Aluminum Silicate Fiber Cotton for Industrial Furnace Backup Insulation 1260°C Class

Aluminum Silicate Fiber Cotton Application Scenarios

• Aluminum Silicate Fiber Cotton in Metallurgy & Foundry Linings

  ✅Key Advantages

  1. Ladle and tundish backup insulation – Aluminum silicate fiber cotton fills gaps behind refractory linings and in covers, lowering heat loss and helping reduce molten metal temperature drop between furnace and casting points.

  2. Lightweight furnace wall upgrades – Replacing part of the brick backup with aluminum silicate fiber cotton-based modules can reduce lining weight by more than 70 % and cut heat loss by 20–40 % in many furnace types.

  3. Quick repair and hot patch work – Loose aluminum silicate fiber cotton can be packed into joints, door frames and cracks as a temporary or semi-permanent repair solution, restoring insulation without full relining shutdown.

  ✅ Problem Solved

  A steel foundry operating a 1100 °C holding furnace replaced part of its dense brick backup with a lining concept using modules and aluminum silicate fiber cotton packing. Measured fuel consumption decreased by about 20 %, and the outer shell temperature dropped by roughly 60–80 °C compared with the original design, extending maintenance intervals and improving the working environment near the furnace. This magnitude of savings is consistent with published data where ceramic fiber linings can cut energy use by 20–40 % versus traditional refractory brick systems.

• Aluminum Silicate Fiber Cotton for Industrial Furnaces & Heat Treatment OEMs

  ✅Key Advantages

  1. Efficient backup insulation behind hot-face refractories – When used as loose fill or as the base fiber for blankets and boards, aluminum silicate fiber cotton provides low thermal conductivity in the 0.13–0.21 W/(m·K) range at 600–800 °C, supporting thin, efficient furnace walls.

  2. Fast heat-up and cool-down cycles – Low heat capacity and low mass enable faster temperature changes in ceramic fiber lined furnaces, reducing start-up time by up to about one hour compared with traditional brick linings in some industrial tests.

  3. Flexible design for complex geometries – Loose aluminum silicate fiber cotton can be packed around burners, flanges and non-standard recesses that are hard to cover with rigid refractory materials, improving overall lining continuity.

  ✅ Problem Solved

  A heat-treatment furnace OEM redesigned a 1050 °C batch furnace using aluminum silicate ceramic fiber products based on fiber cotton instead of mainly firebrick. According to project data and typical industry comparisons, the new design reduced wall thickness by approximately 50 % while maintaining the same internal working temperature and allowed the furnace to reach set point around 40–60 minutes faster per cycle. Fuel usage per batch dropped by more than 20 %, directly improving the operating cost per ton of treated parts.

• Aluminum Silicate Fiber Cotton for Vacuum-Formed Shapes & Ceramic Fiber Products

  ✅  Key Advantages

  1. Consistent base fiber for formed products – Aluminum silicate fiber cotton with controlled fiber diameter and shot content gives a uniform base for vacuum-formed boards, cones, launders and special shapes used in steel, aluminum and ceramic industries.

  2. Adaptable to different binders and formulations – The fiber surface morphology and chemistry work with common inorganic and organic binders used in castables, coatings and formed parts, simplifying formulation changes.

  3. Supports high-temperature performance up to 1260 °C class – Formed products based on aluminum silicate fiber cotton can reach classification temperatures between 1260–1360 °C, depending on grade and formulation, covering a wide range of industrial furnace applications.

  ✅  Problem Solved

  A refractory manufacturer producing vacuum-formed aluminum silicate fiber launders for non-ferrous casting standardized on a specific aluminum silicate fiber cotton grade with defined Al₂O₃+SiO₂ level and fiber length. After the change, dimensional stability of formed shapes improved, scrap rate dropped by several percentage points, and users reported fewer surface cracks after repeated thermal cycling at 900–1000 °C, in line with the known thermal shock resistance and low thermal inertia of ceramic fiber products.

Aluminum Silicate Ceramic Fiber Cotton Usage Guide

• Installation

  1. Unpack aluminum silicate fiber cotton slowly and allow it to expand fully before installation.
  2. For backup insulation, loosely place or lightly tamp the fiber cotton into cavities, behind modules or between structural members; avoid excessive compression that would increase thermal conductivity.
  3. In expansion joints and door seals, pack the fiber cotton to a uniform density to maintain contact without over-stressing the surrounding structure.
  4. When used as raw material for forming, disperse the fiber cotton according to your slurry or mixing procedure to avoid clumps.

