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INDEX Ⅰ. INTRODUCTION 1. INTRODUCTION OF CERAKWOOL 4 2. FEATURES OF CERAKWOOL 4 Ⅱ. PRODUCT INFORMATION 1. MATERIAL 1) CERAKWOOL BULK FIBERS 5 2) CERAKWOOL 1300 BLANKET 7 3) CERAKWOOL 1100 FELT 10 4) CERAKWOOL HTZ-BLANKET 13 5) CERAKWOOL HARD BOARD 16 6) CERAKWOOL WET FELT 19 7) CERAKWOOL 1300 PAPER 21 8) CERAKWOOL MODULE SYSTEM 23 9) CERAKWOOL VACUUM FORMED PRODUCTS 25 10) CERAKWOOL TEXTILE 26 11) CERAKWOOL 1300 ROPE 28 12) CERAKWOOL MOLDABLE 29 2. SUPPLEMENTARY MATERIAL 1) CERAKWOOL RIGIDIZER 31 2) CERAKWOOL BOND 32 3) CERAKWOOL COATING CEMENT 33 3. BIO-SOLUBLE CERAKWOOL 1100•1300 34 4. MARINE INSULATION MATERIAL (H - Class specification) 38 Ⅲ. CONSTRUCTION 1. MATERIAL USE 40 2. INSTALLATION OF CERAKWOOL LININGS 1) CERAKWOOL PAPER LINING 44 2) CERAKWOOL KH-MODULE LINING 54 3) CERAKWOOL K-MODULE LINING 57 4) CERAKWOOL STACK LINING 63 5) CERAKWOOL VENNER LINING 65 3. APPLICATION EXAMPLE 67 ➔ Ⅰ. INTRODUCTION Ⅰ. INTRODUCTION 1. INTRODUCTION OF CERAKWOOL “CERAKWOOL” the brand name of ceramic fiber manufactured by KCC Corporation is a high temperature, fireresistant material produced by Spinning Process, the most advanced technology for ceramic fiber of the best quality. KCC Corporation a global leading manufacturer and supplier of building & industrial materials, provides “CERAKWOOL” with confidence in excellent quality. “CERAKWOOL” by Spinning Process has superior tensile strength and other properties. 2. FEATURES 1. High heat-resistance : The maximum service temperature of CERAKWOOL is (1) CERAKWOOL 1300 BLANKET : 1,260 ℃ (2) CERAKWOOL HTZ BLANKET : 1,430 ℃ 2. Low thermal conductivity : Excellent heat-insulating property due to low thermal conductivity at high temperature. 3.Low heat storage : L  ow heat storage due to its lower density than that of refractory bricks reduces heat loss due to heat storage of furnace components. 4. Light weight : Its light weight and flexibility provide easy installation at any jobsite. 5.Chemical stability : CERAKWOOL made from highly pure silicate and alumina has superior resistance to chemical attack such as acids and alkalis. 6. Cost efficiency : Its excellent insulating property saves fuel costs and its reduction in installation time due to easy handling and application minimizes construction costs. Its easy maintenance offers cost efficiency. ➔ Ⅱ. PRODUCT INFORMATION 1. MATERIAL 1) CERAKWOOL BULK FIBERS CERAKWOOL BULK FIBER is a high temperature light weight ceramic bulk fiber ideal for use as a fill or packing material in a number of industrial applications it is made from alumina-silica fibers and can be used at temperatures ranging to 1,260-1,430 ℃ CERAKWOOL BULK FIBERS has excellent high temperature resistance thermal stability and resistance to vibration as well as outstanding low thermal conductivity and heat storage. CERAKWOOL BULK FIBER has the following outstanding properties which carry through the entire CERAKWOOL products line. ■ OUTSTANDING CHARACTERISTICS * Low thermal conductivity * Low heat storage * High temperature stability * Light weight * Excellent corrosive resistance ■ CHEMICAL PROPERTIES BULK FIBER exhibits excellent chemical stability resisting attack from most corrosive agents exceptions are hydrofluoric areas. * Roofs of furnaces and kilns * Expansion joints * Vacuum formed shapes * Kiln car tops * Packing and fast repairs in kilns and furnaces ● USE AS ASBESTOS REPLACEMENT. ● FIRE STOP IN BUILDINGS. ● LIGHT WEIGHT REFRACTORY FILL. ➔ 5 CERAKWOOL BULK FIBER insulation is used as a resilient fill or as packing material in numerous high temperature 4• ■ TYPICAL APPLICATIONS Technical Book 2013 and phosphoric acids and concentrated alkalies. CERAKWOOL BULK FIBER also resists oxidation and reduction. Ⅱ. PRODUCT INFORMATION ■ PHYSICAL PROPERTIES 1300 BULK HTZ-BULK Maximum service temperature 1,260 ℃ 1,430 ℃ Color White White Fiber diameter Ave 3 microns Ave 3 microns Fiber length Ave 200 mm Ave 200 mm Specific heat (at 1,000 ℃) 0.255 0.255 Specific gravity 2.55 2.72 CERAKWOOL BULK FIBER has a density of about 100 kg/㎥ as it comes from the carton. The packed density when installed will range between 130-160 kg/㎥. It is difficult to achieve a density more 160 kg/㎥ by hand packing thus the installed density will vary depending upon the force used. ■ STANDARD PACKAGE 1300, HTZ Bulk ..................... 15 kg/bag ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) ■ CHEMICAL ANALYSIS 1300 BULK HTZ-BULK Alumina Al2O3 47-49 % 34 % Silica SiO2 50-52 % 48 % ZrO2 16-20 % Trace inorganics 0.5 % 0.5 % Leachable chloride < 10 ppm < 10 ppm 2) CERAKWOOL 1300 BLANKET CERAKWOOL 1300 BLANKET is a low iron, high purity ceramic fiber blanket developed especially for use in highly reducing atmospheres. It is light weight, flexible and suitable for operating temperatures up to 1,260 ℃. CERAKWOOL 1300 BLANKET is a highly efficient insulator having low heatstorage capacity and complete resistance to damage from thermal shock. CERAKWOOL 1300 BLANKET has excellent resistance to oxidation and reduction and can withstand most corrosive agents. Hydrofluoric and phosphoric acids are exceptions. It has excellent strength, both hot and cold. If wet, steam or oil, thermal and physical properties remain unaffected after drying. Its sound absorption ability is greater than dense or insulating refractories and it stores some 95 % less heat than dense fire brick and about 75 % less than insulating brick. *R  emoval insulating blankets for field stress relieving * Glass furnace crown insulation welds * Reusable insulation for steam and gas turbines *H  eat treating furance with high percentages of hydrogen * High temperature pipe insulation * Soaking pit seals * Annealing cover seals * Thermal reactor insulation. * Investment casting mold wrappings * Expansion joint seals * Pressure and cryogenic vessel fire protection * Primary reformer header insulation * High temperature filtration * High temperature gasketing * Nuclear insulation application * Incineration equipment and stack lining 7 * Furance door linings and seals 6• * Furance, kiln and boiler linings Technical Book 2013 ■ TYPICAL APPLICATIONS Ⅱ. PRODUCT INFORMATION ■ OUTSTANDING CHARACTERISTICS *L  ow thermal conductivity * Resiliency *L  ow heat storage. *L  ight weight *T  hermal shock registance. *G  ood sound absorption * Excellent corrosion resistance * Easy to cut, wrap, or form *E  xcellent tensile strength. * Excellent hot strength ■ PHYSICAL PROPERTIES Color White Maximum service temperature 1,260 ℃ Melting point Above 1,760 ℃ Fiber diameter Ave. 3 microns Fiber length Ave 200 mm Specific heat at 1,000 ℃ 0.255 Specific gravity 2.25 Tensile strength #130 80-100 kpa ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) ■ PERMANENT LINEAR CHANGE(% Shrinkage) 24 Hours at 1,000 ℃ 1.6-1.8 % 1,100 ℃ 1.8-2.1 % 1,260 ℃ 2.4-3.0 % The permanent linear change in a 24 hour test is representative of the shrinkage that will be experienced in actual service. Four hour test data is not representative. ■ CHEMICAL ANALYSIS Alumina Al2O3 47-49 % Silica SiO2 50-52 % Trace inorganics 0.5 % Leachable chloride < 10 ppm ■ STANDARD SIZES Density kg/㎥ 100, 130, 160 Thickness mm 12.5, 25, 50 Width mm 610 Length mm 3,600, 7,200, 14,400 The different widths and lengths can be supplied subject to quantity and delivery requirement. ■ ACOUSTIC INSULATION 1,300 BLANKET acts as an efficient acoustic barrier at all temperatures up to its maximum use limit. The absence of chemical binding agents enables 1300 BLANKET to function as acoustic insulation in high temperature applications. It’s commonly used as a low temperature acoustic barrier in situations where it can perform a secondary 9 ➔ Technical Book 2013 function as a fire barrier. 