Indian Manufacturer Enhances Kiln Efficiency With Polycrystalline Mullite Fiber Board Solution

2025-04-12

Client Background
In March 7, 2025, a leading Indian industrial furnace manufacturer sought to upgrade their high-temperature equipment insulation to improve energy efficiency and durability. After evaluating multiple suppliers, they chose our Polycrystalline Mullite Fiber Board (PMF) solution, placing an initial prepayment of 3062.50 USD for a total contract value of 10725 USD.

Project Challenge
The client required a refractory material capable of withstanding prolonged exposure to 1,600°C while minimizing heat loss and reducing downtime. Traditional ceramic fiber boards struggled with thermal shrinkage and brittleness, leading to frequent replacements.

Our Solution: Polycrystalline Mullite Fiber Board
We recommended our advanced PMF Board—a single-phase mullite crystal fiber material engineered for extreme conditions.

Key Features & Benefits:
✅ Ultra-Lightweight & High Rigidity: 30% lighter than conventional refractory boards, reducing structural load on kilns.
✅ Low Thermal Conductivity (<0.12 W/m·K): Ensured superior insulation, cutting energy costs by 18% post-installation.
✅ Minimal Linear Shrinkage (<1.5% at 1,600°C): Maintained dimensional stability for 6+ months in continuous operation.
✅ Chemical Stability: Resisted corrosion from acidic/alkaline atmospheres in metal processing furnaces.
✅ Easy Customization: Pre-cut boards were delivered to match the client’s kiln geometry, slashing installation time by 40%.

Applications in This Project:

Primary insulation layer for rotary kiln walls
Backup insulation for dense refractory linings
Expansion joint filler to prevent heat leakage

Why the Client Chose Us

Technical Expertise: Provided ASTM-certified test reports and a 12-month performance warranty.
Cost-Effective ROI: Our PMF board extended kiln lifespan by 2-3 years compared to competitors’ products.
Fast Logistics: Delivered pre-engineered boards within 18 days via sea freight.
24/7 Engineering Support: WhatsApp-based troubleshooting during installation.

Results & Client Feedback
Post-installation metrics showed:

22% reduction in surface temperature (improved worker safety)
15% longer intervals between maintenance cycles
Annual energy savings exceeding $8,000

"The PMF boards outperformed our expectations. The low heat storage property alone cut our furnace preheating time by 25%. We’re planning to adopt RS Refractory’s mullite fiber modules for future projects."
– Mr. Sharma, Procurement Manager

Your Turn to Optimize Thermal Systems!
Whether you’re in aerospace, ceramics, or metallurgy, our polycrystalline mullite fiber products deliver unmatched performance in:
High-temperature lab equipment
Industrial furnace linings
Backup insulation for reactors

Act Now & Unlock: