In high-temperature steelmaking environments, the choice of insulation material directly impacts energy efficiency, operational safety, and production continuity. Many steel plants still rely on traditional aluminosilicate fiber blankets—often over 100mm thick—to maintain ladle temperatures. But what if you could reduce thickness by 10–18mm while achieving even lower shell surface temperatures (up to 50°C cooler)? That’s exactly what Sunrise’s vermiculite-based steel ladle insulation panels deliver—with measurable performance gains.
“We reduced our ladle shell temperature from 180°C to 130°C after switching to Sunrise vermiculite boards. The thinner layer allowed us to fit more refractory lining without compromising heat retention.” — Engineer, Shandong Steel Plant
| Property | Aluminosilicate Fiber (Typical) | Sunrise Vermiculite Board |
|---|---|---|
| Thermal Conductivity @ 600°C (W/m·K) | 0.12–0.15 | 0.07–0.09 |
| Max Service Temp (°C) | 1260 | 1350 |
| Compressive Strength (kPa) | ≥150 | ≥400 |
| Weight per m² (kg/m²) | ~25 | ~18 |
These numbers tell a clear story: vermiculite-based boards offer superior thermal resistance with less mass and better mechanical stability—especially important when dealing with repeated heating cycles and handling during ladle maintenance.
At a mid-sized steel mill in India, engineers replaced 120mm aluminosilicate fiber with 102mm Sunrise vermiculite board. Post-installation monitoring showed:
This isn’t just about saving fuel—it’s about enabling faster turnaround times, reducing thermal stress on ladle structures, and improving operator safety. In continuous casting operations, every minute counts.
💡 Pro Tip: Don’t just stack thickness—optimize structure. A well-designed vermiculite panel system can outperform thicker fiber layers due to its uniform density and low thermal bridging.
For optimal results:
Remember: proper installation ensures longevity and consistent performance—not just initial results.
You may be facing similar challenges—higher shell temps, longer preheating, inconsistent heat retention. If so, it’s time to rethink your insulation strategy.