8• FREQUENCY CYCLES PER SECOND Ⅱ. PRODUCT INFORMATION 3) CERAKWOOL 1100 FELT CERAKWOOL 1100 FELT is a more economical, less refractory, lightweight, flexible ceramic fiber blanket manufactured from thermally stable alumina-silica ceramic fibers. It is recommended for service to 1,100 ℃ in normal oxidizing conditions, making it an ideal material for lower temperature applications. Even the most extreme temperature changes will not affect the ability of CERAKWOOL 1100 FELT to insulate and stay in place. CERAKWOOL 1100 FELT stores some 95 % less heat than dense fire brick and approximately 75 % less than insulating brick. ■ OUTSTANDING CHARACTERISTICS * Fuel savings * Faster turn arounds * Lower construction costs * Easy to repair * Permits lighter furnace fabrication CERAKWOOL 1100 FELT demonstrates excellent strength, both hot and cold. Even after prolonged exposure to high temperatures it remains in place on the furnace lining anchors. It has good strength before heating, enabling it to resists damage when subjected to normal mistreatment in shipment and handling. ■ RESISTANCE OF CORROSIVE AGENTS Hydrofluoric and phosphoric acids and concentrated alkalies are exceptions. It also is resistant to oxidation and reduction. It CERAKWOOL 1100 FELT becomes wet from water, steam, or oil. Its thermal and physical properties are restored upon drying. Its sound absorption ability is greater than other dense or insulating refractories. ➔ ■ PHYSICAL PROPERTIES Color White Maximum service temperature 1,100 ℃ Melting point Above 1,700 ℃ Fiber diameter Ave. 3 microns Fiber length Ave 200 mm Specific gravity 2.5 Tensile strength #130 60-80 kpa ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) 900 ℃ 1.0-2.1 % 1,000 ℃ 2.4-3.0 % The permanent linear change in a 24 hour test is representative of the shrinkage that will be experienced in actual service. Four hour test data is not representative. 11 0.5-0.8 % 10• 24 Hours at 800 ℃ Technical Book 2013 ■ PERMANENT LINEAR CHANGE(% Shrinkage) Ⅱ. PRODUCT INFORMATION ■ CHEMICAL ANALYSIS Alumina Al2O3 46-49 % Silica SiO2 50-52 % Trace inorganics 0.5 % Leachable chloride < 10 ppm ■ STANDARD SIZES Density kg/㎥ 100, 130, 160 Thickness mm 12.5, 25, 50 Width mm 610 Length mm 3,600, 7,200, 14,400 The different widths and lengths can be supplied subject to quantity and delivery requirement. ■ ACOUSTIC INSULATION 1100 FELT acts as an efficient acoustic barrier at all temperatures up to its maximum use limit. The absence of chemical binding agents enables 1100 FELT to function as acoustic insulation in high temperature applications. It’s commonly used as a low temperature acoustic barrier in situations where it can perform a secondary function as a fire barrier. FREQUENCY CYCLES PER SECOND ➔ 4) CERAKWOOL HTZ BLANKET CERAKWOOL HTZ BLANKET is a high temperature, lightweight, flexible ceramic fiber blanket suitable for temperatures up to 1,430 ℃ in nominal oxidizing conditions. It is manufactured from highest quality thermally stable alumina-silica fibers that remain a soft fibrous structure right up to its maximum recommended usage point. CERAKWOOL HTZ BLANKET was developed to meet the demand for a high temperature, yet lightweight, insulation for use in modern industrial applications. It has high temperature resistance, thermal stability, and resistance to vibration and physical abuse. It has excellent strength, both hot and cold. Even after prolonged exposure to high temperatures it remains in place on the furnace anchors. Its sound absorption ability is greater than other dense or insulating refractories, and it stores some 95 % less heat than dense fire brick and about 75 % less than insulating brick. ■ CHEMICAL PROPERTIES CERAKWOOL HTZ BLANKET exhibits excellent resistance to most corrosive agents. Hydrofluoric and phosphoric acids and concentrated alkalies are exceptions. It is resistant to oxidation and reduction. If HTZ BKANKET becomes wet from * Thermal shock resistance * Low thermal conductivity * Good sound absorption * Low heat storage * Good strength * Light weight * Extremely low shrinkage * Easy to cut, wrap, or form * Excellent corrosion resistance * Resiliency 13 * 1,430 ℃ Temperature limit 12• ■ OUTSTANDING CHARACTERISTICS Technical Book 2013 water, steam, or oil, its thermal and physical properties are restored upon drying. Ⅱ. PRODUCT INFORMATION ■ PHYSICAL PROPERTIES Color White Maximum service temperature 1,430 ℃ Melting point Above 1,950 ℃ Fiber diameter Ave. 3 microns Fiber length Ave 200 mm Specific gravity 2.72 Specific heat at 1,000 ℃ 0.26 Tensile strength #130 70-100 kpa ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) ■ PERMANENT LINEAR CHANGE(% Shrinkage) 24 Hours at 1,200 ℃ 2.0-2.5 % 1,300 ℃ 2.5-3.2 % 1,430 ℃ 3.5-4.0 % The permanent linear change in a 24 hour test is representative of the shrinkage that will be experienced in actual service. Four hour test data is not representative. ➔ ■ CHEMICAL ANALYSIS Alumina Al2O3 34 % Silica SiO2 48 % ZrO2 16-20 % Trace inorganics Less than 0.5 % Leachable chloride < 10 ppm ■ STANDARD SIZES Density kg/㎥ 100, 130, 160 Thickness mm 12.5, 25, 50 Width mm 610 Length mm 3,600, 7,200, 14,400 The different widths and lengths can be supplied subject to quantity and delivery requirement. ■ TYPICAL APPLICATIONS * High temperature kilns and furnaces * Refractory kilns * Billet and slab reheat furnaces * Boiler linings * Forge furnaces * Furnace door linings and seals * Soaking pit seals * Incineration equipment 15 14• ➔ Technical Book 2013 * Glass furnace crown insulation Ⅱ. PRODUCT INFORMATION 5) CERAKWOOL HARD BOARD CERAKWOOL HARD BOARD is a light-weight, refractory material processed form alumina-silica ceramic fibers formed into a predetermined size and thickness. It is especially noted for having low thermal conductivity and exceptionally good handling strength. It’s highly uniform structure assures equal thermal conductivity throughtout HARD BOARD is easily machined, drilled, sawed and fabricated. ■ CHEMICAL PROPERTIES CERAKWOOL HARD BOARD in inert to most chemicals with the exception of hydrofluoric acid, phosphoric acids and concentrated alkalies. If it becomes wet due to water, oil, or steam, its thermal and physical properties will return as soon as the material is throughly dried. ■ OUTSTANDING CHARACTERISTICS * Low thermal conductivity * Low heat storage * Thermal shock resistance * Stability at high temperature * Light weight * High heat reflectance * Good dielectric strength * Excellent corrosion resistance * Easily cut, trimmed, and fitted ➔ ■ TYPICAL APPLICATIONS * Combustion chamber linears * Backup insulation for brick and castables * High temperature gaskets an seals * Non ferrous molten metal throughs and pan linings * High gas velocity furnaces and kiln linings * Incineration equipment, boiler, and stack linings * Carbon bake and reverberatory furnace expansion joints ■ PHYSICAL PROPERTIES 1300 HARD BOARD HTZ-HARD BOARD White White 1,260 ℃ 1,430 ℃ Melting point Above 1,760 ℃ Above 1,790 ℃ Nominal density 250, 300 kg/㎥ 250, 300 kg/㎥ 5.9 kg/㎠ 5.9 kg/㎠ @10 % deformation 4 kg/㎠ 4 kg/㎠ @25 % deformation 6 kg/㎠ 6 kg/㎠ 5-6 % 4-5 % Color Maximum service