Microporous Insulation Panel
A Microporous Insulation Panel is a rigid, high-performance thermal insulation board composed primarily of fumed silica (or other oxide opacifiers) and reinforced with fine inorganic fibers. The material is characterized by an extremely fine, microscopic pore structure (in the nanometer range), which makes it one of the most effective insulation materials available, particularly at high temperatures. These panels are used to achieve maximum thermal insulation in minimum thickness and are crucial for minimizing heat loss in high-temperature industrial equipment.
Main Components and Structure
The material works by minimizing all three modes of heat transfer: conduction, convection, and radiation, due to its unique nanostructure.
| COMPONENT | COMPOSITION | FUNCTION |
| Fumed Silica | High-purity SiO2 | Creates the microscopic pore structure that blocks gas-phase conduction. |
| Opacifiers | Iron Oxide, Titanium Dioxide, or Carbon Black | Blocks radiant heat transfer by absorbing/reflecting IR radiation. |
| Inorganic Fiber | Fiberglass or Ceramic Fiber | Provides structural integrity and handling strength. |
| CLASSIFICATION | MAXIMUM SERVICE T | PRIMARY ADVANTAGE |
| Standard Grade | ~950°C to 1000°C | Best thermal performance for thickness among all refractories. |
| High-Temp Grade | Up to ~1200°C | For backup insulation in ultra-high-temperature furnaces. |
Key Performance Metrics
| PROPERTY | TYPICAL PERFORMANCE | MECHANISM OF ADVANTAGE |
| Thermal Conductivity (k) | ULTRA LOW | Lower than any conventional refractory fiber or board, especially at high T. |
| Thickness Equivalence | SUPERIOR | Achieves the insulation of a 100 mm (4 inch) blanket in just a 25 mm (1 inch) panel. |
| Dimensional Stability | EXCELLENT | Rigid and maintains precise dimensions under heat without slumping. |
| Non-Combustible | EXCELLENT | Purely inorganic composition; highly fire resistant. |
Advantages and Key Characteristics
Microporous panels are a premium insulation solution chosen when space and weight are severely restricted, but high-temperature thermal efficiency cannot be compromised.
- Exceptional Thermal Performance: The combination of nanometer-sized pores (blocking air conduction/convection) and opacifiers (blocking radiation) results in a k value far superior to ceramic fiber or mineral wool, making it the highest insulating material in a rigid panel form.
- Space and Weight Reduction: The most significant benefit is the ability to reduce wall thickness by 50% to 75% compared to conventional insulation for the same thermal drop. This increases the internal volume of a furnace and reduces overall weight.
- Protection of Backup Insulation: Often used as a thin layer immediately behind the hot face (e.g., behind a brick lining) to drastically reduce the temperature seen by the less expensive, bulky backup insulation (like CS board or mineral wool).
- Controlled Heat-Up/Cool-Down: Due to the material’s low thermal mass, it contributes to shorter furnace cycle times, translating directly to energy savings.
Typical Industries and Applications
This specialized material is used in high-value, high-temperature, and space-constrained applications:
- Metallurgy: Back-up insulation for ladle linings, tundishes, and induction furnace casings.
- Petrochemical: Thin-wall insulation for thermal reactors, catalyst vessels, and portable stress-relieving equipment.
- Aerospace and Automotive: Insulation for test rigs, environmental chambers, and specialized heat-treating furnaces.
- Electronics: Lining high-temperature sintering and firing furnaces where minimal thermal mass is crucial.
Key Data Sheet Properties to Consider
Selection is highly dependent on thermal targets and geometry:
- Thermal Conductivity (k): CRITICAL VALUE. Must be checked at the highest anticipated mean temperature (T mean) of the microporous layer, as performance degrades slightly with increasing T.
- Thickness: Specified in minimum thickness required to meet the target cold-face temperature.
- Sheathing/Facing: The panel is often wrapped in glass fiber cloth or poly-film to prevent the fine, dusty silica powder from escaping.11 The sheath must be able to withstand the outer-face temperature.
Technical Guidance: Microporous panels are not suitable for hot-face exposure to high-velocity gases or direct flame impingement. They must be protected by a rigid material (brick or castable) or a high-density ceramic fiber board. Care must be taken during installation to avoid puncturing the outer sheathing, which would release the silica powder.
✨ 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. |
