Ceramic Fiber Module
A Ceramic Fiber Module is a pre-fabricated, highly efficient refractory insulation unit made from Ceramic Fiber Blanket that is folded, edge-compressed, and anchored into a self-supporting block. Modules are designed to be mechanically anchored directly to the furnace steel casing, providing a hot-face lining that achieves superior thermal efficiency, excellent hot-face stability, and maximum installation speed.
Main Features
Modules use high-grade RCF blankets, typically 128 kg/m3 (8 b/ft3) density, and are available in the same Al2O3 content grades as blankets (1260°C to 1540°C MST). The key lies in the mechanical construction.
| FEATURE | DESCRIPTION | PRIMARY ADVANTAGE |
| Compression | 10% to 20% pre-compression (vertical or horizontal folds). | The stored energy presses modules tightly against each other, eliminating air gaps and joints. |
| Anchoring System | Embedded metal or ceramic hardware (e.g., stud, rail, plate) at the cold face. | Allows for direct, rapid mechanical fixing to the furnace shell. |
| Hot-Face Stability | Folds are oriented towards the hot face. | The folded structure minimizes fiber shrinkage in the lateral direction, enhancing durability. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Air Leakage | MINIMAL | Compression ensures a near-monolithic lining with virtually no open joints, minimizing heat loss via convection. |
| Installation Speed | MAXIMUM | Reduces installation time by up to 75% compared to installing loose blanket or brick. |
| Shrinkage/Life | LOW/LONG | The folded pattern is engineered to manage the small amount of thermal shrinkage that occurs, preventing hot spots and gap formation. |
| Thermal Mass | VERY LOW | Retains the essential benefit of RCF for fast, fuel-efficient furnace cycling. |
Advantages and Key Characteristics
Ceramic Fiber Modules are the preferred lining method for large-scale, high-temperature furnaces where energy efficiency, speed of installation, and structural integrity are critical design factors.
- Superior Thermal Performance: By compressing the blanket and eliminating air gaps between units, modules achieve a much tighter, more uniform seal than layered blanket, resulting in the lowest possible thermal conductivity for an RCF lining.
- Ease of Replacement and Repair: Individual modules can be quickly and easily removed and replaced without disturbing the adjacent sections, simplifying maintenance and repairs.
- Robust Mechanical Fixing: The embedded anchoring system provides a secure, reliable connection to the furnace shell, ensuring the lining remains stable even during high-velocity gas flows, mechanical vibration, or furnace pressure changes.
- Compensated Shrinkage: As the fiber on the hot face shrinks slightly over time, the compression releases, keeping the joints tight and closed, which prevents the formation of “hot spots” that would otherwise occur with non-compressed blanket linings.
Typical Industries and Applications
Modules are used in large-scale, high-temperature industrial environments:
- Large Industrial Furnaces: Primary hot-face lining for heat-treating furnaces, forging furnaces, stress-relieving ovens, and large annealing furnaces.
- Kilns: Linings for ceramic and specialty kilns, particularly where the lining needs to be periodically replaced or repaired.
- Ductwork and Flues: High-efficiency insulation for large flues and thermal oxidizers.
Key Data Sheet Properties to Consider
Selection must focus on geometry, density, and anchor type:
- Module Dimensions: The standard size (e.g., 300 x 300 mm or 12 x 12 inches) and thickness (from 100 x 300 mm) must match the furnace design.
- Compression Percentage: Confirms the amount of stored energy available to keep joints tight (typically 15% to 20%).
- Anchor System Type: Must be compatible with the furnace shell material and design (e.g., concealed anchor, visible stud-weld anchor, or rail system).
Technical Guidance: During installation, it is critical that the modules are installed tightly against each other to realize the full benefit of the compression. For continuous use above 1400°C, the anchors must be ceramic or a non-metallic alternative to prevent high-temperature metal failure or chemical attack.
✨ Customization Services
We offer product customization services, allowing you to tailor the appearance, dimensions, or specific markings of items like refractory shapes or bricks. This includes options for incorporating specific geometric requirements to ensure seamless integration into your process systems.
🔬 Sampling for Testing & Validation
Free product samples are available for thorough testing and validation. This allows you to confirm the quality, compatibility, and performance of our materials—such as specific bricks, castables, or raw materials—before committing to a full order.
💡 Expertise in Refractory Solutions
Leverage our deep expertise to receive detailed, application-specific refractory solutions. We move beyond just selling products by providing comprehensive plans that encompass material selection, installation guidance, and performance optimization to maximize the lifespan and efficiency of your high-temperature processes.