temperature Modulus of rupture Compressive strenght (#300) Ignition loss ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature .30 .25 .10 .05 0 400 600 800 → Mean temperature (℃) 1,000 1,200 ℃ 17 .15 16• kcal mh ℃ ↑ Technical Book 2013 .20 Ⅱ. PRODUCT INFORMATION ■ PERMANENT LINEAR CHANGE(% Shrinkage) 1300 H/B HTZ-HARD BOARD 24 Hours at 1,000 ℃ 1.6-2.0 % - 1,100 ℃ 2.0-2.4 % - 1,260 ℃ 4.0-4.5 % - 1,300 ℃ - 2.0-2.5 % 1,430 ℃ - 2.8-3.6 % The permanent linear change in a 24 hour test is representative of the shrinkage that will be experienced in actual service. ■ CHEMICAL ANALYSIS 1300 H/B HTZ-HARD BOARD Alumina Al2O3 44-46 % 34 % Silica SiO2 54-56 % 48 % 14-16 % ZrO2 Iron oxide Fe2O3 Less than 0.2 % Less than 0.2 % Trace inorganics Less than 1.0 % Less than 1.0 % ■ STANDARD SIZES Density kg/㎥ 250, 300 Thickness mm 12.5, 25, 50 Width mm 600 Length mm 900 The different widths and lengths can be supplied subject to quantity and delivery requirement. ➔ 6) CERAKWOOL WET FELT CERAKWOOL WET FELT is made from alumina-silica fiber blanket and inorganic bonding agent. flexibility makes it highly moldable. Upon air-drying the inorganic binder is activated and the fiber becomes rigid. CERAKWOOL WET FELT is ideal for insulation of complex shapes and for service under conditions of high hot gas velocities. ■ CHEMICAL PROPERTIES CERAKWOOL WET FELT resists oxidation, reduction, and attack from most corrosives except hydrofluoric acids, phosphoric acids and heavy alkali concentration. It permits rapid heat-ups and cool-downs never before possible, because it will not spall or crack from thermal shock. ■ OUTSTANDING CHARACTERISTICS ■ TYPICAL APPLICATIONS * Flexibility to fit most configurations * Fire protection for ships and railroad tankers * Light weight for easy handling * Pipe wrapping for both insulation and noise * Easily cut or trimmed reduction * Easily impaled over studs * Hot gas duct, flue and stack lining * Contains no asbestos * Combustion chamber linings * Low thermal conductivity * Reformer header insulations * Low heat storage * Process furnace tube weld protection * Excellent noise reduction properties White Maximum service temperature 1,260 ℃ Melting point Above 1,760 ℃ Nominal density (after dried) 450 ㎏/㎥ Specific heat (At 1,000 ℃) 2.7 kcal/㎏℃ Tensile strength 6 mm thk.(dry) 410 kpa PACKAGED in a clear polyethylene bag to retain the wet binder during shipment at storage. Curing of product can be accomplished by air drying for one or two days or by immediate temperature exposure in the application. Curing is merely a function of removal of the water in the inorganic binder. 19 Color 18• ■ PHYSICAL PROPERTIES Technical Book 2013 * Excellent thermal shock resistance Ⅱ. PRODUCT INFORMATION ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) ■ PERMANENT LINEAR CHANGE(% Shrinkage) 24 Hours at 1,000 ℃ 1.6-2.0 % 1,100 ℃ 2.0-2.5 % 1,260 ℃ 3.5-4.5 % The permanent linear change in a 24 hour test is representative of the shrinkage that will be experienced in actual service. Four hour test data is not representative. ■ CHEMICAL ANALYSIS Alumina Al2O3 40-45 % Silica SiO2 60-55 % Iron oxide Fe2O3 Less than 0.3 % Trace inorganics Less than 0.4 % ■ STANDARD SIZES Density kg/㎥ 450 Thickness mm 6, 12.5, 25 Width mm 600 Length mm 900 The different widths and lengths can be supplied subject to quantity and delivery requirement. 7) CERAKWOOL 1300 PAPER CERAKWOOL 1300 PAPER is a lightweight refractory material processed from alumina-silica ceramic fibers formed into a flexible sheet. It is recommended for continuous use at temperatures up to 1,260 ℃. It is clean and efficient, contains no unfiberized shot. It is especially noted for having exceptional conductivity and good handling strength. Its highly uniform structure assures equal thermal conductivity throughout and its clean, smooth surface makes it ideal as a gasket, seal, and spacer material. CERAKWOOL 1300 PAPER contains an organic binder to provide increased handling strength. It possesses excellent chemical stability resists attack from most corrosive agents. Hydrofluoric and phosphoric acids and concentrated alkalis are exceptions. It also resists oxidation and reduction. * Combustion chamber linears * Temperature stability * Back-up lining for metal through * Low thermal conductivity * High temperature gaskets * Low heat storage * Parting agent in brazing, heat treating, and metal * Light weight forming process * Resiliency * Thermal and electrical insulation * Thermal shock resistance * Blast furnace blow pipe insulation * High heat reflectance * Coke oven door shock absorption medium * Good dielectric strength * Hot top linings * Excellent corrosion resistance 21 * Easy to cut, wrap, or form Technical Book 2013 ■ TYPICAL APPLICATIONS 20• ■ OUTSTANDING CHARACTERISTICS Ⅱ. PRODUCT INFORMATION ■ PHYSICAL PROPERTIES Color White Maximum service temperature 1,260 ℃ Melting point Above 1,700 ℃ Nominal density 180 ㎏/㎥ Nominal thickness, mm 1, 2, 3, 5 Tensile strength 400 kpa Ignition loss 7-8 % ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) ■ CHEMICAL ANALYSIS OF FIBERS(% by weight, binder free) Alumina Al2O3 50-52 % Silica SiO2 47-49 % ■ STANDARD SIZES Density kg/㎥ Thickness mm Width mm Length mm 180 1 2 3 5 20,000 40,000 600 8,000 12,000 The different widths and lengths can be supplied subject to quantity and delivery requirement. If CERAKWOOL 1300 PAPER becomes wet due to water, steam, or oil, its thermal and physical properties will return as soon as the material is thoroughly dried. No water of combination is present. 8) CERAKWOOL MODULE SYSTEM CERAKWOOL MODULE SYSTEM is a block-type product which is compressed over 30 % after folding CERAKWOOL BLANKET with automatic folding machine and inserting anchoring system in it. ■ TYPICAL APPLICATIONS * Iron and steel : Heating furnace, Heat treatment furnace * Nonferrous metal : Aluminum heat treatment furnace * Ceramic : Baking furnace, Annealing furnace * Petrochemical : Naphta analyzing furnace, Reformer ■ FEATURE OF MODULE SYSTEM K-Module (A.I.U TYPE) Veneer Module (I TYPE) It has two kinds of type, Direct Welding Type that Module containing anchor system saves the installing time without marking process and individual module type that stud bolts are prewelded for back-up use. The separation between Module and Anchor provides easy application to the corners and complicated parts. CERAKWOOL VENEERING MODULE provides a fast and simple technique for insulating many types of heat processing equipment. It can be used as the total lining or as a veneer in units already having a refractory lining in satisfactory condition with Cerakwool Bond. Technical Book 2013 (A TYPE) 23 KH-Module Feature 22• Item Ⅱ. PRODUCT INFORMATION ■ THERMAL CONDUCTIVITY Thermal conductivity vs. mean temperature kcal mh ℃ ↑ → Mean temperature (℃) ■ PHYSICAL PROPERTIES KH/K MODULE VENEER MODULE 1300 Module HTZ Module 1300 V-Module HTZ V-Module Color White White White White Maximum service temperature 1,260 ℃ 1,430 ℃ 1,260 ℃ 1,430 ℃ Nominal density 170 ㎏/㎥ 170 ㎏/㎥ 170 ㎏/㎥ 170 ㎏/㎥ 1,100 ℃ 0.5 % 0.2 % 1,260 ℃ 2.5 % 1.2 % Linear shrinkage 1,430 ℃ 2.5 % ■ STANDARD SIZES KH/K MODULE VENEER MODULE 1300 Module HTZ Module V-Module Thickness mm 50-300 50-300 50, 75, 100 Width mm 300 300 300 Length mm 300 300 300 The different width and lengths can be supplied subject to quantity and delivery requirement. ➔ 9) CERAKWOOL VACUUM FORMED PRODUCTS CERAKWOOL VACUUM-FORMED PRODUCTS are formulated