Insulation is crucial for maintaining efficiency and safety in industrial processes operating at high temperatures. Vacuum formed ceramic fiber shapes offer a customizable and durable solution for insulating irregular geometries and complex equipment.
Vacuum formed ceramic fiber uses a specialized process to mold unshaped ceramic fiber into custom insulation parts with complex three-dimensional shapes. The fiber is typically made of aluminosilicate or aluminoborosilicate glass. Heated under controlled vacuum conditions, the fiber softens and can be formed into precise insulation components customized for specific applications. Once cooled and machined, the vacuum formed ceramic shape hardens into a rigid part that retains its customized ceramic fiber vacuum and thermal properties.
Some key benefits of vacuum formed shapes with ceramic fiber are:
1. High Temperature Resistance
Vacuum formed ceramic fiber insulation can withstand continuous operating temperatures up to 1300°C. They lose negligible weight and performance at such extreme high heat, making them well-suited for insulation of industrial equipment operating at or above 1000°C.
2. Thermal Performance
With a very low thermal conductivity of around 0.1 W/mK, vacuum formed ceramic shapes provide effective thermal insulation at high temperatures. They help reduce heat losses and distribute heat more uniformly within enclosures and ducts.
3. Close Tolerances
Ceramic fiber vacuum formed can be formed within close tolerances of just 1-2mm, making them suitable for applications that require a tight fit. They can accurately replicate irregular shapes for effective sealing and reduction of air gaps.
Once cured, vacuum formed ceramic fiber shapes become rigid and durable. They retain their insulating properties even after repeated exposure to extreme high temperatures and thermal cycling. For longer life, metal enclosed or encased ceramic shapes can be custom made.
5. Complex Shapes
The vacuum forming process allows technicians to create complex 3D geometric shapes that conform precisely to the dimensions and contours of industrial parts and equipment. Complex shapes can be molded with accurate thickness and density distribution to optimize insulation performance.
Applications Of Vacuum Formed Ceramic Fiber Insulation
Some common applications of vacuum formed ceramic shapes include:
Furnace Liners – Used to line inner walls, roofs and floors of industrial furnaces, ovens and kilns operating between 800 – 1300°C.Ceramic fiber vacuum formed liners conform accurately to the enclosure shape for effective thermal insulation.
Hot Gas Ducts – Used to insulate gas ducts carrying hot exhaust gases or flue gases from industrial processes at temperatures up to 1100°C. Custom molded duct liners provide close fitting insulation for maximum performance.
Valve Covers – Used as custom insulation covers for valves, rotary joints and other industrial parts exposed to high operating temperatures. Accurately shaped covers prevent heat losses while allowing easy access.
Metal Encasement – Used within metal enclosures to insulate pipes, tubes and vessels carrying or containing high temperature fluids and gases. Encased insulation helps maintain even temperature of the contained medium.