INSULATING FIREBRICK
Insulating Firebricks for High-Temperatures
PRODUCTS > INSULATING FIREBRICK
WHAT ARE INSULATING FIREBRICKS?
Insulating firebricks are specialized refractory bricks offering exceptional insulation properties and thermal stability, pivotal in the development of high-temperature industrial applications. Originating from the need for efficient thermal management solutions, these bricks are manufactured from select refractory powders, undergoing precise processes of compression, vacuum treatment, and high-temperature sintering.
Axim Mica’s insulating firebricks integrate organic fillers to meet specific requirements, presenting a low thermal conductivity, high thermal shock resistance, and low heat capacity. Their evolution reflects a history of innovation, contributing to advancements in energy efficiency and performance in industries globally.
APPLICATIONS
Insulating Firebricks from Axim Mica are versatile and can be utilized in a wide range of industrial applications due to their excellent insulation properties, thermal stability, and mechanical strength. Here are some of the key applications:
Cracking
Furnaces
Essential for petrochemical processing, providing reliable insulation to maintain precise temperature control.
Conversion
Furnaces
Used in various chemical processes, IFBs support efficient temperature management and energy conservation.
Heating
Equipment
Ideal for high-temperature ovens, heaters, and boilers, where durable and efficient thermal insulation is necessary.
Refining
Equipment
In metallurgical processes, IFBs help in maintaining consistent temperatures for refining and processing metals.
Hot Blast Stoves
Critical for blast furnaces in steel production, offering insulation that enhances energy efficiency and process control.
Ceramic Kilns
Provide uniform heat distribution and insulation, crucial for the ceramics industry to achieve desired firing outcomes.
PROPERTIES & COMPOSITION
REFRACTORY POWDER COMPOSITION
Core material in our insulating firebricks, chosen for its ability to withstand extreme temperatures without melting or breaking down, ensures longevity and reliability.
ORGANIC & FILLER MATERIALS
Specific organic compounds and multiple filler materials are added to customize the firebrick's properties, enhancing mechanical flexibility without compromising structural integrity.
HIGH PURITY LEVELS
Manufactured with materials of good purity, our firebricks have low iron content. This is critical for applications demanding high purity levels to avoid contamination, especially in the metallurgical and ceramics industries.
VACUUM COMPRESSION
Ensures a dense, uniform structure of the brick, minimizing pores and potential weak spots, contributes significantly to the brick's insulating properties by reducing pathways for heat transfer.
TECHNICAL SPECIFICATIONS
|
Properties
|
Specifications
|
|---|---|
|
Classification Temperature (ASTM C 155)
|
2300℉ - 3200℉ (1260℃ - 1760℃)
|
|
Density (ASTM C 134)
|
39 - 75 lb/ft³ (618 - 1201 kg/m³)
|
|
Modulus of Rupture (ASTM C 133)
|
124 - 450 psi (0.85 - 3.10 MPa)
|
|
Cold Crushing Strength (ASTM C 210)
|
174 - 609 psi (1.20 - 4.20 MPa)
|
|
Percent Linear Change (24hrs @ Soaking Temp. ASTM C 210)
|
0.0% to -0.7%
|
|
Thermal Conductivity (ASTM C 182)
|
@500℉: 1.0 - 3.9 Btu·in/(ft²·hr·℉), @2000℉: 1.8 - 4.3 Btu·in/(ft²·hr·℉)
|
|
Chemical Composition
|
Al2O3: 45% - 78.3%, SiO2: 20.7% - 50%, Fe2O3: 0.2% - 0.9%, TiO2: 0.5% - 1.3%, CaO & MgO: 0.2% - 1.5%, Alkalies: 0.1% - 0.4%
|
TYPES OF INSULATING FIREBRICKS
- Standard Duty Insulating Firebricks: Ideal for moderate temperatures up to 2300℉ (1260℃), used mainly for general furnace work and backup insulation.
