Revolutionising Single Crystal Furnace Insulation with VSG’s Alumina Fiber Blanket

Single crystal furnaces play a critical role in the photovoltaic industry, where consistent performance and cost-efficiency are key. However, the traditional use of graphite felt as an insulation material for the soft hearth of these furnaces presents significant challenges. Poor thermal conductivity and a high ablation rate lead to frequent maintenance, with materials typically requiring replacement every two years.

At Vulcan Shield Global (VSG), we’ve developed an innovative solution to these challenges: Alumina Fiber Needled Blankets. This advanced material outperforms graphite felt in insulation properties, strength, and durability, making it the ideal choice for single crystal furnace insulation.

The Challenges of Graphite Felt

Graphite felt, despite being widely used, struggles with key performance issues:

Poor thermal conductivity at lower temperatures, leading to inefficient energy use.
High ablation rates, resulting in faster material degradation.
Frequent maintenance requirements, adding to operational costs.

Alumina Fiber: A Superior Alternative

VSG’s alumina fiber needled blankets provide a game-changing alternative to graphite felt. Extensive 3rd party testing reveals the following advantages:

1. Exceptional Thermal Conductivity

Test results show that at 1200°C, the thermal conductivity of alumina fiber blankets is equivalent to viscose graphite felt. However, below 1100°C, alumina fiber blankets outperform graphite felt with lower thermal conductivity, resulting in better energy-saving performance. The benefits become even more pronounced at lower temperatures, providing a significant edge in energy efficiency.

Thermal Conductivity Test Comparison Between Alumina Fiber and Viscose Graphite Felt

2. Superior Tensile Strength

Independent testing from a 3rd party testing facility shows that VSG’s alumina fiber needled blanket has a tensile strength of 256.9 KPa in the length direction, compared to only 76.42 KPa for viscose carbon felt. This higher tensile strength ensures:

Greater durability
Reduced risk of damage during assembly and disassembly of insulation materials
Longer operational lifespan

3. Unmatched Ablation Resistance

Graphite felt, primarily made of carbon, begins to disintegrate at temperatures as low as 300°C. In contrast, VSG’s alumina fiber blanket demonstrates 0% Loss on Ignition (LOI) at 1050°C for 1 hour, showcasing its superior ability to withstand high temperatures without degradation.

View the GDMS of graphite felt and ablation test of VSGs alumina fiber blanket below.

VSG’s Needled Blanket displays 0% LOI at 1050°C at 1 hour.

4. Cost-Effectiveness

Preliminary tests conducted by a leading photovoltaic green energy firm demonstrate that alumina fiber blankets are a more cost-effective solution than carbon fiber felt due to:

Stronger Oxidation Resistance: Alumina fiber blankets can operate in aerobic environments for extended periods, significantly extending service life.
Energy Efficiency: Replacing 50% of the carbon felt in the bottom insulation layer of a single crystal furnace with alumina fiber resulted in energy savings of 1 kW per hour.
Longer Service Life: Alumina fiber blankets last more than twice as long as carbon fiber felt.
Lower Cost: While alumina fiber blankets cost less than double the price of carbon felt, they deliver significantly greater value.

A Greener Future with Alumina Fiber

With our Guangxi production base set to commence operations next month in December 2024, Vulcan Shield Global is poised to offer even more competitive pricing for our products. This positions alumina fiber as an affordable, high-performance solution for the continued evolution of insulation materials in the photovoltaic industry.

Explore the advantages of VSG’s alumina fiber needled blanket and revolutionize your furnace performance with a cost-effective, energy-efficient, and durable solution.

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