In the field of waste incineration, ceramic fibre boards have become the material of choice for furnace linings due to their light weight, high thermal insulation efficiency and excellent thermal shock resistance. However, factors such as high-temperature corrosion, gas flow erosion and operational fluctuations often lead to premature pulverisation and failure of the fibre boards. Through material optimisation, process improvements and upgrades to the maintenance system, Mu Yi has achieved a breakthrough in ensuring the long-term operation of ceramic fibre boards in waste incinerators for up to 10 years. Today, Mu Yi will provide an in-depth analysis covering three aspects: technical principles, implementation pathways and case studies.
I. Failure Mechanisms of Ceramic Fibre Boards: Resolving the Core Contradiction Behind the Service Life Bottleneck
1.1 Structural Deterioration in High-Temperature Environments
Ceramic fibre boards are primarily composed of Al₂O₃-SiO₂ glass-phase fibres, and their failure essentially stems from the crystallisation of the glass phase. When fibres are exposed to high temperatures (>1200°C) over an extended period, the rearrangement of internal particles causes a transition from a glassy state to a crystalline state. The grain size increases to a level comparable to the fibre diameter (approximately 3–5 μm), the bonding strength at grain boundaries weakens, and the fibres become more brittle. Experimental data show that after 2,000 hours of continuous operation at 1300°C, fibre strength decreases by 40 per cent and the modulus of elasticity decreases by 65 per cent.
1.2 Chemical Erosion by Corrosive Gases
Flue gases generated by waste incineration contain acidic gases such as HCl, SO₂ and HF, as well as heavy metal vapours, which react with the SiO₂ in the fibres:
SiO₂ + 4HF → SiF₄↑ + 2H₂O
SiO₂ + 2HCl → SiOCl₂↑ + H₂O
The resulting volatile substances cause cavitation within the fibre structure, increasing surface roughness by 300 per cent and reducing resistance to spalling by 70 per cent. Furthermore, alkaline impurities in the flue gas, such as Na₂O and K₂O, form eutectic compounds with the fibres at 800 °C, accelerating grain growth and leading to extensive spalling of the fibreboard within five years.
1.3 Physical Damage Caused by Airflow Erosion
High-velocity gas flows (>15 m/s) within the incinerator carry particulate matter (particle size 0.1–2 mm), which continuously erodes the surface of the fibreboard, leading to fibre fracture and interlaminar delamination. Simulation experiments indicate that under conditions of a gas flow velocity of 12 m/s and a particle concentration of 5 g/m³, the mass loss rate of the fibreboard reaches 0.8 g/(m²·h), far exceeding the material’s natural wear rate.
II. Technical Approach to Extending Service Life to 10 Years: Mu Yi’s Three Major Innovation Systems
2.1 Optimisation of Material Formulation: Dual Breakthroughs in Corrosion Resistance and High-Temperature Resistance
Through nano-seed induction technology, Mu Yi introduces 0.5–2 μm ZrO₂ and Cr₂O₃ nanoparticles into the fibres, creating a grain boundary pinning effect that inhibits abnormal grain growth. Experimental data show that fibreboard containing 3% ZrO₂, after being held at 1350°C for 1000 hours, maintained a grain size of less than 2 μm and retained 85% of its strength—a 30% improvement over conventional materials.
Furthermore, a screening process utilising high-purity raw materials was employed to limit the content of impurities such as Fe₂O₃ and TiO₂ to below 0.1%, thereby preventing the formation of eutectic compounds. Testing revealed that, in an acidic gas environment (500 ppm HCl) at 1,200 °C, the corrosion rate of the optimised fibreboard was reduced to 0.02 mm/year—merely one-fifth of the industry average.
2.2 Structural Reinforcement Design: Gradient Protection from Single-Layer to Composite
Mu Yi has developed a multi-layer composite fibreboard, with the surface layer treated using a densification process (density 320 kg/m³), the middle layer comprising a thermal insulation layer with 90% porosity, and the base layer consisting of a high-alumina fibre reinforcement layer. This structure quadruples the surface layer’s resistance to scouring, reduces the thermal conductivity of the middle layer to 0.06 W/(m·K), and achieves a tensile strength of 0.8 MPa in the base layer.
Following its application in a waste incinerator with a daily processing capacity of 800 tonnes, the temperature of the fibreboard’s outer wall dropped from 450 °C to 90 °C, reducing heat loss by 65 per cent and yielding annual savings on natural gas costs exceeding 1.2 million yuan.
2.3 Intelligent Maintenance System: Predictive Maintenance and Surface Regeneration
Mu Yi has developed a 5G+AIoT intelligent monitoring system that uses embedded sensors to collect real-time data on the fibreboard’s temperature, strain and corrosion potential, and combines this with machine learning algorithms to predict its remaining service life. When the system detects localised temperature anomalies (ΔT > 50 °C) or strain exceeding 80% of the design value, it automatically triggers an alert and generates a maintenance plan.
Concurrently, nano-coating regeneration technology is employed, involving the application of a 1–2 mm thick composite coating containing mullite (3Al₂O₃·2SiO₂) and silicon carbide (SiC) to the surface of the fibreboard. At 1,000 °C, this coating forms a chemical bond with the substrate, increasing corrosion resistance fivefold and extending the service life to eight years. Combined with annual coating restoration, the overall service life exceeds ten years.
III. Case Study: 10 Years of Practice at a Municipal Waste-to-Energy Plant
3.1 Project Background
A municipal waste-to-energy plant with a daily

III. Case Study: 10 Years of Practice at a Municipal Waste-to-Energy Plant
3.1 Project Background
A municipal waste-to-energy plant with a daily processing capacity of 1,500 tonnes originally used conventional aluminium silicate fibreboard, which had an average service life of just four years and annual maintenance costs of 2 million yuan. In 2015, Mu Yi provided the plant with a comprehensive fibreboard upgrade solution.
3.2 Implementation Results
Extended Service Life: As of 2025, the upgraded fibreboards have been in continuous operation for 10 years. Testing has shown that fibre strength retention stands at 72 per cent, with surface corrosion depth <3 mm, meeting the criteria for continued use.
Energy Efficiency Optimisation: Furnace heat loss has been reduced from 18 per cent to 8 per cent, electricity generation per tonne of waste has increased by 12 per cent, and annual carbon dioxide emissions have been reduced by 12,000 metric tonnes.
Cost Savings: Over a 10-year period, total maintenance costs have been reduced to 30% of those of the traditional solution, with a payback period of just 2.8 years.
IV. Industry Trends: A Paradigm Shift from Material Upgrades to System-Wide Energy Efficiency
As the ‘Dual Carbon’ targets are further implemented, waste incinerators are evolving towards ultra-low emissions and high efficiency, with the application of ceramic fibre boards exhibiting two major trends:
Multifunctional Composites: The development of fibre boards that combine thermal insulation, catalytic decomposition (NOx, VOCs) and anti-coking functions is driving the upgrade of incinerators towards ‘zero emissions’.
Smart Integration: By incorporating digital twin technology, the full life-cycle management of fibre boards is achieved, shifting the focus from reactive maintenance to proactive optimisation.
Through the deep integration of materials science, thermal engineering and the Internet of Things (IoT), Mu Yi provides the waste incineration industry with long-lasting thermal insulation solutions designed to last for 10 years. Choosing Heru means choosing a future of efficient, reliable and sustainable green incineration.