Kaolite Insulating - John J Moroney

1 Kaolite 2000-HSis a general-purpose, lightweight castable for useup to 2000 F (1093 C).It maintains excellent volume stabilitythroughout its temperature use range. This is an excellent advan-tage for applications where strength and low thermal conductivityare 2200is designed for temperatures up to 2200 F (1204 C).It has excellent volume stability and good strength. This general-purpose, lightweight castable has low density, excellent resistanceto thermal shock, and low thermal conductivity. Kaolite 2200-HSis a medium weight, high strength castable thatresists thermal shock, and has excellent volume stability.

2 It pos-sesses the best thermal conductivity-to-weight ratio in the industry. Kaolite 2300-LIis a 2300 F (1260 C)lightweight castable whichincorporates a high-purity binder for applications where hydrogen orreducing atmospheres are present. Kaolite 2500-LIis a high-strength lightweight castable that containsan intermediate-purity calcium-aluminate cement. Total iron oxidecontents of enables use where hydrogen or reducing atmospheres are present. Its low thermal conductivity and densityproduces the most economical 2500 F (1371 C) Insulating castableon a per cubic foot basis. Kaolite 2500-HSis a medium weight, high-strength, insulatingcastable for use where strength and thermal stability are has excellent casting characteristics.

3 Kaolite 2600-LI is designed specifically for use in petrochemicalapplications. It incorporates a cement of sufficient purity for low ironcontent and high-intermediate temperature Monoxide Disintegration Test - Kaolite 2300-LIThe special low-impurity materials were formulated especially for oilrefinery and chemical units as well as other applications operatingin hydrogen or highly reducing atmospheres. In order to test Kaolite2300-LI, a 700 hour carbon monoxide disintegration test was con-ducted. ASTM C 288-62 procedure was followed, with the excep-tion that the samples tested were dried rather than fired. The lack offiring of the samples tends to hasten the attack of carbon monoxideattack.

4 Firing at 2300 F before testing in carbon monoxide atmos-pheres is specified by ASTM procedure to lessen the carbonmonoxide attack. This was omitted because it is not reasonablefrom a practical standpoint, as no castable, will be subjected to2300 F throughout its samples were rated merely as Affected because of slightcracking which occurred between 500 and 700 hours in one of thetwo samples. At the end of 500 hours, which is the specified testingtime of ASTM, no effect was shown by either sample. As a result ofthis severe test, it is recommended that Kaolite 2300-LI be used inapplications where carbon monoxide or other reducing atmos-pheres are Light weight and low thermal conductivity reduce both the quantity of heat storage and heat transfer producing significantsavings in furnace fuel consumption Lower densities reduce the amount of supporting furnace steel-work required and provide more insulation with a thinner lining.

5 Applications Backup insulation in two component linings in petrochemicalprocess units Hot face lining in ductwork from waste heat recovery boilers andprocess unit linings - regenerator. Hydrogen or reducing atmosphere linings Radiant section in steam flood generators. Hydrogen or reducing atmosphere linings. Steam flood generator convection sections and target walls Cat cracker regenerator linings Petrochemical applicationsInstructions For UsingCastingHighest strength is obtained with castable refractory by using theleast amount of clean mixing water. This will allow thorough working of material into place by vibrating or rodding.

6 A mechanicalmixer is required for proper placement (paddle-type mortar mixersare best suited). After achieving a ball-in-hand consistency, mix for6 minutes. Place material within 30 minutes after suitable gunite equipment. Material should be predampeneduniformly with approximately 10 - 12 % by weight of clean water inamechanical mixer before placing into gun. This will reducerebound and dust. Add required water at nozzle for effective placement. Suggested air pressure at the nozzle is 30 to 45 bagged castables in a dry place, off the ground and, whenpossible, with the original shrink wrapping intact.

