MICROTHERM PANEL

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High-Temperature Microporous Insulation Panel

Applications

A low thermal conductivity insulator; Microtherm. In its principle, this material lowers heat loss inside the furnace that escapes from the furnace when Microtherm insulation is installed. Due to the very small porosity of the material that will substantially diminish heat loss, it could be one of the smart options to be applied in the furnace during the overhaul or furnace repair.

1. Case Study Sample :

Installing insulation with a thickness of 10 mm thick for the furnace to be heated at 500oC.

Take note that the calculations of surface temperature in Figure below. There is a temperature differential between the Microtherm that is not installed in numbers 1 and 2. (Fig. 1). When Microtherm was installed, the mean heat loss at the surface was found to be 162.3o C (Figure 2) = 95.4ºC. Comparing Microtherm to traditional insulation, a 66.9°C reduction in heat loss is possible.

Fig.1 162.3ºC for the mean surface temperature Fig.2 Mean surface temperature =95.4ºC with Microtherm.

Microtherm’s Waterproof Material

Figure 3. Microtherm’s Waterproof Material
Figure 4. Thermal Conductivity Graph

Industry Application

  • insulation for industrial furnaces
  • the aluminum sector,
  • warming food
  • glass and ceramics sector
  • Galvanizing and annealing

Foundry & Petrochemical Application

The application in the foundry industry such as in the melting furnace; while in the petrochemical sector is used in Hydrogen reformers.

2. Case Study Sample:

Heat loss is prevented with Microtherm. It helps prevent heat loss inside the furnace and offers insulating qualities. (Conventional insulation for a 600 cubic meter furnace will require an additional investment of about 14 million baht.)

Fig.5 Before installation Fig.6 After installing Microtherm

According to Figures 5 and 6, which depict the heat loss calculation graph inside the furnace wall at a temperature of 930°C. Figure 5 contains four layers of fiber blanket insulation, and it is evident from the image that the heat loss is 72 °C. Insulation, three layers of fiber blankets, and two layers of Microtherm Panel-1000R made up the sixth layer. that heat loss equals 56°C

>> Observed that the temperature ranged from 930°C in layers 2 and 3. The Microtherm Panel-1000R can assist prevent heat loss by up to 16°C when placed, reducing the temperature to 538°C.

Fig.7 Microtherm is installed at Continuous Bright annealing.

Continuous bright annealing furnace with a capacity of 50 to 225 tons per hour.

An illustration is provided from graph 1. which displays the results of the Ceramic Fiber Blanket’s energy loss comparative calculation. When working at 75 tons per hour, Microtherm1000R (Heat loss 56°C) and (Heat loss 72°C)

Calculation

>>Microtherm1000R

The cost of electricity is used to calculate energy loss.

Annually = 27,444,409.61 THB

The squandered energy from the first Ceramic Fiber Blanket was added to the utility bill.

Yearly = 35,285,669.50 THB

During the Microtherm1000R installation, it can reduce the annual electricity bill by 7,841,259.89 baht

Graph 2. Displays the comparative data of the energy loss calculation of Ceramic Fiber Blanket (Heat loss 72°C) and Microtherm1000R (Heat loss 56°C) in case of loading 150 t/h.

>>Microtherm1000R

The cost of electricity is used to calculate energy loss.

annually = 54,888,819.22

The squandered energy from the first Ceramic Fiber Blanket was added to the utility bill.

annually = 70,571,338.99

During the Microtherm1000R installation

can reduce the annual electricity bill by 15,682,519.78 baht.

Summary

In the first graph. When loading 75 tons per hour, compare the energy loss of Ceramic Fiber Blanket (Heat loss 72°C) with Microtherm1000R (Heat loss 56°C).

>> Within 1 year and 9 months, it can help pay back the capital.

From Graph 2. Compare the energy loss of Ceramic Fiber Blanket (Heat loss 72°C) and Microtherm1000R (Heat loss 56°C) in case of loading 150 tons/hour.

>> Within 10 months, it can help pay back the capital.

Conclusion

Thermal insulation (Microtherm)

  • Reduce heat loss up to 90%
  • Thickness: ~25 mm. (2 ply)
  • Material: an opaque blend of pyrogenic silica and fiber reinforced (1200 grade alumina).
  • Service life: 5 years
  • Installation: According to the specified conditions
  • Maximum surface temperature: 1000 °C

Thermal insulation (Blanket)

  • Reduce heat loss up to: 80%
  • Thickness: ~50 mm. (1 ply)
  • Material: silica cloth, fiberglass, ceramic fiber
  • Service life: 2-3 years
  • Installation: According to the specified conditions
  • Maximum surface temperature: 1,260 °C
  • Order: Customer’s Requirement

From the usage example, Figure 5 and Figure 6 can be concluded that: reduction of heat loss up to 16°C.

Why choose Microtherm1000R better than Common Fiber Blanket?

  • Reducing heat loss
  • Reducing electricity usage & expenses
  • Reducing production costs
  • Help to conserve the environment