Ceramic fiber modules and foldable blocks are commonly used as insulation materials for industrial furnace linings due to their excellent heat and thermal insulation properties, as well as their lightweight nature. The installation method for ceramic fiber modules is as follows:

Installation Method:

Rust removal from furnace plate → Weld ceramic fiber module bolts to the furnace wall plate → Remove ceramic fiber module → Screw guide rod onto the bolt head → Pass the ceramic fiber module through the guide rod along the center hole and rest on the furnace plate → Use a special wrench to tighten the nut onto the bolt → Unscrew the guide rod → Install other ceramic fiber modules in sequence → Pull out the central plastic tube of the ceramic fiber module → Unfasten the binding strap of the ceramic fiber module → Compress the installation of the ceramic fiber compensation blanket → Install the next row of folding modules

(II) Installation Requirements:

The anchor bolt welding position should be accurate, with strict control over errors.

The ceramic fiber backing blanket has been installed before proceeding with the ceramic fiber module construction.

First, install the furnace roof module, then the furnace wall.

The installation of the furnace wall ceramic fiber modules should commence from the bottom and proceed upwards.

Ceramic fiber modules are typically arranged in a co-directional "side-by-side" pattern. After installing a row of modules, they should be compressed as per the requirements and covered with the compensating blanket.

Top and wall connections, as well as wall-to-wall joints, should be compressed and covered with compensation mats.

(3) Surface Correction:

After the installation of the ceramic fiber modules is completed, they should be carefully inspected. Any gaps larger than 5mm should be filled with ceramic fiber compensation mats.

After filling the fiber blanket, use square boards to flatten the surface of the folded module.

Section 4: Construction Precautions for Ceramic Fiber Module Lining

Anchoring nail welding

When wiring, it is essential to use the wall panel centerline as a reference, extending to both sides. Bolt positions must be marked strictly according to the design drawings. The cumulative dimensional errors that may occur during actual wiring are reflected in the bolt positions of the next row.

Anchoring bolts must be welded perpendicular to the furnace wall panels, with a deviation in adjacent center distance of ≤2mm and a deviation of ≤±3mm between any two spacing.

Be mindful of the thread protection for the anchor bolt.

Welds must be firm. After welding, inspect each weld individually by hammering and bending to ensure quality, and clean off slag.

Layer backing is flat-laid.

Compress strictly according to the design specifications to the required thickness.

The interlayer seams of the carpet must be staggered, with a stagger amount not less than that shown in the drawings.

Quick Cards must be securely fastened to prevent bounce back.

(3) Module Installation

Assemble piece by piece, row by row, ensuring nuts are securely tightened.

When forming in a platoon formation, pay attention to the installation of the compensation strips between rows. Install them strictly according to the design requirements of the drawings, compressing them to the specified thickness.

To prevent detachment, the compensation strips must be securely fastened with U-bolts onto the fully installed ceramic fiber modules.

After removing the guard plate and central plastic tube, it is essential to carefully inspect the holes and module gaps at the sleeve area, particularly at the corner sections.

(4) Lining Adjustment:

The ceramic fiber lining surface must be pounded flat and dense.

Holes in the casing must be sealed with adjusted folded layers or filled densely with ceramic fiber cotton or mats.

The gap between modules must be corrected by filling with folded fiber blanket or fiber cotton.

Impact of ceramic fiber modular lining construction quality on the damage of ceramic fiber lining

Generally, seven parts design and three parts construction. Through the investigation and summary of the application effects of the construction quality of the ceramic fiber module furnace lining, we found that the construction quality issues causing damage to the ceramic fiber module furnace lining mainly exist in the following aspects:

◎ The nut was not properly installed, preventing it from being tightened onto the bolt, which resulted in the ceramic fiber module and furnace wall panel not being effectively connected. During the high-temperature operation, the module detached and collapsed.

Insufficient compression of the compensation strip led to inadequate compensation at high temperatures, resulting in gaps between modules and causing the anchoring bolts to oxidize and burn the steel plate due to high-temperature exposure.

Ceramic fiber module linings were not properly trimmed, leading to gaps between modules allowing high-temperature flue gases to penetrate. The anchor bolts experienced severe high-temperature oxidation and corrosion, resulting in module detachment.