1. Composition of the Nano Insulation Board
The nano insulation board is a new type of highly efficient insulation material developed based on nanotechnology. Its core material consists of nano-sized inorganic powders and a composite structure reinforcement layer.
1.1 Nano Silica (SiO₂) and Ceramic Fibers
As the base material, nano silica particles have a particle size of less than 20 nanometers. The small size effect prolongs the heat conduction path, and combined with the framework support of ceramic fibers, a microporous structure (with pore diameters of approximately 50 nanometers) is formed, which is much smaller than the free path of gas convection (70 nanometers), effectively inhibiting heat convection.
1.2 Infrared Absorbing Agent and Aluminum Foil Reflective Layer
In the material, nano-sized zirconia, alumina, etc. are added as infrared absorbing agents, uniformly dispersed in the base material. Through reflection, scattering and absorption of radiant heat, the radiant heat transfer is reduced to the minimum. At the same time, a high reflectivity (above 87%) aluminum foil is used as the underlying material to form a "heat wave reflecting mirror", further blocking heat radiation.
1.3 Composite Structure Process
Through continuous coating, compounding pressing and baking processes, the nano powder, ceramic fibers and aluminum foil are combined into a single-layer structure to ensure the integrity of the material. Some products (such as vacuum nano insulation board) also adopt vacuum packaging technology, completely eliminating gas convection, with the thermal conductivity as low as 0.002-0.004 W/(m·K), only 1/10 of traditional insulation materials.
2. Application Advantages of Nano Insulation Board in High-Temperature Kilns
1. Ultra-thin insulation layer, achieving equipment miniaturization
Traditional insulation materials (such as ceramic fiber blankets) need to be 100-200 millimeters thick to achieve insulation effect, while the nano insulation board of Zhengzhou Jiuzhi only requires a thickness of 20-30 millimeters to achieve the same performance. For example, in the application of steel ladles in the steel industry, using the nano insulation board reduces the thickness of the insulation layer by 60%, the temperature of the steel ladle shell drops by 50°C, the equipment volume increases by 15%, significantly improving production efficiency.
2. Low heat storage, shortening heating time
The specific heat capacity of the nano insulation board is only 1/3 of traditional materials, significantly reducing the heat storage capacity. Data from Zhengzhou Jiuzhi laboratory shows that at 1200°C, the heating time of the kiln with nano insulation board is 40% shorter than that of traditional materials, and the single-time heating energy consumption is reduced by 25%, with annual savings of over 100,000 tons of standard coal (based on medium-sized kilns).
3. Uniform temperature control, improving product quality
By reducing heat loss, the nano insulation board controls the temperature fluctuation in the kiln within ±5°C (traditional materials are ±15°C). In the application of glass furnaces, feedback from Zhengzhou Jiuzhi customers shows that the uniformity of the glass liquid increases by 30%, the scrap rate decreases by 18%, and the product qualification rate increases to 99.2%.
4. Long equipment lifespan, reducing maintenance costs
The nano insulation board can reduce the kiln shell temperature by 50-100°C, reducing metal thermal fatigue damage. The service life of the refractory materials of the kiln is extended by 50%, and the annual maintenance cost is reduced by 2 million yuan. In addition, the low-temperature working environment improves the working conditions of workers and reduces the risk of occupational diseases.
5. Energy saving and consumption reduction, significant economic benefits
Taking a 150-millimeter-diameter, 600°C pipeline as an example, when using the nano insulation board (with a thickness only 1/3 of traditional mineral wool), each meter of pipeline saves 1,400 kilowatt-hours of electricity per year. If applied to 1,000 meters of pipeline, the annual electricity savings reach 1.4 million kilowatt-hours, equivalent to reducing carbon dioxide emissions by 1,120 tons.