Alumina Fiber Insulation Blanket for Aluminum Melting and Holding Furnaces

Al2O3 Ceramic Fiber Blanket Applications

• Heat Treatment and General Industrial Furnaces

  ✅Key Advantages

  1. Improved Shell Temperature Control
  Alumina fiber blanket linings can reduce external shell temperatures by 40–60°C compared with brick-only linings at similar operating conditions, helping operators meet safe touch and workplace regulations.

  2. Shorter Heat-Up and Cool-Down Cycles
  Low thermal mass reduces stored heat, which can shorten heat-up and cool-down times by 15–30% in batch furnaces, supporting higher throughput without structural changes.

  3. Lower Fuel Consumption in Continuous Operation
  When used as a backup or primary lining, alumina fiber blanket can reduce steady-state heat losses through the furnace shell, contributing to fuel savings that can reach several percent of total energy input in continuous lines.

  ✅ Problem Solved

  A heat treatment furnace OEM retrofitted a batch furnace from a lightweight brick lining to a combined alumina fiber blanket and module system. At a working temperature of around 950°C, shell temperatures were reduced by approximately 50°C and heat-up time decreased by roughly 20%. Based on measured gas consumption and production cycles, the user reported an annual fuel saving in the range of several tens of thousands of cubic meters of natural gas, with a payback period of around 1–2 years including installation downtime.

• Power Boilers and Waste Incineration Units

  ✅Key Advantages

  1. Weight Reduction for Boiler Casings and Ducts
  Boiler and incinerator casings insulated with alumina fiber blanket can be lighter than those using conventional refractory bricks, which eases structural design on large ductwork and support frames.

  2. Simplified Field Installation and Maintenance
  Flexible blanket layers are easier to cut and fit on large boiler walls and outlet ducts than rigid boards, which can reduce installation time and allow localized replacements during outages.

  3. Support for Emission and Efficiency Targets
  By limiting heat loss and improving thermal efficiency, alumina fiber blanket helps power and waste-to-energy operators lower fuel usage and contributes indirectly to reduced CO₂ emissions per unit of energy output.

  ✅ Problem Solved

  In a retrofit project on a waste incineration boiler outlet duct, an engineering company replaced aging insulation with a multi-layer alumina fiber blanket system. Thermal calculations and subsequent temperature measurements indicated a reduction in external surface temperature by more than 30°C and a measurable improvement in overall boiler efficiency. Maintenance crews reported easier access and shorter repair time during the next scheduled shutdown due to simpler removal and re-installation of blanket layers.

• Non-Ferrous Metallurgy and Aluminum Casting

  ✅Key Advantages

  1. Reduced Heat Loss in Troughs and Launders
  Alumina fiber blanket can be applied under refractory linings of troughs and launders to reduce heat flow into the steel shell, which helps maintain aluminum temperature during transfer and reduces reheating demand.

  2. Fast Repair and Patch Insulation
  In foundries and aluminum plants, maintenance teams can quickly apply blanket patches to doors, lids, and access openings, limiting accidental heat losses during short stoppages.

  3. Better Temperature Stability for Holding Furnaces
  With a lightweight blanket backup layer, holding furnaces respond more quickly to control adjustments and show less temperature variation around the metal bath, improving metallurgical consistency.

  ✅ Problem Solved

  A non-ferrous foundry added alumina fiber blanket behind existing refractory linings in an aluminum holding furnace. Measurements over several months showed smaller temperature swings at metal level and reduced burner on-time. Estimated energy savings were in the low single-digit percentage range of total fuel consumption, while lining repairs during maintenance outages became easier due to the flexible blanket layer.

Alumina Ceramic Fiber Blanket Usage Instructions

• Installation

  1. Verify design drawings for layering, density, and thickness before installation.
  2. Use suitable fixing systems such as stainless steel anchors, studs, and washers that match operating temperature and furnace structure.
  3. Install blanket layers in a staggered joint pattern, paying attention to overlaps and compression so that there are no significant gaps.
  4. For vertical walls or ceilings, ensure adequate mechanical support with anchors and lacing where necessary.
  5. Avoid over-compression, which can increase thermal conductivity and reduce insulation performance.

• Operation and Use

  1. Gradually heat new linings according to a defined startup curve to allow any residual moisture to escape and to stabilize the fiber structure.
  2. Monitor shell temperatures during the first commissioning runs and compare them with design values to confirm insulation performance.
  3. Avoid repeated mechanical impact on exposed blanket areas such as doors and inspection hatches.

