Composite Ceramic Fiber Module
A Composite Ceramic Fiber Module is an advanced refractory insulation unit made by combining two or more distinct layers of fiber material within a single, pre-compressed module structure. This design allows the module to be engineered for optimal performance across the temperature gradient, typically using a high-purity, high-temperature fiber on the hot face and a lower-cost, higher-insulating fiber (or a Low Bio-Persistence fiber) on the cold face. This creates a superior lining with enhanced energy efficiency and cost-effectiveness.
Multi-Layer Design
The composite design is the defining feature, utilizing different fiber grades for specific thermal zones within the wall thickness.
| MODULE LAYER | TYPICAL MATERIAL | FUNCTION |
| Hot Face | High Alumina (1430°C+) | Maximum temperature resistance and minimal shrinkage. |
| Cold Face/Backup | Standard RCF or LBP Fiber (1260°C) | Enhanced insulation performance and lower cost in the lower-temperature zone. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Energy Efficiency | MAXIMIZED | Combines the best thermal properties of two materials for optimal heat retention. |
| Cost Optimization | HIGH | Reduces the overall volume of expensive, high-purity fiber by using it only where needed (the hot face). |
| Hot Face Stability | SUPERIOR | High-grade fiber on the hot face ensures low shrinkage and resistance to chemical attack. |
| Joint Integrity | EXCELLENT | Pre-compression ensures tight, gap-free installation, minimizing convective heat loss. |
Advantages and Key Characteristics
Composite modules are chosen when a furnace requires high performance and energy savings over a long lifespan, justifying the specialized manufacturing process.
- Targeted Performance: By placing the most expensive, highest-temperature-rated material only on the hot face (e.g., 100 mm thick) and a more economical material for the remaining thickness (e.g., $100 \text{ mm}$ thick), the composite module achieves the required hot-face MST without the prohibitive cost of making the entire $200 \text{ mm}$ module out of the premium fiber.
- Reduced Heat Loss and Shell Temperature: The design maximizes the insulation value for the entire thickness, resulting in a lower furnace shell temperature and enhanced safety in the work environment.
- Controlled Shrinkage: The differential shrinkage of the two layers is managed by the tight, pre-compressed folds, ensuring the hot-face layer remains sealed and stable throughout the campaign life.
- Single-Unit Installation: Despite having multiple layers, the composite is installed as a single unit with a single anchor, maintaining the speed and convenience of standard module installation.
Typical Industries and Applications
Composite modules are often specified for large, continuously operating furnaces where long-term efficiency is key:
- Large Annealing and Heat-Treating Furnaces: Where consistent internal temperature is necessary for high-quality products.
- Fired Heaters and Reformers: In petrochemical applications, where energy costs and high reliability are paramount.
- Ceramic and Glass Kilns: Used in high-production continuous kilns requiring precise temperature control and minimal heat loss.
Key Data Sheet Properties to Consider
Selection requires looking at the specifications for both layers:
- Hot Face Layer MST and Al2O3 Content: CRITICAL VALUE. Must meet or exceed the furnace operating temperature.
- Total Thickness and Ratio: The thickness of the premium layer versus the backup layer (e.g., 50% premium / 50% standard).
- Anchor System: Must be suitable for the full weight and thickness of the composite unit and securely bond both layers.
Technical Guidance: When replacing an existing lining, a composite module can often be designed to match the thickness of the original single-layer module while potentially offering superior insulation by using a higher-grade material for the outer layer. Care must be taken to ensure the metallic anchor component does not exceed its MST at the cold-face end of the hot-face fiber layer.
✨ 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. |
