Kilns & Furnaces

For over 30 years Saffil Ltd has provided a range of high temperature furnace lining products capable of meeting the demands of arduous applications in all industry sectors.

Ceramic Industry
The firing of high performance ceramics and refractory shapes require kilns, which operate at extended elevated temperatures (up to 1800°C) and utilise Saffil fibres in their design. Fine ceramics such as porcelain and products, which are produced in aggressive chemical atmospheres often utilise the chemical resistant and high temperature properties of Saffil based products to overcome the problem. Contamination is a sensitive area for the ceramic industry. Saffil based products are virtually shot free and extremely uniform in their composition. Considerable cost savings can be made, using Saffil products by reducing reject levels caused by contamination. Rapid firing intermittent kilns utilise the low thermal mass and resistance to thermal shock properties of Saffil products. Significant fuel savings as well as low kiln manufacturing costs can be enjoyed from this approach.

Products
The principle product forms used in the ceramic industry as the actual kiln lining are Saffil, Mat, Blanket, modules or vacuum formed board. These products are available formed from 100% Saffil fibre or in composite form. Seals, shrinkage and expansion gaps can be accommodated using Mat, Blanket, Paper or Bulk. Saffil Felt, a unique product designed specifically for these applications, is delivering real benefits to the customer in sealing and gasketing applications.

Iron and Steel Industry
Iron Making
Expansion gaps in Blast Furnace brickwork utilise Saffil's high temperature / chemical resistance and inherent resilience to provide high performance seals.

Steel Reheating
Arduous conditions and the cyclic operation found in modern reheat furnaces make them excellent candidates for Saffil based linings in veneer or full fibre module format. High performance expansion gap seals local to burners formed from Saffil fibres ensure that heat is not able track back and damage the furnace steel work and lead to unnecessary heat loss.

Heat Treatment
Continuous strip furnaces used for annealing or galvanising high quality steels utilise Saffil linings. Virtually zero shot content ensures that reject product caused by fall out from the lining is eliminated. Vacuum furnaces utilise Saffil's insulating qualities in vacuum conditions. Furnace lining's operating in aggressive chemical atmospheres are formed from Saffil. High purity and low silica levels reduce the possibility of chemical attack.

Forging
Car bottom intermittent furnaces utilise the low thermal mass benefits offered by Saffil to allow rapid firing of the charge and deliver significant fuel savings. Hot Isostatic Pressing (HIP) furnaces benefit from Saffil fibres high performance properties.

Products
Saffil is used in a multitude of forms in the Iron and Steel industry. Saffil Mat, Blanket, modules and vacuum formed board are most commonly used as furnace construction materials. These products are available formed from 100% Saffil fibre or in composite form. Seals, shrinkage and expansion gaps can be accommodated using Mat, Blanket, Paper or Bulk. Safseal, a unique product designed specifically for these applications is delivering real benefits to the customer. Process consumables in the form of Saffil paper or vacuum formed shapes can be formed to insulate or convey molten metal.

Petrochemical Industry
Ethylene Heaters
High costs of downtime caused by lining failure or extended overhaul time has seen an increasing use of Saffil based products, on the basis of its superior performance when compared with refractory ceramic fibres . The linings are formed in Saffil blanket or vacuum formed modules and boards. Brick lined units often utilise Saffil in expansion joints.

Process Heaters and Reformers generally operate at lower temperatures than Ethylene Heaters but failure critical areas local to burners and sight door surrounds can lead to costly downtime. Strategic use of Saffil products in high performance seals can significantly reduce the risk of unplanned downtime.

Chemical Industry
Catalyst Kilns
High soda levels in certain catalyst heat treatment processes are extremely aggressive to linings containing silica. The benefits of low thermal mass and a high resistance to chemical attack can be fully utilised in these intermittent applications by using high alumina / low silica content Saffil-based linings.

Sulphur Recovery Units
Traditionally these units are lined with Alumina bricks. Saffil's high alumina content makes it an ideal product for use as brickwork expansion joints.

Products
Saffil is used in a multitude of forms in the Chemical industry. Saffil, Mat, Paper, Blanket, modules and vacuum formed board are most commonly used as furnace construction materials. These products are available formed from 100% Saffil fibre or in composite form. Seals, shrinkage and expansion gaps can be accommodated using Mat, Blanket or Bulk. Saffil Felt, a unique product designed specifically for these applications is delivering real benefits to the customer in high performance areas such as local to burners and vacuum formed inspection door surrounds as well as a multitude of other sealing applications.

Miscellaneous
Saffil and its derived products are utilised in numerous speciality applications, which include.
· Kilns for firing electrical components such as Ferrite cores for magnets.
· Laboratory / development kilns.
· Powder metallurgy furnaces.
· Semi conductor kilns
· Extreme high temperature kilns (1700 & 1800°C)
· Fuel cells
· Nuclear industry
Saffil Customer Services

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