Need Insulation Recommendation for Record Protect Products 1

[waynef43]

All,

I have been given a mandate to upgrade our current record (paper & computer media) protection products. We'd like to eliminate the ovens that we currently use for drying our wet castings.

We currently use gypsum in our products and have done so for many years. Our business is a high volume operation and we use up to 1300 cubic feet of wet stucco per day.

What we're looking for, ideally, is a pourable(for use in molds), high temperature material that sets up relatively quickly (1/2 hour would be ideal). Weight is also an issue but can be addressed by using additives.

Our products are UL rated and tested pursuant to UL 72 which requires exposure to temperatures up to 2000 degrees F for up to an hour. They must also survive an impact test which involves dropping test units from a height of 30 ft.

FYI, a phenolic resin material I recently tested exploded in the oven as a result of gasses that were evolved due to decomposition of the material. Obviously, I'd like to avoid any materials that may potentially generate explosive gasses.

I've also looked at calcium aluminates but I'm running into some resistance because the general feeling it that the poured castings would need an extended period of time to cure and cast off the excess water in the body of the unit (excess water is a significant issue with us because of potential rust problems).

I would appreciate any insight into technologies and materials that may help up to achieve our goal. Thanks.

Wayne

 

[unclesyd]

You might give these people a call based on a recommendation by my high temp insulation buddy.

Mkae sure you talk to their Engineering Dept.

http://www.fssperry.com/index.html

 

[Compositepro]

Your application involves more than simply fining an insulation. One of the main mechanisms that will keep the temperature down in any fireprotection system is heat absorption by boiling or off-gassing. Plaster and other materials release water vapor when heated above a certain point. The temperature will not rise above that point until all the off-gassing is done. You want to direct the gasses in the direction opposite to the heat flow by having a vapor barrier on the protected side.

I'm not an expert in plaster but usually excess water is added to make it pourable. The water that actually sets the plaster is chemically bound and will not cause rust. It is the excess water that needs to be removed by drying to prevent rust.

A plaster-material is your best bet from a cost standpoint. Phenolic composite must be processed correctly to work. To prevent it from blowing-up it must be cured so it is slightly porous and permeable to the gasses it releases when it chars. Also, phenolic is a condensation cured polymer, which means the curing reaction releases water (usually 4 to 5%). This water remains trapped in the polymer if a high pressure cure is used to make a non-porous laminate. After cure this water will slowy dry-out. If you reheat a recently cured laminate that was not dried it will explosively delaminate. Phenolic composites are used to make rocket nozzles so they can work very well. But you have understand how it works.

 

[EdStainless]

We have a storage vault that was insulated with a cement based based material. No drying, just the cure time. I don't recall what the filler in it is. It is something with a phase change at about 250-300F and then vaproizes a bit higher. I know that it has some inert fillers just to lighten it also.

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Corrosion never sleeps, but it can be managed.

http://www.trenttube.com/Trent/tech_form.htm