Monolithic Fiber Modules


Morgan Thermal Ceramics announces the availability of its exclusive Pyro-Bloc® modules, ideally suited for furnace and boiler lining applications, that reduce the risks of hot spots and lining failures. They are the only monolithic fiber modules on the market and combine the insulating material advantages of high temperature insulation fiber with rapid furnace installation.  Compared to standard folded modules, Pyro-Bloc® modules feature higher density, better tolerance compliance, superior resistance to erosion from high velocity gas, and significant installation advantages. They are ideal for applications such as stack, flare, and ductwork linings, as well as kiln car block and seals, burner blocks, and peep sights. Pyro-Bloc® modules have a much higher standard density than folded modules, making them ideal for applications with harsh conditions, and where a high velocity of air moving through the unit tends to abuse linings. The material’s higher density options, 12 and 15 PCF, are particularly suitable for resisting wear and tear damage in areas that typically sustain a significant amount of abuse, including walkways where personnel conduct cleanouts.  In addition, the density of the 15 PCF Pyro-Bloc® module provides the best thermal conductivity available with modular systems. Pyro-Bloc® HS modules, offered in densities as high as 23 PCF, have been specifically designed for enhanced mechanical abuse resistance. Pyro-Bloc® module’s monolithic edge grain surface is more resistant to high velocity gas erosion than folded systems. Along with erosion resistance, the surfaces will more readily accept any required post treatments due to the grain of the fiber, which allows a deeper penetrating bond of the substrate. A number of treatments are available, with some improving velocity resistance by as much as 35 percent. 

Morgan Thermal Ceramics provides superior quality control of the Pyro-Bloc® module’s density, because the density is not dependent upon the fiber manufacturer’s control of blanket density, thickness variables, or folding machine compression tolerances.  Each Pyro-Bloc® module is made up of two sections of Pyro-Log® in edge-grain orientation, held in position with two stainless steel tubes mounted transversely through the modules and remote from the hot face. They are anchored to the furnace casing with patented SS-316 hardware designed for corrosive gas resistance and a specially designed tube support yoke, which allows the module cold face to conform to any discontinuity of the furnace shell, while still maintaining structural support and hardware integrity. The design provides a close-fitting lining against the furnace shell and offers an extremely tight seal. Pyro-Bloc® modules are easy to install. The monolithic fiber is easy to cut and fit around openings and modify in the field. It provides a superior finished surface for such special shapes as peep site frames, tube penetrations and burner tiles. The modules are especially ideal for corners, bullnoses, or transition sections. Pyro-Bloc® modules can be installed with far fewer through joints running from the hot face to the cold face compared to folded modules. The extra joints present in a folded system can increase shrinkage over time, creating opportunities for shrinkage gaps and shell damage. With Pyro-Bloc® modules, there is only one joint on either side of an individual module; folded modules typically require as many as eight to ten folds, each one a possible location of shrinkage. Overall, folded modules create about ten times the number of opportunities for openings from shrinkage, compared to Pyro-Bloc® modules.


  • higher density
  • resistance to erosion
  • for furnace and boiler lining applications

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