Introducing ArmorWool™

ThermalMax is proud to introduce ArmorWool™ insulation products, a next-generation of high-temperature fiber materials using the innovation of ultra low-shot (ULS) technology. These premium blankets, boards and paper – available in PCW, RCF and AES – are superior high-temperature insulating solutions for the steel, aluminum, ceramics, auto and OEM industries. They provide lower shot, higher mechanical strength, optimum thermal performance, superior handling, higher quality and greater cost-effectiveness.


Ultra Low-Shot (ULS) Technology

High temperature fibers – Refractory Ceramic Fibers (RCF) and Alkaline Earth Silicate (AES) fibers – have been used for many high temperature applications over the past few decades and have consisted of up to 50% of their weight in ‘shot’.

Shot is defined as small granular glass formed during production and not converted into a fibrous material. These shot particles do not contribute to a better thermal insulation of the product, or help the mechanical properties. Shot only adds weight to the bulk, blanket, module, paper, board or felt product.

In 2005, the first low shot fiber product was introduced, enhancing the quality and performance of high-temperature fiber products. It delivered a few of the advantages of the new ArmorWool™ technology compared to the standard fiber products.


Superior Handling

When installing fiber materials in a furnace, working with fiber which delineates, tears or creates too much dust can be challenging.

While wearing personal protection equipment (PPE) is advised, it does not eliminate airborne fibers from reaching unprotected skin, common problems typical of poorly needled fiber products. As a result of the ULS technology, the interlocking of the fibers from needling is highly increased by the fiber index.

Fiber diameter (i.e. 5-7 microns) also is linked to potential skin irritation; however, the ULS technology means finer fibers, better needling, less dust—all resulting in less skin irritation.


Toughest Tensile Strength

The superior fiber index and the needling technique give ArmorWool™, with its ULS technology fiber products, a superior mechanical strength. By withstanding a higher gas velocity, both parallel and perpendicular to the main fiber orientation, helps with your furnace. Plus, at installation, it offers a better tensile strength as well as a much higher resiliency after compression—up to 20% more resiliency.

This highest mechanical strength means no tearing of blankets and no sagging of fiber blanket on studs over time. In addition, particularly in module making, the resiliency perpendicular to the main fiber orientation is very important for the strength of the module and the required compression required to make a tight and compacted fiber lining.


Lowest Thermal Conductivity

Heat flow in a refractory lining is based on the performance of the insulation materials. For lightweight fibrous products at high temperature (>1112°F), thermal radiation is the most dominant form of energy transfer.

Fibrous products block radiation by having a large number of surfaces which scatter incoming light. As the radiation interacts with each surface, its intensity is reduced, restricting transfer through the fiber structure.

Through a unique fiberization process in our ArmorWool™ products, the conversion from molten glass to fiber is improved, optimizing the ratio of shot to fiber and minimizing the size of the pieces of shot. This process enhances the thermal conductivity of ArmorWool™ up to 30%.

The key is increasing the fiber index; the higher the fiber index, the better the performance of the high temperature fiber in its lifetime. Key factors for improving the fiber index include minimizing the shot contents and optimizing fiber diameter. The rest is related to the fiber orientation as a result of the needling system.

By combining these key factors, our ArmorWool™ ULS technology delivers superior thermal insulation properties in high temperature fiber products, as well as optimizes lining thickness or reduce energy consumption and CO2 emissions.