• Use

  1. Keep fiber cotton clear of direct flame impingement and mechanical abrasion unless designed as a replaceable hot-face packing.
  2. Ensure the hot-face refractory or module system in front of the aluminum silicate fiber cotton is rated for the maximum furnace temperature.
  3. Monitor shell temperatures after start-up to verify that the thickness and density of the aluminum silicate fiber cotton layer meet your design assumptions.

• Storage

  1. Store unopened bags in a dry, covered area away from rain and standing water.
  2. Avoid heavy loads on top of pallets to prevent excessive pre-compression.
  3. For bio-soluble or special grades, keep original labels visible to distinguish them from standard fiber stock.

• Cleaning and housekeeping

  1. Use industrial vacuum cleaners with suitable filters when cleaning work areas; avoid dry sweeping to reduce airborne fiber.
  2. Collect offcuts and loose fiber for possible reuse in patch mixes, where quality requirements allow.

• Common misuse and corrective actions

  1. Over-compressed packing behind hot-face linings
  Issue: Excessive tamping increases density and thermal conductivity, leading to higher shell temperatures.
  Fix: Follow recommended loose density ranges; if shell temperatures are high, reduce packing density or increase layer thickness.

  2. Using aluminum silicate fiber cotton as the only hot-face material in high gas velocity zones
  Issue: Direct erosion by high-velocity gases shortens lifetime.
  Fix: Use brick, castable or rigidized fiber products on the hot face and keep aluminum silicate fiber cotton as backup insulation.

  3. Incorrect grade selection for high-temperature or chemically aggressive atmospheres
  Issue: Standard 1260 °C grade may sinter or shrink under repeated exposure above its class temperature.
  Fix: For demanding atmospheres or higher temperatures, specify high-alumina or zirconia-containing alumino-silicate fiber cotton grades within the design.

Aluminum Silicate Ceramic Fiber Cotton FAQ

1. Q: What is the typical service temperature of aluminum silicate fiber cotton?
   A: For 1260 °C class aluminum silicate fiber cotton, continuous service temperature is usually designed up to around 1050–1100 °C, depending on atmosphere and safety margin.
2. Q: What is the density range of aluminum silicate fiber cotton?
   Q:  Aluminum silicate fiber cotton is typically used at loose bulk densities matching blanket and board products, around 64–128 kg/m³, with higher densities possible when compressed in confined spaces.
3. Q: How does aluminum silicate fiber cotton compare with firebrick in energy efficiency?
   Q:  Because of its low thermal conductivity and low heat storage, aluminum silicate ceramic fiber insulation can reduce energy use by roughly 20–40 % compared with traditional refractory brick linings in many furnace applications and also shortens heat-up and cool-down times.
4. Q: Can aluminum silicate fiber cotton be used as raw material for vacuum-formed products?
   Q: Yes, aluminum silicate fiber cotton is widely used as the base fiber in vacuum-formed ceramic fiber boards, cones, launders, burner blocks and other special shapes.
5. Q: What key parameters should I define when ordering aluminum silicate fiber cotton?
   Q:  It is helpful to define the required classification temperature, approximate operating temperature, desired bulk density, fiber length range, chemical composition window (especially Al₂O₃+SiO₂ content) and whether a bio-soluble grade is needed.

Aluminum Silicate Fiber Cotton Reviews

• ⭐️⭐️⭐️⭐️⭐️
  We changed our ladle backup insulation to aluminium silicate fiber cotton and saw a noticeable reduction in metal temperature drop during transfer. The material packs well behind the brick and has been stable through multiple relines.
  -- Michael Turner – Maintenance Manager, North Steel Castings Inc.
• ⭐️⭐️⭐️⭐️⭐️
  In several 1050 °C batch furnaces we design, using aluminium silicate fiber cotton as the backup layer helped us shorten heat-up time and keep shell temperatures within our targets. ADCERAX as the ceramic fiber supplier has been responsive on grade selection and technical details.
  -- Javier Morales – Technical Director, ThermoFurnace Engineering
• ⭐️⭐️⭐️⭐️⭐️
  We use aluminum silicate fibre cotton as the base fibre for vacuum-formed shapes. After switching to the new grade, the surface finish became more uniform and scrap related to fiber clusters decreased, which made downstream machining easier.
  -- Sophie Nguyen – Production Engineer, EuroRefractory Components
• ⭐️⭐️⭐️⭐️⭐️
  For our kiln projects we buy aluminum silicate fibre cotton in bulk bags and pair it with blankets and modules. The pricing from ADCERAX as a factory supplier is competitive, and the consistency between lots has been good for our repeat designs.
  -- Daniel Kim – Purchasing Manager, HeatPro Kiln Systems