Lightweight Refractory Can Improve Kiln Insulation Performance and Fuel Efficiency
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Lightweight Refractory Can Improve Kiln Insulation Performance and Fuel Efficiency Ever-widening end use application possibilities, allied to novel production techniques, have resulted in a higher strength version of a unique refractory insulating product. The particular product in question is manufactured by Mantec Refractories in Stoke-on-Trent in the UK. The company is a division within Mantec Technical Ceramics that has a historical pedigree going back over 50 years and was constituted in its current form in 2005. The lightweight refractory’s central role is as an insulating refractory in kilns and furnaces, helping companies to employ easier car configuration techniques or to lighten the overall weight while increasing thermal efficiencies in the superstructure, and thereby substantially reducing fuel consumption. It is seen as a modern substitute for more traditional insulation materials across a number of quite distinct applications. Ultralite is an ultra-lightweight, microporous refractory material – a specialist foamed aluminosilicate aggregate product that was formulated by ceramic technologists in the UK. The new refractory formulation that is used to produce it is said to give it the edge over, for instance, micaceous and siliceous minerals and it routinely offers a suite of in-use benefits, such as: }} Stability at elevated temperatures above 900 °C }} High open porosity, in excess of 70 % }} Low thermal mass }} Ultra-lightweight (~ 70 kg/m3) }} High internal void space }} Low thermal conductivity }} Low bulk density }} Free flowing – easy void filling }} No ceramic fiber – so it doesn’t become brittle and lose its insulation efficiency over time }} Negligible free silica – significantly reduced carcinogenic exposure }} High energy saving characteristic }} No volatiles produced }} Disposal at end of life is problem-free – standard landfill disposal is acceptable
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The science behind the lightweight refractory, developed over several decades, is what has led to its excellent performance. Most naturally occurring expanded minerals used for insulation applications, for example perlite or vermiculite, can lead to a final product that is problematic in terms of extremely variable pore size and limited thermal stability at elevated temperatures in excess of 900 °C. Conversely, the experience with the lightweight refractory product in the high-volume manufacture of ceramic sanitaryware,
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tableware and heavy clay products has been long-term consistent product performance allied to sustained cost and energy savings. Many installations are still using their original material after more than 15 years. “Probably the biggest single thing that we have achieved recently with our product is its remarkable lightweight feature,” comments Managing Director of Mantec Technical Ceramics, Andy Clark. “We help our customers to reduce the thermal mass of their kiln car design by replacing older more dense
Lightweight refractory pellet (© Mantec Technical Ceramics)
Refractories Manual 2020www.interceram-review.
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