Though the example of the steel, aluminium and ceramic industries

WDS® – All the advantages are on your side:

  • Very low heat losses
  • Best possible temperature distribution
  • Increased effective volume
  • Improved energy efficiency
  • Prolonged service life
  • Increased operating reliability
  • Harmless to health
  • Easy to handle

When WDS® is used, a uniform temperature profile is established. This prolongs equipment lifetimes and improves operating reliability. WDS® products are supplied in forms appropriate to the application. They are therefore extremely easy to handle.

The best solution for every industry

A widespread application of WDS® in the steel industry is back-up insulation in steel ladles. The molten steel may reside for about 8 hours here, at temperatures up to 1,700 °C. There are also more severe demands on the effective volume. These demands can be satisfied by newly developed refractory materials employing WDS® Flexible. Because WDS® Flexible can be used in thinner layers to achieve the same insulating effect, the effective volume is increased by 10 percent. On the other hand, in a steel ladle, WDS® Flexible back-up insulation with the same thickness as conventional insulation can increase energy efficiency by almost 50 percent.

In the aluminum industry, furnaces and launders are particularly critical process components in the processing of both primary and secondary aluminum.

If the molten metal is to be homogeneously liquid in all parts of the furnace, there must be an optimum temperature distribution. With WDS® Ultra as back-up insulation, this can be achieved while also gaining 15 percent more effective volume. The significant reduction in the cold-face temperature by an average of 20 °C reduces operating costs and improves process reliability.

Another application in the field of high-temperature industrial insulation is in kilns for the ceramic industry. In order to ensure that the product quality stays constant throughout the production process, the launders and tundishes must also be lined with a high-efficiency insulation material.

WDS® Flexible and WDS® Ultra have proven to be ideal for this purpose.

Thanks to the significantly improved thermal insulation capacity of the launder, no reheating is needed over short and medium distances. Over long distances, less energy is required for reheating, and operating costs are therefore lower. This additionally increases the lifetime of the launders, since there is much less risk of aluminum deposits on the refractory lining as a result of premature solidification.

Kilns, including tunnel and roller kilns, are important components in the production of coarse and fine ceramics. With newly developed WDS®Ultra insulation systems, kiln manufacturers can reduce wall thickness with no loss in insulation effect. This allows the effective volume of the kiln to be increased by an average of 15 percent without changing the external size. The appreciable reduction in the cold-face temperature improves energy efficiency per metric ton of fired final products by an average of 25 percent over kilns with conventional insulation.

Further detailed information you will find under Applications