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PyroBloc modules have a higher standard density than folded modules so they are recommended for applications with highvelocity air moving through the unit which may degrade the lining

High-Density Refractory Modules

July 15, 2012
Material reduces lining failure risks for harsh, aggressive conditions

MORGAN THERMAL CERAMICS indicates its Pyro-Bloc® is the only monolithic fiber module and combines the insulating material advantages of high-temperature insulation fiber with rapid furnace installation. Compared to standard folded modules, Pyro-Bloc modules provide higher density, better tolerance compliance, superior resistance to erosion from high-velocity gas, and important installation advantages. They are ideal for applications such as stack, flare, and ductwork linings, as well as kiln car block and seals, burner blocks, and peep sights.

Because Pyro-Bloc modules have a higher standard density than folded modules they are well suited for applications with harsh conditions, and where a high velocity of air moving through the unit tends to abuse linings. The material’s higher density options, 12 and 15 PCF, are particularly suitable for resisting wear damage in areas that typically sustain a significant amount of abuse, including walkways where personnel conduct cleanouts. In addition, the density of the 15 PCF Pyro-Bloc module provides the best thermal conductivity available with modular systems. Pyro-Bloc HS modules, offered in densities as high as 23 PCF, have been specifically designed for enhanced mechanical abuse resistance.

Pyro-Bloc module’s monolithic edge grain surface is more resistant to high-velocity gas erosion than folded systems. Along with erosion resistance, the surfaces will more readily accept any required post treatments due to the grain of the fiber, which allows a deeper penetrating bond of the substrate. A number of treatments are available, with some improving velocity resistance by as much as 35%.

MTC maintains quality control of the Pyro-Bloc module’s density because the density is not dependent upon a fiber manufacturer’s control of blanket density, thickness variables, or folding machine compression tolerances. Each module is made up of two sections of Pyro-Log in edge-grain orientation, held in position with two stainless steel tubes mounted transversely through the modules, and remote from the hot face. They are anchored to the furnace casing with patented SS-316 hardware designed for corrosive gas resistance and a specially designed tube support yoke, which allows the module cold face to conform to any discontinuity of the furnace shell, while still maintaining structural support and hardware integrity. The design provides a close-fitting liner against the furnace shell and offers an extremely tight seal.

Pyro-Bloc modules are easy to install. The monolithic fiber is easy to cut and fit around openings and modify in the field. It provides a superior finished surface for such special shapes as peep site frames, tube penetrations and burner tiles. The modules are especially ideal for corners, bullnoses, or transition sections.

Compared to folded modules, Pyro-Bloc can be installed with fewer through joints running from the hot face to the cold face. The extra joints present in a folded system can increase shrinkage over time, creating opportunities for shrinkage gaps and shell damage. With Pyro-Bloc modules, there is only one joint on either side of an individual module; folded modules typically require as many as eight to ten folds, each one a possible location of shrinkage. Overall, folded modules create about ten times the number of opportunities for openings from shrinkage, compared to Pyro-Bloc modules.