from a blend of high purity alumina-silica ceramic fibers with an appropriate combination of organic and inorganic binders. Handling strength is provided by the organic binder, while product integrity at high working temperature is maintained by the inorganic binder. Maximum use temperature for the standard formulation is 1,260 ℃. ■ CHEMICAL PROPERTIES CERAKWOOL VACUUM FORMED SHAPES is inert to most chemicals with the exception of hydrofluoric acids, phosphoric acids and concentrated alkalies. If it becomes wet due to water, oil, or steam, its thermal and physical properties will return as soon as the material is throughly dried. ■ OUTSTANDING CHARACTERISTICS ■ TYPICAL APPLICATIONS * Low thermal conductivity * Combustion chambers for oil and gas fired heating boilers * Low heat storage * Gaskets * Excellent thermal shock resistance * Flue linears * Stability at high temperature * Tap-out cones for aluminum furnaces * Light weight for easy handling * Tundish linear boards and hot tops for nonferrous metals * Non wetting by nonferrous molten metals * Riser sleeves * Good dielectric strength * Electric range burner insulation * Asbestos free * Giant rings to line aluminum crucible furnaces White 1,260 ℃ Melting point Above 1,760 ℃ Nominal density ㎏/㎥ 150-600 Typical chemical analysis of fibers (% by Weight, binder free) Alumina, Al2O3 50-52 % Silica, SiO2 47-49 % 25 Color Maximum service temperature 24• ■ PHYSICAL PROPERTIES Technical Book 2013 * Easily cut, trimmed, and fitted Ⅱ. PRODUCT INFORMATION 10) CERAKWOOL TEXTILE CERAKWOOL TEXTILES are noted for superior insulating ability to 1,260 ℃. These products have excellent resistance to thermal shock, corrosive attack and breakdown due to mechanical vibration and stress. CERAKWOOL TEXTILE product forms are unique high temperature fabrics useable in a wide variety of industrial applications. These are made from long staple CERAKWOOL BULK FIBER and 15-20 % organic fiber as a carrier fiber. A blend of long staple fibers and organic carrier fibers, CERAKWOOL TEXTILES are an excellent choice where a flexible, strong temperature resistant product is required. All TEXTILES contain 15-20 % organic fiber added during the carding process to produce roving. The roving is further processed into two-ply yarn for weaving into CERAKWOOL TAPE, CLOTH and SLEEVING. Insert material are incorporated into the CERAKWOOL YARN to increase fabric tensile strength. Alloy wire inserts are available for obtaining maximum strength at elevated temperatures. Glass filament inserts are used in applications where metal is undesirable as in the case when using CERAKWOOL TEXTILES as a dielectric. These may be used to 1,260 ℃ in applications where tensile strength is not important. ■ TYPICAL APPLICATIONS * Fuel line insulation * Furnace heat zone separators * Cable and wire insulation * Infrared radiating diffusers * Gasket and wrapping material * Induction heating furnace coil insulation * High pressure steam portable flange covers ■ CHARACTERISTICS OF WOVEN TEXTILES Type Temperature (Limit of insert) Insert material Weave GF 650 ℃ Glass filament Twill or Plain SS 800 ℃ Stainless steel wire - FC 1,100 ℃ Fe-Cr wire - IN 1,200 ℃ Inconel wire - ■ PHYSICAL PROPERTIES Thickness (mm) 2 Tensile strength (kgf/25 mm) 20 Loss on ignition (WT %) 20 (1,000 ℃) ■ CONSTITUTION OF CERAKWOOL TEXTILES YARN Insert material Diameter Packing unit Glass filament 2, 3 mm 1 kg/m (1 g/m) Inconel wire 2, 3 mm 1 kg/m (1 g/m) CLOTH Thickness (mm) 2, 3 Width (mm) 1,000 Length (mm) 30,000 Thickness (mm) 2, 3 Width (mm) 25, 50, 75, 100 Length (mm) 30,000 27 ➔ 26• The different widths and lengths can be supplied subject to quantity and delivery requirement. Technical Book 2013 TAPE Ⅱ. PRODUCT INFORMATION 11) CERAKWOOL 1300 ROPE ■ TWIST ROPE CERAKWOOL TWIST ROPE is a twisted three-ply rope manufactured from CERAKWOOL long staple fibers. It contains 15 to 20 % organic carrier fiber to facilitate the carding process and impact mechanical strength. The carrier fiber burns out at a low temperature, but this has no affect on the properties of the CERAKWOOL itself. CERAKWOOL TWIST ROPE is a dense, resilient, high temperature refractory processing the thermal properties and chemical stability common to all CERAKWOOL product forms. ■ BRAID ROPE CERAKWOOL BRAID ROPE is comprised of high strength CERAKWOOL BLANKET STRIP, twisted and wound with a cordage to achieve a round, compacted rope product. The inherent strength of the base constituent, CERAKWOOL BLANKET STRIP, is sufficient to eliminate the need for textile process, woven ropes in most application. ■ TYPICAL APPLICATIONS * * * * * * * * ■ STANDARD PACKAGE Glass furnace tuckstone seal Skid rail insulation Expansion joint packing in boilers & furnaces Furnace door seal Hot top seal Car deck seal Gasket, flange packing Seal for pressurized atmosphere furnaces Diameter (mm) Length/Roll 6 90 m 12 60 m 25 30 m 40 12 m 50 10 m ■ PHYSICAL PROPERTIES Twist rope Braid rope-G Braid rope-A 1,260 ℃ 1,260 ℃ 1,260 ℃ Braided material - Glass yarn SUS 304 wire Density (kg/㎥) 130-160 130-160 130-160 Diameter (mm) 6-50 6-50 6-50 Maximum service temperature 12) CERAKWOOL MOLDABLE CERAKWOOL MOLDABLE is easy to install. Directly from the pail it can be installed in thicknesses from 3 mm up to 100 mm thickness over existing refractory or directly applied to metal surfaces. It is applied by hand using rubber gloves-kneaded, patted, or smeared into place and then smoothed and shaped with a trowel or putty knife. ■ OUTSTANDING CHARACTERISTICS * Non-wetting to molten aluminum and other non ferrous metals * Will stick to most any surface * Lightweight, good insulator * High strength * Excellent thermal shock resistance * Excellent workability * Excellent compressibility Small ladle lining, ladle maintenance Die cast dipping wells Tap holes, pot line ladle seals Carbon bake furnace fuel caps Void fills of all kinds 29 Throughs, runners, distribution pans 28• * ALUMINUM and NON-FERROUS Technical Book 2013 ■ TYPICAL APPLICATIONS Ⅱ. PRODUCT INFORMATION * HYDROCARBON PROCESSING Reformer and heater tube seals Filling cuplocks on CERAKWOOL LINING Flue and ductwork linings or expansion joint Filling voids around burnerblocks and access doors * HEAT TREATING, KILNS, BOILERS Flue stack linings and repairs Void fills-cracks and patching Door and burner seals * IRON AND STEEL Coke oven standpipe and door seals Expansion joints for reheat and other furnaces Crack and void fill throughout the plant ■ PHYSICAL PROPERTIES Color Off-White Recommended temperature For maximum service temperature 1,260 ℃ For cuplocks and void fills 1,340 ℃ Nominal density(after drying) 450, 700 Permanent linear shrinkage Heated at 1,100 ℃ and then cooled Quantity required for installation 2.7-3.2 % 1,400-1,600 kg/㎥ NOTE : Store in 5-25 ℃ room. ■ STANDARD PACKAGE 25kg/can ➔ 2. SUPPLEMENTARY MATERIAL 1) CERAKWOOL RIGIDIZER CERAKWOOL RIGIDIZER is a colloidal silica compound dispersed in water, which is used as a surface treating agent to increase hardness, erosion-resistance, flame-resistance and gas permeability of CERAKWOOL materials. It is easily applied by employing standard brushing, spraying, dipping, techniques. It contains a wetting agent for better saturation of the substrate. CERAKWOOL RIGIDIZER shall be diluted with water to a suitable viscosity for each application technique as applied. ■ TYPICAL APPLICATIONS *E  rosion resistant surface for CERAKWOOL BLANKET, FELT, BOARD