High-Efficiency Microporous Insulation for Solid Oxide Fuel Cell Systems
Customer Background and Challenge
A leading engineering company specializing in stationary solid oxide fuel cell (SOFC) systems for distributed power generation approached us with a critical thermal management challenge. Their SOFC units were designed for residential and light-commercial combined heat and power (CHP) applications, where system efficiency, voltage stability, footprint, and external surface temperature are all key performance metrics.
The customer faced three key challenges in insulating the hot box: (1) achieving high-efficiency thermal insulation within extremely limited space — the hot box enclosure left minimal room for insulation, yet the external shell temperature had to remain below 60°C despite an internal temperature of 750°C; (2) accommodating complex internal structures, including small-diameter piping, multiple bends, irregular shapes, and various penetrations; and (3) ensuring stable, reliable performance throughout the system's entire operational life.
Unicorn Solution
To ensure installation convenience across the system's complex internal structures while delivering outstanding thermal efficiency throughout the hot box, Unicorn applied G1000 high-strength boards for bottom load support, custom-shaped or granulate-based microporous insulation for the complex piping systems, and TT 1000 Classic boards combined with SFlex flexible panels around the SOFC stack. All products are rated for continuous service up to 1,000°C, providing ultra-low thermal conductivity together with sufficient mechanical strength at elevated temperatures.
Customer Benefits
Minimizes heat loss through ultra-low thermal conductivity, helping improve the overall thermal efficiency of the SOFC hot box.
Reduces insulation thickness by up to 60% compared with conventional insulation, enabling more compact SOFC system designs.
Supports complex hot box geometries through precision-machined components, flexible panels, and microporous granules suitable for curved surfaces, pipe penetrations, and confined spaces.
Provides long-term thermal stability and reliability. The inorganic microporous structure contains no organic binders, eliminating thermal decomposition while ensuring excellent long-term dimensional and thermal stability under continuous high-temperature operation. This material design supports an extended service life in demanding SOFC applications.
Delivers outstanding fire safety performance in SOFC systems. Its A1 non-combustible classification provides the highest level of fire protection for both the system and its operating environment.
Engineering Support – Our engineers work closely with customers from concept development through product validation, providing thermal simulations, insulation material selection, prototype testing support, and customized insulation solutions. This engineering-driven approach helps optimize thermal performance while reducing development time.
Microporous Insulation Panel for Steel Ladle Thermal Efficiency Improvement
Customer Background and Challenge
A leading Chinese steel manufacturer operating dozens of steel ladles approached Unicorn to improve the thermal efficiency of its ladle insulation system. The primary objective was to reduce ladle shell temperatures and minimize heat loss without increasing the existing insulation thickness.
Due to the fixed ladle dimensions and required production capacity, increasing the insulation thickness was not a viable option. The customer therefore required a higher-performance insulation material capable of delivering superior thermal protection within the available installation space.
The original ladle insulation structure and measured shell temperatures were as follows:
Working lining: 220 mm corundum + 100 mm bauxite
Backup insulation layer: 10 mm ceramic fiber board
Measured outer shell temperature: 315–330°C during normal operation, increasing to above 380°C after multiple heating cycles.
Unicorn Solution
Unicorn replaced the existing 10 mm ceramic fiber backup insulation layer with TT 1000 Ironflex, a flexible microporous insulation board specifically developed for demanding high-temperature industrial applications.
Compared with conventional ceramic fiber insulation, TT 1000 Ironflex offers significantly lower thermal conductivity at elevated temperatures, reducing heat transfer from the molten steel to the ladle shell while maintaining the same insulation thickness.
This solution delivered a substantial thermal performance upgrade without requiring any modification to the existing ladle structure or reducing its working capacity.
Test Results
The customer conducted extensive performance monitoring across multiple steel ladles. The results demonstrated a significant improvement:
| Parameter |
Before (Ceramic Fiber) |
After (Unicorn Panel) |
| Cold side temperature |
315°C – 330°C |
~260°C (avg.) |
| Peak shell temperature |
380°C+ |
<320°C |
| Production validation |
Routine operation |
1,500+ heats |
Customer Benefits
Improved Thermal Efficiency and Reduced Heat Loss
Replacing conventional ceramic fiber with microporous insulation significantly reduces heat transfer through the ladle shell. The measured reduction in shell temperature demonstrates superior thermal insulation performance, helping minimize overall heat loss without increasing the insulation thickness.
Lower Shell Temperature for Improved Workplace Safety
The insulation upgrade reduced the outer shell temperature by approximately 50–80°C, lowering radiant heat around the ladle and creating a safer working environment for plant personnel.
Supports More Stable Steelmaking Operations
By reducing heat loss from the ladle, the microporous insulation helps maintain more stable thermal conditions during molten steel handling. This contributes to more consistent steelmaking performance while preserving the existing ladle structure and production capacity.
Potentially Extends Ladle Service Life
Lower shell temperatures help reduce thermal stress on the ladle shell and surrounding structures, potentially extending maintenance intervals, reducing maintenance costs, and increasing overall ladle service life.
