Aluminum Silicate Fiber Module | Aluminum Melting Furnace Insulation Solution | CCEWOOL®

An Aluminum Melting Furnace is mainly used for melting and holding aluminum ingots, recycled aluminum, and other aluminum materials. Pure aluminum has a melting point of approximately 660°C, but the actual molten aluminum temperature in industrial production is typically higher. Meanwhile, the furnace roof, upper walls, and burner areas are exposed to flames, high-temperature flue gases, and thermal radiation, resulting in even higher thermal loads.

For this reason, the lining system of an aluminum melting furnace should not be selected solely according to molten aluminum temperature. Instead, different furnace areas should be designed and insulated according to their specific operating conditions. A typical lining structure includes:
Refractory Working Lining + Backup Insulation + Flexible Fiber Sealing

CCEWOOL® can provide Aluminum Silicate Fiber Module, Ceramic Fiber Blanket, Ceramic Fiber Board, Ceramic Fiber Paper, Ceramic Fiber Rope, and Ceramic Fiber Bulk for different furnace zones, allowing each material to perform specific functions such as high-temperature insulation, backup insulation, structural support, joint sealing, and thermal expansion compensation.

Furnace Roof and Upper Walls

The furnace roof and upper walls above the molten metal line are generally not in direct contact with molten aluminum, making them primary application areas for ceramic fiber modules.

Depending on the actual long-term operating temperature, suitable options include:

1260°C Aluminum Silicate Fiber Module
For conventional high-temperature furnace roof and wall areas;

1400°C Aluminum Silicate Fiber Module
For areas close to burners or locations with higher thermal loads;

1430°C Aluminum Silicate Fiber Module
For special areas requiring higher temperature capability.

A Ceramic Fiber Blanket can also be installed behind the modules as backup insulation to further reduce heat transfer toward the furnace shell.

Ceramic Fiber Modules are typically secured to the furnace shell or steel structure using an anchoring system. The modules are pre-compressed before installation, and fiber recovery after installation helps maintain compression between adjacent modules and reduce heat loss through joints.

In many industrial applications, the term aluminum silicate fiber module is also used for alumina-silica refractory fiber module systems. For engineering selection, however, the actual temperature grade, recommended operating temperature, fiber chemistry, density, and service conditions should always be confirmed.

Furnace Walls Below the Metal Line and Furnace Hearth

Areas below the molten metal line remain in long-term contact with molten aluminum and must withstand metal penetration, chemical attack, and mechanical effects. Therefore, standard Ceramic Fiber Modules should not be used as the direct working lining in these areas.

A more suitable lining structure is:
Aluminum-Resistant Refractory Working Lining + Rigid Backup Insulation

The refractory working lining provides resistance to molten aluminum and mechanical damage, while the backup insulation layer helps reduce heat loss.

The furnace hearth should likewise primarily use dense refractory materials, insulating fire bricks, or other rigid insulation materials rather than fiber modules as the direct load-bearing working surface.

Furnace Door and Burner Areas

Furnace doors are exposed to frequent opening, closing, and thermal cycling. Depending on the design, the internal insulation layer can use:
Ceramic Fiber Module / Ceramic Fiber Blanket / Ceramic Fiber Board
For furnace door edges and moving sealing areas, the following products can be combined:
Ceramic Fiber Paper, Ceramic Fiber Rope, and Ceramic Fiber Blanket

These flexible products help provide high-temperature sealing and accommodate movement during furnace operation.

Because burner openings are directly exposed to flame impingement and high gas velocities, refractory burner blocks or refractory castables are typically used as the working lining. The surrounding insulation area can then be configured with:
1260°C / 1400°C Ceramic Fiber Module
to provide high-temperature thermal insulation.

Flue, Expansion Joints, and Interfaces

High-temperature flue sections can use:
Ceramic Fiber Module or Ceramic Fiber Blanket
depending on the actual flue gas temperature.

For downstream sections where the flue gas temperature has been reduced after heat recovery or regenerative systems, lower temperature grades can be selected according to the actual operating conditions.

Areas such as wall-to-roof joints, furnace doors, burner surroundings, and expansion joints need sufficient flexibility to accommodate thermal movement. Depending on the structure, the following materials can be used:
Ceramic Fiber Blanket — for larger gaps and flexible filling
Ceramic Fiber Paper — for thin interfaces and gaskets
Ceramic Fiber Rope — for grooves and compression sealing
Ceramic Fiber Bulk — for irregular-shaped areas

CCEWOOL® Aluminum Melting Furnace Insulation Solution

For different temperature zones and structural areas of an Aluminum Melting Furnace, CCEWOOL® can provide a complete range of high-temperature fiber insulation products.

Ceramic fiber modules are mainly used for furnace roofs, upper walls, and other high-temperature areas that are not continuously exposed to direct contact with molten aluminum.

Ceramic Fiber Blanket can be used as module backup insulation, flexible insulation layers, and interface filling materials.

Ceramic Fiber Board is suitable for backup areas requiring greater rigidity and dimensional stability.

Ceramic Fiber Paper, Rope, and Bulk are mainly used for expansion joints, furnace doors, interfaces, and flexible sealing of complex structures.

For furnace hearths and wall areas below the molten metal line that remain in direct contact with molten aluminum, suitable refractory working linings should be combined with backup insulation. An aluminum silicate fiber module should not simply be used as a substitute for the refractory working lining.

Through a zoned configuration of Refractory Working Lining + Ceramic Fiber Module + Backup Insulation + Flexible Fiber Sealing, different materials can perform their respective functions in corrosion resistance, high-temperature insulation, heat-storage reduction, flexible sealing, and thermal expansion compensation, creating a more practical and systematic insulation solution for Aluminum Melting Furnaces.