Applications in industry
The steel industry is one of the primary consumers of ceramic fiber MacroModules, due to the need to line the interior of blast furnaces used to produce steel and iron with refractory materials.
MacroModules allow damaged or worn lining sections, such as furnace doors, covers, or side walls, to be quickly replaced, thus minimizing downtime and maintaining productivity with minimal interruptions.
Many steel mills stock spare MacroModules for the most wear-prone sections, allowing specific modules to be replaced when damage is detected rather than repairing the entire liner.
It is estimated that the use of MacroModules in the steel industry has reduced downtime by up to 70%, generating significant increases in productivity.
In the metal industry, MacroModules are used for the internal lining of smelting furnaces and other system parts exposed to molten metal.
Other common uses include applications in distribution channels, hoppers, heat treatment furnaces, and slag covers. In all these cases, MacroModules facilitate maintenance and reduce production downtime.
In the glass industry, ceramic fiber MacroModules insulate high-temperature furnaces, operating at temperatures up to 2910°F (1600°C).
MacroModules offer a crucial advantage: they allow deteriorated insulation sections to be replaced without shutting down for long periods, which avoids costly production losses and saves energy by eliminating the need to cool and reheat the entire unit.
Oil, Gas, and Energy Industries
MacroModules are used in a variety of ways, including the side walls and removable internal structures of boilers, post-combustion systems, and the thermal protection of gas turbines in combined cycle units.
These processes often involve temperatures above 1830°F (1000°C), making MacroModules an ideal solution in terms of durability and heat resistance.
Composition and properties
NUTEC´S MacroModules uses the same types of fibers found in traditional blankets and modules:
- Low Biopersistent Fiber (LBP) rated to 2200°F (1200°C).
- Refractory Ceramic Fiber (RCF) based and rated to 2300°F (1260°C).
- Refractory Ceramic Fiber (RCF) based with enhanced chemistry for applications up to 2600°F (1425°C). They are more expensive than the 2300 fiber but offer superior performance and durability.
- Polycrystalline Wool (PCW) for use in applications up to 3000°F (1650°C). These fibers are ultra-resistant to extreme temperatures offering maximum durability. While they are more expensive than other fiber compositions, they are the best choice for applications requiring extreme performance and reliability.
The support structure where the fibers are mounted is usually expanded or perforated metal, which provides strength at a lower weight than a solid steel plate. The metal also allows the macromodule to be easily anchored to the structure of the equipment.