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