For export-oriented steel manufacturers, reducing energy consumption while boosting continuous casting efficiency isn’t just a goal—it’s a competitive necessity. One often-overlooked area with massive impact? The insulation layer inside your steel ladles.
Traditional refractory insulation materials like ceramic fiber blankets typically require 40–60 mm thickness to maintain safe operating temperatures. But that means higher heat loss, longer reheating times, and increased fuel costs—especially critical in markets like the Middle East or Southeast Asia where energy tariffs are rising fast.
Sunrise’s advanced vermiculite-based steel ladle insulation board offers a smarter solution. By optimizing particle structure and thermal bonding technology, it delivers the same performance as traditional materials—but at just 22–30 mm thickness (a reduction of 10–18 mm).
| Material Type | Avg. Thickness (mm) | Max Temp (°C) | Heat Loss Reduction (%) |
|---|---|---|---|
| Silica Aerogel | 25–35 | 1200 | ~35% |
| Vermiculite Board (Sunrise) | 22–30 | 1300 | ~50% |
| Ceramic Fiber Blanket | 45–60 | 1100 | ~25% |
In real-world trials across three Chinese steel plants, this thinner layer led to an average drop of 48–52°C on the outer shell surface during ladle transfer—a measurable improvement in both safety and operational continuity.
“We saw our reheat time cut by 12 minutes per cycle after switching to Sunrise’s vermiculite board. That’s nearly 2 hours saved daily across two shifts.” — Zhang Wei, Plant Manager, Jiangsu Steel Co.
Even the best material fails if installed incorrectly. Key steps include:
After installation, perform infrared thermography scans every 48 hours for the first week. Track temperature gradients across the ladle wall—any spike above 30°C from baseline indicates poor contact or voids.
This isn’t just about saving energy—it’s about building resilience into your production line. In regions like Saudi Arabia or Vietnam, where downtime costs exceed $10k/hour, even minor improvements compound into major savings over time.