and MODULE… furnace linings exposed to high -velocity gases. * Bonding agent in the manufacture of CERAKWOOL composites and laminated. * Structural hardening agent for CERAKWOOL PAPER, BLANKET, and BOARD. ■ PHYSICAL PROPERTIES Specific gravity Solid content Viscosity, CPS (25 ℃) PH 1,500 ℃ 1.2 30 ~ 40 % 6 9 Composition Colloidal silica Quantity required for installation 0.5-1.0 kg/㎡ NOTE : Store in 5-25 ℃ room. 30• Repeated freezing may damage it. Technical Book 2013 For maximum service temperature Transparent liquid 31 Appearance ■ STANDARD PACKAGE 20kg/can Ⅱ. PRODUCT INFORMATION 2) CERAKWOOL BOND CERAKWOOL BOND has been expecially developed for CERAKWOOL MODULE applications to walls of furnaces in use and as an undercoat for MOLDABLE lining. It is a pre-mixed refractory bonding mortar, with high strength and excellent erosion and abrasion resistance. CERAKWOOL BOND attains high strength upon air setting at room temperature and expands and contracts with temperature change. Other features include, slag resistant, spall resistant, virtually no shrinkage. When MODULES are to be used as a complete lining, they can be mortared with CERAKWOOL BOND to expanded metal which has been tack welded to the steel shell. This prevents any metal hardware from being exposed to the furnace environment. ■ TYPICAL APPLICATIONS * Adhering MODULE to refractory * Adhering BLANKET to refractory * Adhering BLANKET to BLANKET ■ PHYSICAL PROPERTIES Color Brown For maximum service temperature 1,500 ℃ Bonding strength, ㎏/㎠, fired and cooled 125 ℃ 91.4 540 ℃ 77.3 1,000 ℃ 77.3 Al2O3 52 % SiO2 44 % Fe2O3 0.2 % Others 3.6 % Chemical analysis Quantity required for installation (3 mm thk.) NOTE : Store in 5-25 ℃ room. ■ STANDARD PACKAGE 25kg/can 6-8 kg/㎡ 3) CERAKWOOL COATING CEMENT CERAKWOOL COATING CEMENT is especially formulated for coating or bonding CERAKWOOL products. The inorganic binder provides an irreversible bond which will not soften in the presence of moisture. It dry to a hard surface which is resistant to erosion and flame abrasion. It help prevent substrate material from spalling because of its insulating efficiency and inherent resistance thermal shock. Its excellent chemical resistance to wetting by many nonferrous molten metals, enables the cement to be used as a protective coating for a wide variety of porous and nonporous materials. ■ TYPICAL APPLICATIONS * Module lining adhesive for CERAKWOOL paper used with high purity metals and glass. * Flame resistant coating for CERAKWOOL linings of domestic oil-fired combustion chambers. * Electronics potting compound. * Oxidation resistant coating for chlorine injection tubes and graphite crucibles. * Corrosion barrier for aluminum dip tubes, cast iron thermocouple tube and galvanizing tanks. * Electrical insulation for counter-top stove heating elements * Infrared radiating surface for heating elements. For maximum service temperature 1,260 ℃ Specific gravity 1.5 Nominal shelf life 3 months Quantity required for installation 3-4 kg/㎡ NOTE : Store in 5-25 ℃ room. Repeated freezing may damage it. ■ STANDARD PACKAGE 20kg/can 33 White paint 32• Appearance Technical Book 2013 ■ PHYSICAL PROPERTIES Ⅱ. PRODUCT INFORMATION 3. BIO-SOLUBLE CERAKWOOL 1100·1300 KCC CERAKWOOL New-Bio is high temperature, fire-resistant insulation material manufactured by Spinning Process with high purity of Calcium, Magnesium, Silicate. It can be applicable to ship building industry, various marine structure and other general industry. KCC CERAKWOOL New-Bio is safe insulation material to human body and it successfully passed Europe Animal Test. (EU directive 67/548 EWG & German TRGS 905) It’s fiber can be quickly soluble and exhausted from human body even after inhalation. ■ OUTSTANDING CHARACTERISTICS * Exonerated from carcinogenic classification under EC and restriction under German regulation * Low thermal conductivity * Low heat storage * Easy to cut, wrap, or form ■ KCC CERAKWOOL New-Bio CERAKWOOL New- Bio 1100 Chemical Analysis CERAKWOOL New- Bio 1300 SiO₂ 58-67 % 75-80 % 10-14 % CaO 26-34 % MgO 2-8 % 4-9 % Etc. 0-4 % ‹ 1.5 % Al₂O₃ ‹1% Maximum service temperature 1,100 ℃ 1,260 ℃ Tensile strength (128K, ASTM C 209) › 50 kPa › 50 kPa at 1,100℃,24h ≤2% ≤1% at 1,260℃,24h - ≤3% Typical linear shrinkage ■ STANDARD SIZES Density (kg/㎥) 12.5 25 38 50 Width (mm) 610 610 610 610 Length (mm) 14,640 7,320 4,880 3,660 ➔ Technical Book 2013 15 kg/Bag 35 Bulk fiber Thickness (mm) 34• Blanket 64, 96, 100, 128, 130, 160 Ⅱ. PRODUCT INFORMATION ■ THERMAL CONDUCTIVITY (ASTM C 201) Thermal conductivity vs. mean temperature Biosoluble CerakWool 1100 96K mean Temp℉ mean Temp℃ Thermal Conductivity,W/mK 200 93.3 0.038 400 204.4 0.058 800 426.7 0.110 1200 648.9 0.183 1600 871.1 0.284 mean Temp℉ mean Temp℃ Thermal Conductivity,W/mK 200 93.3 0.039 400 204.4 0.056 800 426.7 0.102 1200 648.9 0.164 1600 871.1 0.243 [Biosoluble Cerakwool 1100 96K] Biosoluble CerakWool 1100 128K [Biosoluble Cerakwool 1100 128K] Biosoluble CerakWool 1300 128K [Biosoluble Cerakwool 1300 128K] mean Temp℃ Thermal Conductivity,W/mK 200 0.058 400 0.097 600 0.154 800 0.231 1,000 0.338 ■ BIO-PERSISTENCE TEST Certificate authority : Fraunhofer ITEM(German) Target : Lower durability in-vivo condition / Higher durability in use condition Technology : Glass composition research / Production process development Sucess : Successful animal test result / Getting the EU certificate of safety * Fiber dissolution * Animal test of fibers ■ CERTIFICATES OF BIO-PERSISTENCE TEST 37 Technical Book 2013 BIO-CERAKWOOL 1300 36• BIO-CERAKWOOL 1100 Ⅱ. PRODUCT INFORMATION ■ MARINE INSULATION MATERIAL (H-CLASS SPECIFICATION) Bulkhead H-60 Deck H-120 Insulating Thickness Product Item Bulkhead Deck Palte/Stiffener, mm 50+50/50+50 CERAKWOOL Bio_ Marine 1100 96K 38+38/38+38 50+38+38/50+38+38 CERAKWOOL Bio_ Marine 1100 96K ,128K 50+38/50+38 H-60 Bulkhead Cerakwool Bio-Marine packed into stiffner Fire Either side Anchor 50mm From blanket edge 50mm x 96kg/㎥ KCC Cerakwool blanket Second Layer First Layer H-60 Deck Cerakwool Bio-Marine packed into stiffner Fire Insulation side Anchor 50mm From blanket edge 38mm x 96kg/㎥ KCC Cerakwool blanket Second Layer First Layer H-120 Bulkhead 25mm x 128kg/㎥ KCC Cerakwool Blanket Fire Either side Anchor 50mm From blanket edge 38mm x 96kg/㎥ KCC Cerakwool Bio- marine Blanket 38mm x 128kg/㎥ KCC Cerakwool Bio- marine Blanket 50mm x 128kg/㎥ KCC Cerakwool Bio- marine Blanket H-120 Deck Fire Insulation side Anchor 50mm From blanket edge ➔ 38mm x 96kg/㎥ KCC Cerakwool Blanket 50mm x 96kg/㎥ KCC Cerakwool Blanket H-120 Bulkhead (DNV) Technical Book 2013 H-120 Deck (DNV) 39 H-60 Bulkhead (DNV) 38• H-60 Deck (DNV) Ⅲ. CONSTRUCTION Ⅲ. CONSTRUCTION 1. MATERIAL USE A typical furnace lining of the commonly used “layer” construction is made up of CERAKWOOL BLANKET and less expensive back-up insulation. The lining selection is generally dependent on four factors : 1. The maximum furnace temperature to which the lining will be subjected. 2. The desired temperature of the shell or cold face. 3. The velocity of the gas inside the furnace. 4. The furnace atmosphere and the fuel which will be used. After the above four factors are known, these further decisions can then be made : 1. T  he first thing to the decide is the hot face material to be used. Generally 130 ㎏/㎥ density is recommended for all hot face layers. Depending on what the temperature will be, a selection of CERAKWOOL BLANKET or CERAKWOOL HTZ BLANKET will be used. CERAKWOOL BLANKET should be selected for temperatures up to 1,260 ℃, If temperatuers exceed 1,260 ℃-up to 1,430 ℃-CERAKWOOL HTZ BLANKET should be used. To be considered in this selection is the tendency of all ceramic fiber to shrink at temperatures above 985 ℃. This shrinkage is taken into account by design. 