Most energy intensive industries are voicing concern about their capacity to remain competitive. Among those, temperature process industries face specific challenges:  provide optimal products or services, while improving energy efficiency safely.

Not an easy task to comply with legislation, keep costs under control and develop effective new solutions. Safe, light, effective high temperature insulation can help mitigate issues pertaining to energy and health and safety field.

Two main types of materials have been used for decades in industry:  brick or refractory fibres, a rigid heavy solution and a light fibrous one

Light high temperature insulation without using fibres is now possible!

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Refractory bricks are heavy, small sized and therefore cannot replace fibre blocks in most applications. They also have lower insulation properties than their light fibrous counterparts : high temperature insulation wool will be preferred when flexible or short duty cycle or narrow insulation walls are required. Unfortunately concerns arise from the potential risk of airborne disease or health issues induced by fibre exposure. It  remains a major drawback when operators are working in high temperature environment with classified fibres. No easy choice between old cumbersome firebrick and classified light fibres blocks.

“ IPSIIS Foam innovative solution ”

IPSIIS is proud to unveil a  new high-temperature insulating and fiber free mineral foam. Light, high-temperature insulation available in prefabricated panels.

This new solution helps drive energy and operating costs down:

• Low thermal conductivity for energy efficiency
• Light product and low heat storage for shorter duty cycles
• Compatibility and interoperability with conventional solutions
• Fibre free

“ Fibre free ”

IPSIIS product can be customised to end-user demand: density, air tightness, bearing capacity can be tailored to meet specific needs thanks to the safe production process. Various shapes and dimensions are obtained by moulding or conventional machining.

“ A safe production process ”

An aqueous suspension containing water, refractory mineral powders and proprietary natural binders is formulated.  This slurry is foamed in a continuous flow aerator to yield a soft foam that can be spread or cast: the wet foam (W foam).

– The Wet Foam becomes rigid and highly insulating when dried and transformed in rigid raw foam (R foam)

– The raw foam can be sintered and transformed in ceramic foam for the most demanding applications: sintered foam (S foam)

“ 90% of porosity ”

Essential properties result from the open porosity:  air trapped in a refractory sintered matrix counts for more than 90% of the volume.

Density is low (around 300 kg/m3) but retains mechanical strength and thermal shock resistance.

Conductivity values range from 0,14 W/mK at 200ºC; 0,17 W/mK at 800ºC to  0,24 W/mK at 1000ºC. Working temperatures ranges from 1100°C to 1300 ºC.

Raw foam  can be produced on site in any quantity thanks to small sized producing units.  S foam precast and cured in metric size boards of thickness ranging from 5 to 100 mm.

“ Up-cycling ”

IPSIIS foam can be manufactured from high purity industrial resources but upcycling of  industrial mineral resources is also an option: refractory wastes, sawing sludges or cyclone dust can be used to improve energy efficiency in the very same plant that produce them.

The foams are water-resistant, frost resistant and can be dried rapidly from a drenched stage without damage even in hot environments.

End of life: thanks to their characteristics they can be easily recycled as inert wastes or upcycled as new insulating foams.