Sustainability

CCEWOOL® Discovering the Secrets of Insulation Fiber: Delve into the history and development of insulation fiber, study CCEWOOL®'s advanced technologies and processes, and explore the unique properties of insulation fiber.

History & Introduction
Classification
Production
Characteristics

History & Introduction of
High Temperature Insulation Wool (HTIW)

History of
High temperature insulation wool (HTIW)

The term High Temperature Insulation Wool (HTIW) was introduced in the late 1990s and encompasses a variety of material types, including Refractory Ceramic Fibers (RCF) and Alumino Silicate Wool (ASW).

1942
RCF/ASW was first developed in 1942
RCF/ASW was first developed in 1942 and entered the commercial market in 1953. These materials saw significant advancement during the 1970s due to the first energy crisis and the rising demand for efficient insulation solutions.

The production of RCF involves the melting and fiberizing of calcined kaolin at temperatures around 2000°C. Since these fibers are made from kaolin—a traditional ceramic material—they possess a more "glass-like" or amorphous structure, yet are still referred to as "ceramic" fibers.
1970s
Industrial Sector Began to Recognize the Potential of ASW/RCF
By the 1970s, the industrial sector began to recognize the potential of ASW/RCF to reduce energy consumption, particularly in applications for industrial furnaces. Although more expensive, these materials offered several advantages over traditional, rigid refractory materials, such as excellent heat and thermal shock resistance, low thermal conductivity, and lightweight and flexible properties.
1980s
The Use of HTIW Expanded into the Automotive Industry
In the 1980s, the use of HTIW expanded into the automotive industry, significantly contributing to the production of exhaust systems, catalytic converters, and diesel particulate filters—crucial for reducing vehicle emissions and improving air quality.
1990s
The Renaming of HTIW
The renaming of HTIW in the 1990s aimed to more accurately reflect the diversity of materials developed for high-temperature applications and to avoid the potentially misleading term "ceramic." This name change marked a significant evolution in the field, highlighting the continuous development and versatility of these insulation materials.

Introduction of
High Temperature Insulation Wool (HTIW)

Synthetic Products Derived From Mineral Raw Materials
High Temperature Insulation Wools (HTIWs) are synthetic products derived from mineral raw materials, distinctly different from natural fibers. Unlike natural fibers, which have an orderly crystalline structure, Man-Made Mineral Fibers (MMMF), such as HTIW, do not split into finer and longer fibers; instead, they fracture widthwise, producing shorter fibers of the same diameter. Understanding this structural difference is crucial for appreciating their unique properties and applications.
Capable of Withstanding Extreme Temperatures Up to 1800°C
HTIWs are designed to withstand temperatures exceeding 1000°C, contrasting sharply with mineral and glass fibers typically used below 650°C. This category includes Alkaline Earth Silicate (AES) fibers,
Alumino Silicate Wool (ASW), and Polycrystalline Wool (PCW), which are essential in industrial applications capable of enduring extreme temperatures up to 1800°C.
Advantages of High Temperature Insulation Wool (HTIW) in Modern Kiln Design
During production, either blowing or spinning processes ensure the uniformity of fiber diameter. When the dimensions of the material change, it forms "wool." Technically, therefore, HTIWs are not fibers, which explains the inaccuracy of the term "Refractory Ceramic Fiber (RCF)." Despite this, the term is still widely used.

One major advantage of high temperature insulation wool is its low density. Compared to traditional refractory materials like castables or bricks, they have a lower heat capacity, which is critical in modern kiln design. HTIWs' high resistance to temperature fluctuations allows for rapid heating or cooling of equipment. This characteristic, combined with their low mass, greatly enhances the operational efficiency and processing speed of batch furnaces, promotes more streamlined steel structure construction, and accelerates maintenance and refurbishment processes.