2. T  he decision can now be made as to what material is to be used behind the hot face. This question is dependent upon the desired temperature of the shell or cold face. Normally, an economic balance of lining thickness can be achieved by using a rule of thumb that the cold face be designed for 10 % of the hot face. If this does not meet the criteria selected, additional layers can be added or subtracted or a change in the density of each layer can be made. This is to say that if a typical lining of does not meet the customer’s needs, consider the following change. ➔ The addition of 25 mm of #130. reduces the cold face to 76 ℃. or, changing the density of the layers as shown below reduces the cold face to 79 ℃. ➔ Technical Book 2013 76 ℃ Cold Face Heat Loss of 559 kcal/㎡h 41 985 ℃ Hot face 84 ℃ Cold Face Heat Loss of 673 kcal/㎡.h 40• 985 ℃ Hot Face Ⅲ. CONSTRUCTION 79 ℃ Cold Face Heat Loss of 605 kcal/㎡h 985 ℃ Hot face 3. T  he next factor to be considered-the velocity of the gas inside the furnace-is one of importance. CERAKWOOL FELT, CERAKWOOL 1300 BLANKET, or CERAKWOOL HTZ-BLANKET in the 130 ㎏/㎥ range will perform quite satisfactorily on the hot face layer at velocities created under normal combusion conditions. If the velocity should exceed 10 m/second, an application of RIGIDIZER can be sprayed or brushed on. A pressure atomizing gun is ideal for applying RIGIDIZER and should be applied to get a penetration of approximately 3-4 mm. In addition, care should be taken to run the blankets aprallel to these velocities. The surface is much more resistant to velocities than an exposed edge. See Figure D-1. VELOCITY DIRECTION GAS FLOW FIGURE D-1 With the rigidizer applied, the blanket will withstand velocities up to approximately 25 m/second * AT 900 ℃ Product CERAKWOOL BLANKET #130 Velocity (m/sec) 0-10 CERAKWOOL BLANKET #130 with RIGIDIZER 10-25 CERAKWOOL HARD BOARD 25-33 NOTE : O  ver 1,000 ℃ these numbers will decrease. Please contact CERAKWOOL ENGINEERING DIVISION for velocity resistance at elevated temperatures. These numbers are for clean air containing no particulate. The last factor to consider for the lining selection is the furnace atmosphere and the fuel which will be used. CERAKWOOL FELT, CERAKWOOL BLANKET, and CERAKWOOL HTZ-BLANKET are suitable for all furnaces burning in normal atmospheres(i.e.light oil or natural gas). When heavier fuels are burned(i.e.low grade crude), caution must be taken to protect the anchoring system. The use of CERAKWOOL BLANKET, and CERAKWOOL HTZ-BLANKET in reducing atmospheres is acceptable in many cases, provided the temperature limitations of the material are observed. Endothermic atmospheres, which are common in the heat treating industry, can reduce metal or metal oxide at about 650 ℃ therefore, the use of CERAKWOOL 1300 BLANKET, a high purity ceramic fiber, should be recommended for the hot face layer. CERAKWOOL HTZ-BLANKET, a high purity blanket by nature, may also be used in this application. The use of Inconel 601 studs and ceramic cuplocks should be incorporated to prevent carbon absorption and 43 42• ➔ Technical Book 2013 embrittlement. Ⅲ. CONSTRUCTION 2. INSTALLATION OF CERAKWOOL LININGS 1) CERAKWOOL PAPER LINING Once determination of the stud pattern has been made, the first step in the installation is to lay out the pattern on the furnace shell. Start the stud pattern in a corner, taking the lining thickness of the adjacent wall into consideration. Starting from the corner, measure 75 mm plus the lining thickness out from the wall and down from the roof. This properly locates the edge row of anchors and prevents them from being buried. It also provides working areas between opposing studs located at the corners. The same procedure is followed at each corner location. Since almost all studs run in vertical and horizontal rows, it is necessary only to measure and mark the perimeter of the area to be lined. A chalk line is then snapped across the corresponding points vertically and horizontally, resulting in a grid whose points of intersection are the placement points for the studs. See Figure D-2. Additional studs around burners, flue openings, and other apertures are desirable. After the stud pattern has been laid out on the steel shell, the studs are welded to the steel shell either with an automatic stud gun or by conventional welding methods. While manual welding can be done, it is slow and the potential for a defective weld is greater than with stud gun welding. STUD LAYOUT OVERHEAD FIGURE D-2 After the studs have been welded in place, the back-up insulation is impaled on the studs. To facilitate temporary retention of the back-up insulation, especially on a roof, sus 304 speed clips are installed over the studs. One speed clip for every fourth stud is sufficient on roofs. If cuplocks are used as retainers, speed clips cannot be used within 75 mm of the hot face since they will prevent proper installation of the cuplocks. In this situation, twine or rubber bands can be strung across the studs and left in place. This will hold the intermediate layers temporarily in place. Special consideration should be given to back-up insulation around burner blocks and other openings in the hot face lining so the hot gases cannot reach lower grade back-up insulations and cause deterioration. Most installations are more than one layer of back-up insulation. It is important that the joints on successive layers be staggered a minimum of 100 mm so that hot gases cannot be channeled back to the steel shell. See Figure D-3. STAGGERED LAYERS FIGURE D-3 Anchor patterns are based on the proper positioning of the studs with the exposed hot face layer of insulation without regard to the intermediate layers. When installing successive layers of material, care must be taken to insure that all joints are staggered by at least 100 mm and that the exposed hot face layer is properly positioned on the studs. When using alloy washers as the final retainer, place the washers on the washers on the studs and push in until the lining is compressed about 20 mm then lock into place. For higher temperature applications where ceramic cuplocks will be used, different techniques are required when installing hot face insulation. Since the stud will not protrude through the final layers, these layers cannot be impaled on the studs. Thus the blanket must be temporarily held in place until the cuplocks are installed. On sidewalls, the easiest method is to place the blanket in position, then stick small dowels through the entire lining at a 45° to 60° angle. The dowels can be any available material(i.e. welding rods, gutter nails, etc). Three or four dowels near the top of the vertical strip are normally sufficient to temporarily hold a 600 mm wide piece in place. If an additional layers is required, simply repeat the procedure, being sure to remove any metallic dowels from the under layer. See Figure D-4. When the final layers are temporarily secured, about 20 % of the cuplocks should be installed at random and the dowels removed. This same procedure can be used on a roof, although more dowels will be required