Good insulation is one of the cheapest ways to cut fuel cost and protect the steel shell. Ceramic fibre and calcium silicate are two of the most common choices, and each has its place.
Ceramic fibre
A lightweight, flexible material supplied as blankets, boards and modules, with grades for service temperatures up to about 1400 °C. Its low weight and low heat storage make it ideal where equipment heats up and cools down often, such as batch furnaces, doors and hot air generator chambers. It can be used as a hot face lining in suitable conditions or as a back-up layer behind dense refractories.
Calcium silicate
A rigid material supplied as blocks, boards and pipe sections, generally used at lower temperatures than ceramic fibre. Its strength means it holds its shape under load and handles mechanical contact better, which is why it is widely used for pipelines, vessels, ducts and as a back-up layer in furnace walls.
How to choose
- Service temperature at the insulation layer, not just inside the furnace
- Whether the surface sees load, impact or vibration
- How often the equipment heats up and cools down
- Exposure to gas velocity, moisture or chemicals
- Required shell temperature and space available
In many linings the best design uses both: dense brick or castable on the hot face, then insulating brick or ceramic fibre, with calcium silicate behind it where temperatures are lower.
Handle fibre safely
Ceramic fibre should be handled with the right protective equipment, including dust masks, gloves and covered skin, and waste should be collected rather than swept into the air. Follow the manufacturer's safety data sheet.
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