Classification of High Temperature Insulation Wool (HTIW)

Alumino Silicate Wool(ASW)
Low Biopersistence(LBP) Fibers
Polycrystalline Wool (PCW)

Alumino Silicate Wool (ASW)
Alumino Silicate Wool (ASW), commonly known as "Refractory Ceramic Fiber" (RCF), was introduced in 1942 and began commercial sales in the 1950s. It is primarily used in industrial sectors that require resistance to high temperatures, typically ranging from 600°C to 1400°C. ASW/RCF is favored for its excellent chemical resistance, made by melting and mixing specific ratios of Al₂O₃ and SiO₂ to form amorphous fibers. These products are widely used in industrial furnaces and automotive exhaust systems, where operating temperatures often exceed 900°C.

ASW/RCF is recognized for its low thermal conductivity and excellent chemical stability. Under EU REACH Regulation (EC) No 1907/2006, the use of these materials requires a rigorous registration process to ensure their safety in health and environmental aspects. CCEWOOL®'s ASW/RCF products have been successfully registered under REACH, demonstrating their suitability for the European market.
Low Biopersistence (LBP) Fibers
Low Biopersistence (LBP) fibers were developed in the 1980s and began commercial sales in the early 1990s. LBP fibers have become a key category in various fields, including domestic appliances and industrial applications, exempt from classification as carcinogens due to their low biopersistence. LBP fibers, like AES fibers, are made from a mixture of CaO, MgO, and SiO2 to form amorphous fibers, usable up to 1400°C. LBP fibers must contain more than 18% by weight of alkali or alkaline earth metal oxides and meet specific biopersistence standards to qualify for the Note Q exemption. Current research focuses on developing new types of high-temperature insulation LBP fibers, considering their low thermal conductivity, low biopersistence, and minimal linear shrinkage.

LBP fibers comply with the exemptions of the Classification, Labeling, and Packaging Regulation (EC/1272/2008), supported by biopersistence testing or long-term animal studies. CCEWOOL®'s LBP fibers are also registered under REACH, proving their suitability for use in the European market.
Polycrystalline Wool (PCW)
Polycrystalline Wool (PCW) has been commercially available since the early 1970s, mainly used in temperatures ranging from 600°C to 1700°C. PCW is primarily composed of aluminum (in oxide form constituting 71-73%) and silicon, produced via sol-gel technology. The fibers undergo high-temperature treatment to form a unique polycrystalline structure. PCW is known for its specific dimensions, chemical and thermal stability, low linear shrinkage, low thermal mass, high tensile strength, and minimal "shot" (non-fibrous particles) content, making it highly suitable for demanding thermodynamic/mechanical performance requirements in various industries, including ceramics, metals, petrochemicals, aerospace, and automotive.

In terms of regulation, while PCW does not have a specific classification within the EU, like other high-temperature insulation materials, it adheres to REACH regulations. CCEWOOL®'s PCW products have been registered under REACH, ensuring their availability in the European market.

Production of High Temperature
Insulation Wool (HTIW) and Products

For over fifty years, Alumino Silicate Wool (ASW), also known as ceramic fiber or refractory ceramic fiber (RCF), has played a revolutionary role in plant engineering and kiln construction due to its outstanding performance.

