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Kilns & Furnaces
Designing linings for demanding
applications have been the day-to-day business of Saffil Ltd for
over twenty five years. A range of products has been developed 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 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. Safseal, 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.
Ceramic 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 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.
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 Saffil
based linings.
Sulphur Recovery Units Traditionally these units are lined in 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. Safseal, 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
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