REPLACING INDUSTRIAL FURNACE INSULATION
It is a common practice for plants to perform a general overhaul of industrial furnaces as part of a maintenance schedule. This process often includes the replacement of existing insulation with new and updated materials. This operation is carried out approximately every 4-7 years depending on the degree of exploitation of the device during this period. In practice, we encounter furnaces where, for various reasons, the insulation has not been replaced since the furnace was commissioned – even after 20 years!
The experience of SECO/WARWICK service specialists shows that improper or leaky insulation is the main reason for heat losses. Replacing it can save money in the heat treatment process.
/Stages of insulation replacement
Before each replacement, our specialists thoroughly analyze the needs of the heat treatment process and select the most effective solution. Whether it will be hard or soft insulation or a combination of both solutions, we present it in the form of numerical and economic arguments.
The replacement of insulation, in the area of maintenance, falls into the category of a major overhaul or capital repair of the furnace. On this occasion, it is also worth considering the replacement or modernization of the furnace heating system, as it is also a crucial cost element of heat treatment. When deciding to change the system, it should be included in the furnace insulation design, taking into account, e.g., special finishes of openings for gas burners or electric heating elements.
More information on heating system
/Benefits of replacing industrial furnace insulation
/Reducing heat losses
New, airtight insulation minimizes heat escape, which translates into lower energy consumption
/Savings in the heat treatment process
Lower energy consumption means lower furnace operating costs
/Extending the life of the furnace
Protection of the furnace structure against overheating and thermal deformation
/Improved work safety
Modern insulation protects against burns and reduces the risk of fire spreading
/Better temperature control
Even temperature distribution in the furnace chamber reduces the risk of production defects
/Aesthetics and technical order
New insulation improves the appearance of the furnace, and makes it easier to maintain order in the plant
/Increased reliability and ease of maintenance
Modern insulation materials are easy to install and dismantle, facilitating future repairs
/Resistance to harsh industrial conditions
New materials are resistant to vibrations, moisture, mechanical and chemical damage
/Maintaining the compact dimensions of the furnace
Modern insulations are thin, therefore they do not reduce the furnace’s working space
/The ability to adapt equipment to modern heating systems
Replacing insulation is a good opportunity to modernize heating elements (e.g., gas burners, and electric heaters)
/Increased energy efficiency
Better insulation helps maintain a constant temperature inside the furnace, improving the quality of technological processes
Why is the thermal insulation in industrial furnaces a challenge for enterprises?
Because it must withstand extreme working conditions – high temperatures, vibrations, moisture, and the action of chemicals. Additionally, it cannot significantly increase the dimensions of the furnace or restrict its working space.
What qualities should characterize the effective application of industrial insulation?
It should be resistant to mechanical damage, vibrations, high temperature, moisture, corrosion, and chemical action. Durability and fit to the furnace structure are also important attributes.
What does the choice of insulation material for an industrial furnace depend upon?
On the function of the furnace, the temperature range of its operation, and the specific place where the insulation is to be applied.
What insulating materials are most commonly used in industry?
Ceramic fiber materials (e.g., mats, boards, modules) and vermiculite cements and concretes are most commonly used.
What are the advantages of ceramic fibers as an insulating material?
They are lightweight, flexible, easy to install, resistant to high temperatures, chemical action, and gas erosion. They work well in places with complex shapes.
Where are ceramic fiber insulations used?
In metallurgical furnaces, such as bell furnaces, heating furnaces with a movable bottom, annealing furnaces, controlled cooling furnaces, as well as in casting pits, furnace doors, and vaults.
What characterizes various types of vermiculite concrete?
They are lightweight, resistant to temperatures from 800 to 1300°C, but have low abrasion resistance. They are used as an additional insulating layer in less exploited places.
How is vermiculite formed and why is it useful?
Vermiculite expands under heat treatment, increasing its volume. This results in a low-density material with good insulating properties.