Rabatec products are exclusively manufactured in facilities that have achieved rigorous ISO certifications across Quality (ISO 9001), Environmental Management, and Occupational Health & Safety. This commitment ensures every product, from refractory bricks to specialized equipment, meets the highest global benchmarks for performance, sustainability, and workplace safety.
📦 Logistics Excellence: Shipping, Packaging, and Marking
Minimizing Risk: We manage all logistics to minimize handling touchpoints and transit shock. Our carriers are pre-vetted for their experience in transporting heavy, fragile, and sensitive industrial materials.
Traceability: Every shipment includes comprehensive documentation and tracking information, providing end-to-end visibility and ensuring precise delivery coordination for your site.
Protection is Paramount: Our packaging strictly follows industry standards to prevent damage, corner chipping, and moisture absorption—especially critical for materials like Basic Refractory Bricks and Refractory Mortars & Mixes.
Robust Palletization: Products are secured on fumigated, high-strength export pallets (e.g., 1100x950mm or similar sturdy dimensions) using heavy-duty strapping and durable protective wrapping (polyethylene sheeting, cardboard, etc.) to withstand long-distance travel and multiple loadings.
Moisture Control: Sensitive materials are protected with appropriate sealing and, where necessary, desiccants or moisture-vapor proof enclosures to maintain the product's integrity until installation.
Clear Identification: All outer packaging is clearly marked on multiple sides with large, legible text for immediate identification and safe handling.
Full Traceability: Markings include all essential data points: Product Name, Quality Grade, Batch Number, Quantity, Net/Gross Weight, Order Number, and the Final Destination/Construction Area. This ensures every pallet can be accounted for and correctly staged upon arrival.
Safety & Compliance: We adhere to all regulatory requirements for marking, labeling, and placarding—especially for any items classified as Dangerous Goods—to ensure full compliance with international and domestic transport regulations.
❓ Frequently Asked Questions (FAQ)
Question | Elaborated Answer |
Q: What is the Refractoriness Under Load (RUL) of your refractories? | A: Refractoriness Under Load (RUL) is a critical property that defines the maximum temperature our materials can withstand while under compressive stress before deforming (softening). Since we offer a wide range of materials—from Alumina-Silicate Bricks to high-performance Silicon Carbide Bricks—the RUL varies significantly. For specific product data, please refer to the product data sheet or submit a quote request for the material you are interested in. |
Q: Where are the Rabatec refractories and materials produced? | A: Our products are primarily sourced from specialized manufacturing plants in China. Crucially, these facilities have all undergone rigorous audits and achieved comprehensive ISO certifications (Quality, Environment, and Safety), ensuring that production adheres to the highest global standards for consistency and performance. |
Q: What refractory materials does the company offer? | A: We supply a comprehensive portfolio of advanced refractory solutions, including: Shaped Products: Alumina & Silica Bricks, Basic & Specialized Bricks (e.g., Magnesia), SiC & Structural Ceramics, and Precast Shapes. Monolithic Products: Refractory Castables, Mixes & Mortars. Insulation: Insulation Fibre and High-Performance Insulation Products. |
Q: How should I choose the appropriate refractory material for my application? | A: Selecting the correct refractory is paramount to process efficiency. The choice depends on three key factors: 1. Operating Environment: Maximum process temperature and thermal cycling (shock). 2. Chemical Attack: Type of slag, molten metal, or corrosive gas being handled (acidic, neutral, or basic). 3. Mechanical Stress: Abrasion, erosion, and static load requirements. We recommend utilizing our detailed refractory solutions service to consult with our engineers for an optimized, application-specific recommendation. |
Q: Which monolithic material should I choose when patching an existing lining? | A: For patching and minor repairs, the ideal monolithic material depends on the parent lining material, the patching depth, and the need for a rapid return to service. Common choices include: Refractory Mortars & Mixes (for minor joints/surfaces) or Plastic Refractories (for areas requiring physical compaction). Always choose a patch material chemically compatible with the existing lining to ensure proper bonding and service life. |
Q: Can I receive product samples before placing a major order? | A: Yes. We gladly provide product samples for your internal testing and validation purposes. This ensures you can confirm the quality, composition, and fit of the material—such as our Refractory Castables or Alumina-Silicate Bricks—in your specific operational environment before committing to a bulk purchase. |
Q: Do you provide certifications to verify material quality? | A: Absolutely. We provide product-related inspection certificates and quality assurance documentation upon request. This verifies that your order has passed all internal quality control checks and meets the required material specifications and industry standards. |
Q: What measures are taken for product protection during transport? | A: We ensure quick, reliable transport by using robust, industrial packaging that strictly follows industry standards. This includes high-strength palletization, heavy-duty strapping, and weather-resistant wrapping to protect fragile items like bricks and mixes from corner chipping, mechanical damage, and moisture during transit. |
