Calcium Silicate Insulation Board Manufacturing Business. Calcium Silicate Board Production
Calcium silicate board is an asbestos-free thermal insulation product that can withstand continuous high operating temperatures. It is a light weight, low thermal conductive, high strength, easy to install, reliable and durable product. Industrial grade piping and equipment insulation is often fabricated from calcium silicate. It is a white free-flowing powder obtained by reacting calcium oxide and silica. It has a low bulk density and high physical water absorption.
Calcium Silicate Boards are manufactured from a mixture of Portland cement, fine silica, special cellulose fibers and selected fillers to impart durability, toughness and moisture resistance. Calcium Silicate Sheet is then cured by an autoclaving process whereby the ingredients are reacted together under heated steam and high pressure.
Calcium Silicate Insulation Board is a medium density fiber reinforced calcium silicate board which has been formulated without inorganic fiber. Available in a standard 10mm thickness, it is off-white in Colour and has a smooth surface on the front face and textured on the reverse. The smooth face is for painting and the textured for thin coat polymeric renders. It is pre-treated with a silicone water repellent on both faces. This reduces water uptake and enhances the compatibility with the coating system and may eliminate the need for further priming.
Calcium Silicate Board applications
Calcium silicate boards are white, non-asbestos, high temperature structural insulating boards that exhibit good thermal shock resistance and stability, consistently low thermal conductivity, high structural strength at elevated temperatures, incombustibility, electrical insulating properties when dry, excellent machinability, insolubility in water, and non-corroding properties.
Few Indian major players are as under:
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4.11
Insulation thickness used = (inches)
4
The chart above represents kvalues of the most common insulation types, drawn from information published by the manufacturers.
Thus, based on a surface temperature of 130°F and an exit gas temperature from the furnace to a heat recovery system of 700°F, the mean temperature would be 415°F (see See Chart 1.) So, no matter what type of material or density you choose, the thermal calculation will give you roughly the same insulation thickness requirement.
As an example, compare mineral wool board and ceramic fiber blanket insulation for thickness requirements. We will base the calibration on the following design conditions and assume the area is a flat surface:
This is a demonstration for the reason R. L. Schneider, a pioneer in heat transfer calculations, wrote, "... since it is harder to keep improving insulation by decreasing the k (thermal conductivity), let's increase the thickness when necessary."
So if the k-values of the insulation are about the same then we must look at the difference in the materials themselves, and their impact on material and labor costs to determine the proper material selection.
Material advantages, disadvantages
Calcium silicate block (meeting ASTM c-533)
Advantages
Disadvantages
Mineral wool board (8 in./ft3; ASTM c-612 class 4 )
Advantages
Disadvantages
* Installation cost estimates do not account for other factors that affect overall labor cost, such as stiffener sizes, casing configurations, and the lagging application.
Mineral wool board (1,900°F; meeting ASTM c-612 class 5; Fibrex FBX 19K, or equivalent)
|Advantages
Disadvantages
Fiberglass board (less than 3 in./ft3 ; Knauf ET board or equivalent)
Advantages
Disadvantages
Ceramic Fiber Blanket (8 in./ft3)
Advantages
Disadvantages
A little knowledge pays off
Understanding the differences or similarities of insulation materials can help save money and still meet your thermal requirements. A greater understanding of the insulation materials that you choose will ensure that you get the right material type for your application method and area to be insulated. Choosing the correct material type based on application will help to keep initial installation costs down.
Foundries need cost-effective insulation systems that are installed correctly and thermally efficient. According to John F. Malloy, author of Thermal Insulation, "Thermal insulation installed to save energy also saves money at the rate that is essential for efficient plant operation."
Gary Bases, author of "The Bril Book" (a guide to brick, refractory, insulation, & lagging systems), is president of BRIL inc., an independent consulting firm specializing in energy saving solutions. Contact him at Tel.330-665-2931 or by email at [email protected].
Contact us to discuss your requirements of calcium silicate board manufacturing plant. Our experienced sales team can help you identify the options that best suit your needs.