over the entire surface of the strip. ATTACHING ADDITIONAL LAYERS FIGURE D-4 45 CERAKWOOL Felt and Blanket 44• CUPLOCK Technical Book 2013 NAIL OR DOWEL FOR TEMPORARY ATTACHMENT BE SURE TO REMOVE Ⅲ. CONSTRUCTION After the final layer of insulation is secured by about 20 % of the cuplocks, the remaining studs will not be visible on the surface. These studs can be located by pressing the lining in the general area of the stud. The point of the stud can be felt through the CERAKWOOL BLANKET. A knife blade is then inserted through the insulation, making the cross cut. Then slip the shank of the cuplock on the stud, push it back until the flange of the cuplock has compressed the lining slightly, and turn it 90 ℃, locking it in place. After the cuplocks are in place, the opening in the cuplock is then packed with CERAKWOOL BULK dipped in mortar. Pack the entire cuplock in this manner. In some installations it may not be practical to remove the brick lining from an existing furnace or kiln and replace it with fiber. An example of this is the classic bee hive kiln that does not have a steel shell. The fuel savings obtainable by the use of CERAKWOOL BLANKET are available to operators of this type of equipment simply by installing blanket over the hot face of the existing brick or castable. This approach, called veneering, is now widely accepted. Installing CERAKWOOL BLANKET over existing refractory linings gives reduced fuel consumption and faster cycles. Also, the service life of the existing refractory is increased as the brick or castable no longer reaches the full operating temperature of the kiln. Fuel consumption is reduced because of the reduction in heat loss through the walls and because the refractory section of the lining is not brought up to the operating temperature of the kiln, thereby requiring fewer calories. Heat-up time is reduced for the same reasons. Figures D-5 and D-6 show the method for laying CERAKWOOL BLANKET around an inside corner. LAP JOINT BLANKET INTERSECTION AT A CORNER CERAKWOOL Felt and Blanket METAL ANCHOR FIGURE D-5 BLANKET EXTENDING AROUND A CORNER CERAKWOOL Felt and Blanket METAL ANCHOR FIGURE D-6 Figure D-7 shows a method used to protect CERAKWOOL BLANKET joints against directional gas flow. GAS FLOW METAL ANCHOR 47 46• FIGURE D-7 Technical Book 2013 CERAKWOOL Felt and Blanket Ⅲ. CONSTRUCTION Figure D-8 and D-9 show methods used to lay CERAKWOOL BLANKET around a burner block. Figure D-8 details design when using all CERAKWOOL BLANKET. Figure D-9 details design when a fire brick support ledge is used. BURNER BLOCK SURROUNDED BY CERAMIC FIBER BLANKET CERKWOOL Felt and Blanket FIGURE D-8 BURNER BLOCK w / SUPERDUTY FIRERICK SUPPORT CERAKWOOL Felt and Blanket SUPERDUTY FIREBRICK 48• FIGURE D-9 49 Technical Book 2013 CERAKWOOL PAPER Ⅲ. CONSTRUCTION Figure D-10 shows the method for repairing an existing ceramic fiber blanket wall. PEPAIRING A DAMAGED WALL CERAKWOOL BLANKET REMOVE DAMAGED MATERIAL AND CLEAN DAMAGED AREA REPLACE WITH NEW MATERIALS AND COVER WITH AN EXTRA LAYER OF CERAKWOOL BLANKET FIGURE D-10 Figure D-11 and D-12 details the construction techniques for typical door seals. Figure D-11 details the use of CERAKWOOL BLANKET for a guillotine door. Figure D-12 details the use of CERAKWOOL BLANKET for a door face seal. BOTTOM SEAL FOR A GUILLOTINE DOOR CERAKWOOL Blanket CERAKWOOL Blanket METAL ANCHOR 25 mm MIN FIGURE D-11 TYPICAL DOOR SEAL CERAKWOOL Blanket FIGURE D-12 51 METAL ANCHOR 50• DOOR Technical Book 2013 WALL OR ROOF Ⅲ. CONSTRUCTION ■ CERAKWOOL PAPER LINING HEAT FLOW THK. (mm) INNER TEMP (℃) 700 800 900 1000 25 HTZ Blanket (#130) 1,300 Blanket (#130) 25 25 50 50 1,100 Felt (#100) 25 75 75 75 Mineralwool (#100) 50 50 50 50 Lining thk. (mm) 100 150 175 200 Surface temp. (℃) 68 61 67 72 Heat loss (Q) 490 441 678 544 Heat storage (H) 1,189 2,062 2,893 3,381 30 #1 ET 30 0 #1 NK 10 T LA T# E B K Z EL 0 N T H 10 LA LF L B O L# O L OO OO OO KW KW W A W L A R K A R CE RA ER CE CE MIN 1,000 ℃ 0 13 0 T# 10 KE 00 T# AN #1 L EL OL LB LF O O O O WO L W W A K K ER RA RA CE CE MIN 900 ℃ * Condition Ambient Temp. : 25 ℃ Emissivity : 0.9 Wind Velocity : 0 m/sec * Heat Loss(Q) : kcal/㎡h Heat Storage(H) : kcal/㎡ 0 13 0 T# 10 KE 00 T# AN #1 L EL OL LB LF O O O O WO L W W A K K ER RA RA CE CE MIN 800 ℃ 0 13 T # 100 # KE 00 AN ELT #1 L OL LB LF OO WOO WO L W A K K ER RA RA CE CE MIN 700 ℃ ➔ ■ ANCHORING SYSTEM FOR PAPER LINING * ROD TYPE Material SUS 304 SUS 310S INCONEL 601 Max. application temperature 800 ℃ 1,000 ℃ 1,200 ℃ 5.3 5.3 6 Diameter (mm) STUD Length (mm) 50, 75, 100, 125, 150, 175, 200, 225, 250, 300 Washer-nut Material : SUS 310S, Size : M6 (Ø 6 mm) × 38 mm Speed-clip Material : SUS 304, Size : 0.3 mm(T) × 38 mm * TWIST TYPE Material SUS 310S INCONEL 601 Thk.x Width (mm) 3.2 X 7 Length (mm) 75, 100, 125, 150, 175, 200, 225, 250 Speed clip Material : SUS 304, Size : 0.3 mm X 38 mm 53 Lock Washer (2 mm X 38 mm), Ceramic CUP-LOCK 52• Washer Technical Book 2013 STUD Ⅲ. CONSTRUCTION 2) CERAKWOOL KH-MODULE LINING INSTALLATION PROCEDURE FOR CERAKWOOL KH-MODULE LINING STEP 1 : ATTACH WELDING-STUD(BOLT) TO STEEL SHELL ON 300 mm CENTERS. (STUD GUN) Wall STEP 2 : PUSH BACK UP BLANKET OVER ANCHOR M8 (Ø 8 mm) Nut BASES THIS ACTS AS A SEAL TO REDUCE CHANCES OF STRAIGHT THRU JOINTS. Anchor Plate Backup Blanket Floor ➔ INSTALLATION PROCEDURE FOR CERAKWOOL KH-MODULE LINING STEP 3 : INSTALL MODULES ONTO BASES IN A Backup Blanket PARQUETED DESIGN. EACH MODULE EXPANDS AGAINST TWO ADJACENT MODULES WHEN NET RAP or BAND IS CUT. Module Strip Blanket STEP 4 : WHEN MODULES BORDER AN OPENING, TURN THE EDGE GRANIN TOWARD THE OPENING SO THAT THE INSERTS CANNOT FALL OUT OF THE MODULES. A COMPRESSION STRIP MAY BE DESIRED IN THIS AREA. WHEN A JOB IS FINISHED, REMOVE TUBES Tool M8 (Ø 8 mm) Nut 54• 55 Technical Book 2013 Wrench Ⅲ. CONSTRUCTION ■ ANCHORING SYSTEM for KH-MODULE LINING TP 304 Ø 10.5 mm 1.5 mm (SUPPORT TUBE) TP304 2 mm (ANCHOR PLATE) 40 Ø 10.5 mm 15 20 20 160 Ø 9.5 mm 120(Tube Center To Center) 20 20 160 ■ DETAIL for KH-MODULE Stud Bolt & Nut TP 304 M8(Ø 8 mm) NUT TP 304 M8(Ø 8 mm) NUT TP 304 STUD BOLT FERRULE 3) CERAKWOOL K-MODULE LINING CERAKWOOL K-MODULE LINING SYSTEMS MR BASE w/MK CERAKWOOL K-MODULE CERAKWOOL K NODULE BLANKET BACK-UP MR BASE w/MK FOLDED BLANKET STRIP PROTECTING ANCHOR BLANKET BACK-UP MODULES & FOLDED BLANKET STRIP OVER ANCHORS w/BLANKET BLANKET BACK-UP FOLDED STRIP STACKED BLANKET STRIP STACKED ACCORDION FOLDED FOLDED BLANKET STRIP PROTECTING ANCHORS MR BASE w/MK LOOP FOLD w/ BLANKET BACK-UP ACCORDION FOLD w/ BLANKET BACK-UP 57 EDGE STACK w/ BLANKET BACK-UP BLANKET BACK-UP 56• BLANKET BACK-UP Technical Book 2013 MR BASE w/MK Ⅲ. CONSTRUCTION INSTALL ATION PROCEDURE FOR CERAK WOOL K-MODULE LINING STEP 1 : WELD ANCHORS TO THE SHELL ON PREDETERMINED ANCHOR LAYOUT. ADD 25 mm OF LENGTH TO ALL BASES FOR EVERY 25 mm OF BACKUP BLANKET. STEP 2 : IMPALE BLANKET LAYER(S) OVER MR-ANCHOR BASES. INSTALLATION PROCEDURE FOR CERAKWOOL K-MODULE LINING STEP 3 : INSTALL FIRST ROW OF MODULES OVER BACK-UP BLANKET. STEP 4 : PLACE FOLD OF BLANKET BETWEEN ROWS OF MODULES FOR NO THROUGH JOINTS TO THE ANCHOR 58• 59 Technical Book 2013 BASES. Ⅲ. CONSTRUCTION With the new MR-anchor system you have the capability of using safety lining with the CERAKWOOL K-MODULE. If any joints should open, the steel shell will be protected by layer(s) of blanket. Vapor Barrier MR(ADD 1〞 OF LENGTH FOR EVERY 1〞 OF BLANKET) MODULE W/A BLANKET BACK-UP ➔ REPLACING A MISSING OR DAMAGED MODULE WITH THE MR ANCHOR Cut off one of the tines or replace it with a half tine. Weld a new base next to the base with the half tine. Stick another half tine into a new module. Impale the opposite side of the new module onto the existing tine. Push the module down flush with the other modules. Reach in between the modules 60• 61 Technical Book 2013 and slide the new half tine into the new base. Pat the module faces down to close any openings. Ⅲ. CONSTRUCTION ■ ANCHORING SYSTEM for K-MODULE(I,U,A Type Module) LINING * MR & MK SYSTEM SUS 310S Max. application temp. 1,250 ℃ 2.5 30 Material 230 Per customer specifications 2.5 60。 