- High-Purity Insulating Firebricks: Suitable for up to 2600℉ (1427℃), these bricks offer lower impurities and are used in environments requiring minimal contamination.
- High-Duty Insulating Firebricks: Designed for conditions up to 2800℉ (1538℃), perfect for high-temperature kilns and furnaces requiring structural integrity.
- Super-Duty Insulating Firebricks: For the most extreme heat up to 3200℉ (1760℃), offering the best thermal stability for critical high-heat processes.
- Low-Iron and Low-Alkali Insulating Firebricks: Tailored for applications sensitive to impurities, used in processes like clean-room furnaces or sensitive alloy production.
BENEFITS & ADVANTAGES OF INSULATING FIREBRICKS
- Maximize Efficiency: Keep the heat exactly where you need it. Our firebricks ensure your furnaces work smarter, not harder, conserving energy and reducing costs.
- Enhanced Durability: Say goodbye to constant replacements. Built to withstand extreme conditions, our firebricks promise a longer lifespan for your equipment.
- Superior Thermal Control: Achieve precision in heat management. Our bricks offer exceptional insulation, providing the stable temperatures your processes depend on.
- Environmentally Friendly: Embrace sustainability without compromise. Low thermal conductivity means lower energy use, aligning your operations with eco-friendly practices.
- Simplified Maintenance: Spend less time on upkeep and more on what matters. Our durable and reliable bricks make maintenance a breeze.
- Custom Solutions: Every project is unique. Whatever your industry, we’re here to supply insulating firebricks tailored to your specific needs.
HOW INSULATING FIREBRICKS ARE MADE
The manufacture of Insulating Firebricks (IFB) involves a series of precise and controlled steps that ensure the bricks meet the high standards required for thermal insulation in industrial applications. Here’s a simplified overview of the general process:
- Material Selection and Preparation: The process begins with the selection of high-grade refractory powders and materials. These materials are often mixed with organic and multiple filler materials according to specific proportion requirements to enhance the brick’s physical and thermal properties.
- Mixing: The selected materials are thoroughly mixed to ensure a uniform composition. This homogenized mixture is crucial for achieving consistent quality and performance across all bricks.
- Molding & Shaping: The mixture is then compressed in vacuum molds to form bricks. This step may involve pressing the material into desired shapes and sizes, depending on the application requirements.
- Sintering (High-Temperature Firing): The shaped bricks are sintered in high-temperature kilns. This process binds the materials together at a molecular level, enhancing the brick’s strength, thermal stability, and insulation properties. The sintering temperature and duration depend on the specific type of insulating firebrick being produced.
- Quality Checks: After sintering, each brick undergoes stringent quality control checks. These include inspections for dimensions, density, thermal characteristics, and structural integrity to ensure they meet the specified standards.
- Finishing Touches & Packaging: Finally, the bricks are finished to the required dimensions, if necessary, and packaged for shipping.
ENGINEERING EXCELLENCE WITH AXIM MICA
Ready to move forward? Our engineering team collaborates with clients to develop optimal solutions for their specific applications, ensuring every component meets exact specifications and performance requirements.
FAQs
Insulating fire bricks (IFB) are specialized refractory bricks designed to withstand high temperatures while providing excellent thermal insulation. They are lighter and more porous than traditional refractory bricks, making them ideal for use in furnaces, kilns, and other high-temperature processing environments.
The primary function of insulating brick is to minimize heat loss in furnaces, kilns, and other high-temperature equipment. This ensures efficient energy use, maintains optimal processing temperatures, and protects the equipment’s outer structure from excessive heat.
Insulating fire bricks come in various standard sizes, with common dimensions being 9″x4.5″x2.5″. However, sizes can vary and custom dimensions are often available to meet specific application requirements.
Insulating firebricks are made from high-grade refractory powders and materials, such as silica and alumina, mixed with organic and inorganic fillers. This composition provides the bricks with their lightweight, porous structure and insulating properties, while ensuring they can withstand extreme temperatures.