Alumino Silicate Wool (ASW)
ASW is made from raw materials such as kaolin (clay) or coal gangue (primarily composed of alumina and silica) or directly from alumina and silica synthetic materials, melted in an electric arc furnace with carbon electrodes. The molten material is either blown by compressed air or spun from a rotating disk to form fibers several centimeters long and 2-4 microns in diameter, typically with a teardrop-shaped head. These heads and unfiberized materials are collectively known as “shot.” CCEWOOL ceramic fibers contain about 5% to 15% shot. Reducing shot can significantly enhance the thermal insulation perfor-mance of the product.
Alkaline Earth Silicate (AES) Fibers
AES fiber raw materials consist of silicate combined with calcium carbonate, magnesium oxide, and other alkaline earth metal oxides. The production process is similar to that of ASW, where alkaline earth silicates are prepared via a high-temperature melting process. The main chemical components include calcium oxide (26-32%), magnesium oxide (4-7%), and silica (over 62-70%). These components are highly soluble and biodegradable in bodily fluids, ensuring they are safe for human health and the environment. They fully comply with the Global Harmonized System (GHS), so no carcinogenic warning labels are needed. CCEWOOL alkaline earth silicate fibers have passed solubility tests by Germany's Fraunhofer Laboratory, confirming their biodegradability and safety. Additionally, AES fibers are classified as non-carcinogenic by the International Agency for Research on Cancer (IARC).
Polycrystalline Wool (PCW)
PCW is an ideal choice for high-temperature and chemically aggressive applications. Polycrystalline fibers, made using sol-gel technology, are specifically manufactured to have a high alumina content of 73%. These fibers are more acid and alkali resistant than traditional fibers and possess excellent insulating properties. PCW contains almost no shot, resulting in very low thermal conductivity and excellent insulation performance. Its classification temperature reaches up to 1600°C (2912°F).
Alumino Silicate Wool (ASW)
ASW is made from raw materials such as kaolin (clay) or coal gangue (primarily composed of alumina and silica) or directly from alumina and silica synthetic materials, melted in an electric arc furnace with carbon electrodes. The molten material is either blown by compressed air or spun from a rotating disk to form fibers several centimeters long and 2-4 microns in diameter, typically with a teardrop-shaped head. These heads and unfiberized materials are collectively known as “shot.” CCEWOOL ceramic fibers contain about 5% to 15% shot. Reducing shot can significantly enhance the thermal insulation perfor-mance of the product.

High-temperature insulation fibers can be processed into various product forms, including fiber blankets, vacuum-formed boards, and shaped parts, extensively used to make insulation boards, burner parts, or kiln furniture. These products are made by combining fibers with inorganic fillers and organic binders and molding them on vacuum screens into diverse geometric shapes, with finished densities ranging from 170 kg/m³ to 1300 kg/m³. The variety in density and structure allows for the pro-duction of products with different mechanical and thermal properties.

Additionally, flexible papers and felts can be produced using organic binders, often used as sealing materials or where soft insulation materials are required.

Characteristics of High Temperature Insulation Wool (HTIW)

High temperature insulation wool, known for their low bulk density, low heat capacity, and low thermal conductivity, are ideal materials for constructing high-efficiency systems requiring fast heating and cooling cycles.

Low Bulk Density
- Reduces kiln load, extends furnace life
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Low Heat Capacity
- Less heat absorption, faster temperature rise, cost savings
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Low Thermal Conductivity
- Less heat loss, energy savings
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Thermal-Chemical Stability
- Stable performance under rapid heating and cooling
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Mechanical Vibration Resistance
- Elastic and air-impermeable
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Erosion Resistance
- Strong resistance to airflow erosion, wider application
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
High Thermal Sensitivity
- Enables automated kiln control
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Sound Insulation Performance
- Sound absorption and noise reduction, improving environmental quality
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Easy Installation
- Reduces the steel structure load of kilns, saving costs
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
Wide Range of Uses
- Meets the insulation needs of various industries
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.
No Oven Required
- Simple operation, more energy-efficient
CCEWOOL high temperature insulation wool is a fibrous refractory material. The most commonly used CCEWOOL high-temperature insulation fiber blanket has a bulk density of 96-128 kg/m3, while fiber blankets folded into CCEWOOL high temperature insulation fiber modules have a bulk density of 200-240 kg/m3. This is 1/5 to 1/10 the weight of lightweight refractory bricks or unshaped materials, and 1/15 to 1/20 the weight of heavy refractory materials. Thus, CCEWOOL high temperature insulation wool lining materials can achieve lightweight and efficient heating furnaces, significantly reducing the structural load of the kiln and extending the lifespan of the furnace body.

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Sustainability

History & Introduction of High Temperature Insulation Wool (HTIW)

History of High temperature insulation wool (HTIW)

Introduction of High Temperature Insulation Wool (HTIW)