15 ■ CERAKWOOL K and KH MODULE LINING HEAT FLOW INNER TEMP (℃) 850 950 1,050 1,200 K/KH Module (#170) 150 175 200 250 Back up Blanket (#130) 25 25 25 25 Lining thk. (mm) 175 200 225 275 Wind velocity : 0 m/sec Surface temp. (℃) 50 55 58 61 * Heat loss(Q) : kcal/㎡h Heat loss (Q) 361.4 429.2 471.2 516.0 Heat storage (H) 3,289 4,356.8 5,486.2 7,760.5 THK. (mm) CERAKWOOL MODULE CERAKWOOL BLANKET Ambient Temp. : 25 ℃ Emissivity : 0.9 Heat storage(H) : kcal/㎡ CERAKWOOL MODULE CERAKWOOL MODULE CERAKWOOL MODULE CERAKWOOL BLANKET CERAKWOOL BLANKET CERAKWOOL BLANKET 1,200 ℃ 1,050 ℃ 61 ℃ 58 ℃ 250 mm 25 mm 1,200 ℃ * Condition 200 mm 25 mm 1,050 ℃ 950 ℃ 850 ℃ 55 ℃ 50 ℃ 175 mm 25 mm 950 ℃ 150 mm 25 mm 850 ℃ 4) CERAKWOOL STACK LINING Figure D-13 shows the stacked method of construction using the MR anchor system. With this system a back-up safety lining feasible. In the loop fold detail on the bottom of the page, note the anchor is buried in a fold of blanket. Stack seal linings should be compressed from 25 to 30 %. STACKED LAYER LINING BURIED ANCHOR SYSTEM 300 mm 600 mm MR w/MK 63 62• FIGURE D-13 Technical Book 2013 CERAKWOOL BLANKET LOOP FODL Ⅲ. CONSTRUCTION ■ ADVANTAGE AFTER INSTALLING STACK LINING ① ② INSULATING FIRE BRICK CERAKWOOL FELT INSULATING BRICK 1,300 ℃ 1,300 ℃ 839 ℃ 383 ℃ 156 ℃ Stack installation 180 mm 180 mm 50 mm 87 ℃ 25 mm Heat loss (kcal/m2h) 2,353 (100 %) 816 (35 %) Heat storage (kcal/m2) 112,286 (100 %) 4,901 (4 %) ■ INSTALLATION EXAMPLE Installation example 1 (Usage of bond) Installation example 2 (Usage of stud) BOLT NUT WASHER CASTING CASTING CERAKWOOL FELT CERAKWOOL BLANKET 175 25 50 CERAKWOOL BOND 25 m/m X 16 pcs “L” TYPE PIN CERAKWOOL BLANKET 300 m/m ROD 5) CERAKWOOL VENEER LINING Cerakwool Veneer Lining is an all-round energy saver Cerakwool Veneer may be applied directly to the ground-work(brick, plastic, refractories, etc) with an inorganic bond. ■ FEATURES *N  o Stud is used, so there is no damage or energy lost from stud heat release. *Q  uick heating for greater productivity. *F  ast heating and cooling-down. *E  xcellent spalling resistance protects groundwork refractories. *E  xcellent sound absorption reduces burner noise. ■ APPLICATIONS *B  aking furnace, Ceramic shattle kiln, Tunnel kiln. *A  nalyzing furnace in petrochemistry *H  eating furnace. ■ INSTALLATION EXAMPLE OF VENEER LINING CERAKWOOL BOND 65 ➔ Technical Book 2013 EXISTING REFRACTORY BRICK 64• VENEER MODULE LINING Ⅲ. CONSTRUCTION ■ STANDARD INSTALLATION OF CERAKWOOL VENEER LINING BY FURNACE INNER TEMPERATURE Furnace inner temp (℃) 900 1,100 1,300 Existing refractory brick (S.K34) 230 (B-1) 115 230 115 230 115 Veneer module lining 75 75 75 Lining thickness (mm) 445 445 445 Surface temp (℃) 72 84 99 Heat loss (kcal/㎡h) 808→550 1,054→733 1,319→985 Heat saving rate (%) 31.9 30.5 25.3 Heat storage (kcal/㎡) 119,249→90,439 145,831→113,830 172,125→142,146 Heat saving rate (%) 24.3 22 22 Material thickness (mm) (Condition) Ambient Temp : 25 ℃ Emissivitc (Ø) : 0.85 ■ VENEER LINING ENERGY-SAVING EFFECTIVENESS ③ ④ RE FR AC TO RY BR ICK INS UL AT ING BR ICK ② CE RA KV EN EE RM OD RE UL FR EL AC ININ TO RY G BR I C INS K UL AT ING BR ICK Side wall CE RA KV EN EE RM OD RE UL FR EL AC TO ININ RY G BR I CK HIG HT EM PE RA TU RE SIL ICA BO AR D ① INS UL AT ING FIR EB RIC HIG K HT EM PE RA TU RE SIL ICA BO AR D Celling ① ② ③ ④ Heat loss (kcal/m2h) 2,101 (100 %) 1,642 (78 %) 98 1(100 %) 767 (78 %) Heat stoage (kcal/m2) 138,594 (100 %) 115,834 (84 %) 103,223 (100 %) 87,120 (84 %) 3. APPLICATION EXAMPLE ■ USE FOR EXPANSION ZONE Pipe Hot air generator furnace Castable & Insulating brick Cerakwool bulk fiber Refractory Cerakwool bulk fiber, blanket Castable Fire-proofing of duplicate pipe Insulating brick cerakwool blanket(felt) Interior pipe Refractory brick Castable Exterior pipe Vapor-barrier film ■ USE FOR MAINTENANCE & IMPROVEMENT OF EXISTING REFRACTORY Reparing damage part Improvement of existing refractories Refractory brick or Castable Cerakwool bond (about 3 mm) Existing refractory brick Veneer module Insulation 67 66• Stick veneer module on existing refractory brick with Cerakwool bond Technical Book 2013 Cerakwool moldable Ⅲ. CONSTRUCTION ■ USE FOR INSIDE OF FURNACE Furnace lining(with blanket) Mineralwool board To accommodate high velocities, surface defacement Cerakwool felt Cerakwool blanket (#100) Cerakwool blanket (#130) Mineralwool board Cerakwool felt or Cerakwool blanket Cerakwool wet felt Stud bolt Washer net Hardening the surface Cerakwool paper lining or module lining Rigidizer Spray Cerakwool wet felt ■ USE FOR INSULATION OF SKID PIPE Skid Rail ① ② Cooling water Skid pipe Item After insulating Before insulating ① Castable 47.5 mm 60 mm ② C/F Wet felt 12.5 mm 0 mm Heat loss (103 kcal/h) 40.0 52.2 ■ USE IN VARIOUS PROCESS Uniform heating furnace Heating retaining cover Module (Cerakwool K-module) Bumer hole Ingot Seal material blanket Heating retaining cover(Cerakwool blanket) Veneering (Cerakwool V-module) Slab Plastic refractory Table Roller Cerakwool heat retaining cover prevents drop in temperature resulting from insulating hot ingot such as slab Insulating brick Flue gas line Continuous casting machine Kiln car Platform ① ② ③ Insulating surrounding steel support and frame with Cerakwool 69 ① Seal material : Blanket ② Packing : Module system, paper(insulation : Blanket) ③ Packing : Vacuum formed products or paper 68• Cerakwool bulk or blanket Technical Book 2013 Tundish Ⅲ. CONSTRUCTION ■ USE IN GLASS INDUSTRY Furnace ① Insulating crown arch ② Insulating side wall Refractory brick Port neck Melter and refiner crown Cerakwool blanket Regenerator crown Metal line Expanded steel backup plate (Insulation thickness : 25 mm ~ 100 mm) Cerakwool blanket has a great effect on insulating regenerator crown, melter and refiner crown, port neck. Preventing burner block thermal shock Cerakwool hard board Refractory brick (Sidewall joint area) (Thickness : 25 mm-100 mm) Cerakwool hard board should be installed in the outside refractory brick to insulate melter side wall and refiner side wall Insulating feeder channel Refractory brick Cerakwool bulk Cerakwool hard board (#300, 12.5 mm) Cerakwool rope 12.5 mm Cerakwool bulk Refractory brick Cerakwool bond is used to stick cerakwool hard board Insulating feeder bowl & orifice ring and sealing Casing Cerakwool bulk should be packde between refractory brick and casing to insulate feeder channel. Preventing tuckstone thermal shock Feeder bowl Tuckston Plunger Sleeve Fil ing with Cerakwool bulk for insulation and using Cerakwool rope or hard board and paper along with Cerakwool bond for sealing Cerakwool bulk Casing Cerakwool rope or hard board paper Orifice ring Side wall Cerakwool paper or #300 hard board Cerakwool hard board or paper is used with Cerakwool bond to prevent thermal shock