced and need to be burned off. Fiber modules play an ideal role whether you’re processing wood products, plywood, food products, paper, or other materials.
Fiber modules allow units to cool down quickly for fast access (something essential in chemical processing). At RSI, we have many coatings and innovative solutions that protect the fiber against degrading chemical environments.
Our standard fiber modules can withstand temperatures up to 2150° F. Modules made with zirconia have a temperature rating up to 2450° F, while the highest grade of modules made with pure alumina withstand temperatures up to 2850° F (almost the melting point of steel).
No matter the job, RSI has your refractory needs covered with superior products designed to handle the harshest environments. Explore our wide range of excellent refractory products and materials. Reach out if you have any questions or need support.