• Storage

  1. Store alumina fiber blanket in a dry, covered warehouse away from rain, standing water, and direct sunlight.
  2. Keep rolls in their original packaging until installation to minimize contamination and fiber loss.
  3. Do not place heavy loads directly on top of blanket rolls that could deform the fibers.

• Cleaning and Handling

  1. During cutting and installation, use appropriate personal protective equipment such as masks, gloves, and protective clothing as recommended in the material safety data sheet.
  2. Keep work areas ventilated and remove loose offcuts and dust by vacuum rather than dry sweeping.
  3. Avoid oil, grease, or other contaminants on blanket surfaces that may degrade at high temperatures.

• Typical Misuse Points and How to Address Them

  1. Insufficient Fastening on Overhead Surfaces

  Problem: Blanket installed on ceilings or vertical walls with too few anchors can sag over time.
  Solution: Follow design guidelines for anchor spacing and pattern; add extra fixings in high-vibration or frequent opening areas.

  2. Over-Compression of Layers

  Problem: Excessive compression to “save space” increases thermal conductivity and can reduce insulation performance.
  Solution: Keep compression within recommended limits and use correct thickness and density instead of squeezing fewer layers.

  3. No Controlled Heat-Up During First Firing

  Problem: Rapid heating can lead to localized stresses, shrinkage, or cracking of other refractory layers.
  Solution: Apply a controlled initial heat-up schedule so that moisture and residual binders in the whole refractory system are removed gradually.

Alumina Fiber Blanket FAQ

1. Q: How is alumina fiber blanket different from standard ceramic fiber blanket?
   A: Alumina fiber blanket is a needle-punched alumina–silicate ceramic fiber blanket designed for higher classification temperatures and lower shrinkage than many general ceramic fiber blankets, making it suitable for continuous high-temperature industrial furnace duty.
2. Q: What temperature range can an alumina fiber blanket handle in continuous operation?
   A: An alumina fiber blanket is normally classified at 1260–1430°C, but typical continuous operating temperatures are lower (for example around 1000–1200°C) depending on the selected grade, design safety margin, and service conditions.
3. Q: Which density should I choose for my alumina fiber blanket lining?
   A: Lower density grades such as 64–96 kg/m³ are often used as backup insulation where weight and cost are key, while 128–160 kg/m³ alumina fiber blankets are selected for hot-face or single-layer linings that require higher mechanical strength and lower shrinkage.
4. Q: Can alumina fiber blanket be used as the primary hot-face lining?
   A: Yes, alumina fiber blanket can be used as a primary hot-face lining in many medium and high-temperature furnaces when combined with suitable anchors and a correct multi-layer design; however, in abrasive or high-gas-velocity zones it is frequently used as a backup layer behind modules, boards, or castables.
5. Q: Is alumina fiber blanket suitable for direct contact with molten metal?
   A: Alumina fiber blanket is generally used behind refractory linings or as external insulation and is not intended for direct contact with molten metal; facing layers and higher-density refractory materials are normally required in metal contact areas.
6. Q: Can I cut alumina fiber blanket on site, and which tools should be used?
   A: Yes, alumina fiber blanket can be cut on site using sharp knives or serrated blades; cutting surfaces should be protected and offcuts collected to reduce dust and keep consistent dimensions.

Alumina Ceramic Fiber Blankets Reviews

• ⭐️⭐️⭐️⭐️⭐️
  We used alumina fiber blankets from ADCERAX in a series of heat treatment furnace upgrades. The blanket density and thickness matched our drawings, and shell temperatures were aligned with the calculated values, which made commissioning straightforward.
  -- Mark H., Project Engineer – Furnace Systems Europe GmbH
• ⭐️⭐️⭐️⭐️⭐️
  For our boiler and duct insulation projects we purchase alumina fiber blanket rolls in mixed density grades. ADCERAX as a factory supplier has been able to combine standard rolls with custom-cut pieces in one shipment, which helps us reduce site cutting time.
  -- Laura P., Procurement Manager – Thermal Equipment Solutions Inc.
• ⭐️⭐️⭐️⭐️⭐️
  We added alumina fiber blanket as backup insulation under existing trough linings. The installation was simple and the blanket layers have held their shape during several maintenance cycles, supporting more stable metal temperature during casting.
  -- Kenji S., Maintenance Supervisor – Aluminum Casting Plant, Japan
• ⭐️⭐️⭐️⭐️⭐️
  Our team uses alumina fiber blanket for furnace doors, burner blocks and patch insulation. The material arrives well packed, cuts cleanly on site, and the range of densities allows us to adapt to different projects without redesigning the whole lining.
  -- Diego R., Owner – Refractory Service Contractor, Mexico