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New type of insulation material for kiln vehicles

Acting as the agent of thermal insulation materials and heating elements for high temperature kilns in Germany, JFCC temperature measuring blocks in Japan, FERRO temperature measuring rings in the United States, Bullers temperature measuring rings and coins in the United Kingdom, as well as Private label 1800 ℃ high temperature ceramic fiber binder


Keywords: temperature measuring materials, refractory materials, heating materials


Ultralite  Technology

Mantec's in-house ceramic experts have developed the unique, patent-pending Ultralite technology, a highly porous open structure, and production has begun at its factory in Stoke-on-Trent, the heart of the UK ceramics region. Ultralite is designed to replace traditional materials in many unique applications - loose fill insulation for kiln cars, insulating refractory bricks, cover bricks for kiln cars, insulation of kiln wall cavities, refractory castables, precast shapes & graded aggregates.
What is  Ultralite  Loose Fill Material ( ULF )?

Basic loose fill insulation for kiln cars Unique lightweight refractory polymeric material for superior thermal insulation

Heavy clay, sanitary ware & ceramics industries are now benefiting energy and cost by installing Ultralite worldwide

Ultralite  Loose Fill ( ULF ) product range

product code Classification temperature density Typical fields of application
ULF-10 1050°  (1922°F) 75Kg/m³ (4.68 lb/ft³) Bricks, roof tiles, sanitary ware
ULF-12 1250°C (2282°F) 110Kg/m³ (6.87 lb/ft³) Sanitary ware, household porcelain, refractory materials
ULF-14 1450°C (2642°F) 132Kg/m³ (8.24 lb/ft³) Refractory materials, technical ceramics, industrial ceramics

Advantages of Ultralite Loose Filler Material (ULF)
Efficient and lightweight=Real energy-saving and easy operation can be achieved with each roasting. Low density, low thermal mass, low thermal conductivity, high porosity=Lower kiln energy consumption cost, reducing carbon emissions
Free flowing and loose filling=easy to install, easy to pour into the cavity, no need to manually compact non refractory ceramic fiber (RCF)=not classified as hazardous waste to replace other low thermal stability kiln car heat cutting media, such as ceramic fiber, vermiculite and Perlite, etc. Life cycle=can be reused after kiln car repair and maintenance without degradation, Stable under high temperature=consistent performance throughout the permanent service life, reducing construction and maintenance costs=extending maintenance intervals
Comparison between Ultralite Loose Filler Material (ULF) and Refractory Ceramic Fiber (RCF)
Ultralite Loose Filler Material (ULF) is intended to replace the more traditional insulation materials installed at the bottom of kiln cars, and it does not face the health and safety issues of increasing concern for the use of ceramic fibers. So ULF is really a valid alternative for sensible producers.

Compared to refractory ceramic fibers, ULF's low thermal mass and low thermal conductivity allow each kiln car to save energy during firing. This helps to reduce energy consumption to a great extent. The graph to the right shows a density comparison where it can be seen that the standard Ultralite loose fill material ULF-10 has a minimum density value of 75Kg/m³ (4.68lb/ft³). The installed density of refractory
ceramic fibers is often misunderstood. Usually the density indicated by the supplier may be 90kg/m3, but the actual density after installation is 125~200kg/m³(7.80  ~ 12.49lb/ft³), which depends on how tightly the refractory ceramic fiber is installed in the kiln car.
ULF, on the other hand, is free-flowing (can be easily poured into cavities), easy to install (no manual compacting required), and allows for a uniform density across the bottom of the kiln car.
The graph to the right shows a comparison of heat transfer between ULF and various refractory ceramic fiber grades. As can be seen from the figure, ULF has lower thermal conductivity, especially at high temperatures (above 1000°C/1832°F).
Practical advantages over ceramic fibers
Ultralite does not have the health and safety issues associated with refractory ceramic fibers; it does not disintegrate and brittle during use, so Ultralite's thermal performance remains stable and long-lasting, saving installation costs throughout its lifetime.

Email:       Save up to 40% on kiln car energy costs
Tel: 021-59543611 , 13918873363


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