7 Normal shelf lifeis 12 months if properly forms must be used when placing material. All poroussurfaces that will come in contact with the material must be waterproofed with a suitable coating or membrane. For maximumstrength, cure 24 hours under damp conditions before initial heat-up. Keep freshly placed castable warm during cold weather,ideally between 70 F and 80 F. New castable installations must beheated slowly the first placed lightweight castables are prone to a deterioratingcondition called alkali hydrolysis when they are kept in a non-driedstate for a sustained period of time in a warm, humid these conditions, the castables should be force-dried soonafter placement or coated with Kao-Seal to resist the possible dete-rioration InsulatingCastablesProduct 14-720 Kaolite InsulatingCastablesProduct InformationPhysical Properties32000-HS22002200-HS2300-LI2500 -LI2500-HS2600-LIRecommended use limit, F ( C)12000 (1093)2200 (1204)2200 (1204)2300 (1260)2500 (1371)2500 (1371)

8 2600 (1427)Avg. lb req. to place one cubic ft2,(kg)58 (26)58 (26)71 (32)56 (25)68 (31)82 (37)82 (37)Nominal density, fired, pcf (kg/m3)@ use limit55 - 64 55 - 64 68 - 78 55 - 6464 - 7380 - 8880 - 88(881 - 1026)(881 - 1026)(1090 - 1250) (881 - 1026)(1026 - 1170)(1282 - 1410) (1282 - 1410)@1500 F (816 C)53 - 6353 - 6367 - 7854 - 6559 - 7278 - 8878 - 88(849 - 1010)(849 - 1010)(1074 - 1250) (865 - 1042)(946 - 1154)(1250 - 1410) (1250 - 1410)Method of installationcast/guncast/guncast/guncast /guncast/guncast/guncast/gunRecommended Water Ranges, % by weight3 Casting (by vibrating) 44 - 54 44 - 54 38 - 44 48 - 5541 - 4830 - 3531 - 35 Pounds per bag (kg)40 (18)

9 40 (18)50 (23)40 (18)50 (23)50 (23)50 (23)Shelf life, months12121212121212 Modulus of rupture, psi (MPa) ASTM C 133, cast, gunnedDried 18-24 hrs. @ 220 F (104 C)90 - 150 90 - 150 250 - 400 120 - 200200 - 300250 - 400300 - 500( - )( - )( - )( - )( - )( - )( - )Fired 5 hrs. @ 1500 F (816 C)85 - 150 85 - 150 150 - 250 90 - 250150 - 300175 - 325175 - 325( - )( - )( - )( - )( - )( - )( - )Fired 5 hrs. @ use limit 80 - 150 80 - 200 200 -300 150 - 300200 - 300400 - 600500 - 900( - )( - )( - )( - )( - )( - )( - )Cold Crushing strength, psi (Mpa)Dried 18-24 hrs. @ 220 F (104 C)350 - 650 350 - 650 850 - 1400 350 - 500500 - 800700 - 1000800 - 1200( - )( - )( - )( - )( - )( - )( - )Fired 5 hrs.

10 @ 1500 F (816 C)350 - 900 3500 - 900 900 - 1600 350 - 1000600 - 1200800 - 1600700 - 1400( - )( - )( - ) ( - )( - )( - ) ( - )Fired 5 hrs. @ use limit 450 - 900 450 - 900 700 - 1200 400 - 950900 - 1500900 - 15001200 - 1800( - )( - )( - )( - )( - )( - ) ( - )Perm. linear change, % (ASTM C 113)4 Dried 18-24 hrs. @ 220 F(104 C)0 to 0 to 0 to 0 to to to to 5 hrs. @ 1500 F (816 C) to to to to to to to 5 hrs. @ use limit to to to to to + to to Analysis, %5 Alumina, Al2O338 38 43 41444446 Silica, SiO237 37 28 37353536 Ferric oxide, oxide, oxide , CaO 20 (12) 20 (12) 25 (18) 19 (10)17 (11)17 (13)14 (11)Magnesium oxide, MgO , as, Conductivity, BTU ft2 F (w/m k), ASTM C 417mean temperature@500 F (260 C) ( ) ( ) ( ) ( ) ( ) ( ) ( )@1000 F(538 C) ( ) ( ) ( ) ( ) ( )