Tri-Mor® Kaolite® LI MonolithicsDatasheet Code US: 3-14-103 MSDS Code US: 103, 153

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© 2009 Morgan Thermal Ceramics, a business within the Morgan Ceramics Division of The Morgan Crucible Company plc

Product DescriptionKaolite 2000-LI is a lower density cast/gun 2000°F (1093°C)monolithic traditioinally used to reduce the amount of supportingfurnace steel work required and provide more insulation with athinner lining.

Kaolite 2300-LI and Kaolite 2300-LI Gun are 2300°F (1260°C)lightweight monolithics which incorporates a high-purity binder forapplications where hydrogen or reducing atmospheres are present.

Kaolite 2500-LI and Kaolite 2500-LI Gun are high-strengthlightweight monolithics that contains an intermediate purity calcium-aluminate cement. Total iron oxide contents of 0.9% enables usewhere hydrogen or reducing atmospheres are present. Its lowthermal conductivity and density produces the most economical2500°F (1371°C) insulating monolithic on a per cubic foot basis.

Kaolite 2600-LI and Kaolite 2600-LI Gun are designed especiallyfor use in petrochemical applications. They incorporate a cement ofsufficient purity for low iron content and high-intermediatetemperature strengths.

Carbon Monoxide Disintegration Test - Kaolite 2300-LI

The special low-impurity materials were formulated especially for oilrefinery and chemical units as well as other applications operating inhydrogen or highly reducing atmospheres. In order to test, a 700hour carbon monoxide disintegration test was conducted. ASTM C288-62 procedure was followed, with the exception that the samplestested were dried rather than fired. The lack of firing of the samplestends to hasten the attack of carbon monoxide attack. Firing at2300°F before testing in carbon monoxide atmospheres is specifiedby ASTM procedure to lessen the carbon monoxide attack. This wasomitted because it is not reasonable from a practical standpoint, asno monolithic, will be subjected to 2300°F throughout its structure.

The 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 atmospheresare present.

Applications• Backup insulation in two component linings in petrochemicalprocess units• Hot face lining in ductwork from waste heat recovery boilers andprocess unit• F.C.C.U. 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 applications

Features• Light weight and low thermal conductivity reduce both the quantityof heat storage and heat transfer producing significant savings infurnace fuel consumption• Lower densities reduce the amount of supporting furnace steelworkrequired and provide more insulation with a thinner lining.

Instructions For UsingCastingHighest strength is obtained with monolithic refractory by using theleast amount of clean mixing water that will allow thorough workingof material into place by vibrating or rodding. A mechanical mixer isrequired for proper placement (paddle-type mortar mixers are bestsuited). Mix for 6 minutes to achieve a good ball-in-handconsistency. Place material within 30 minutes after mixing.

GunningUse suitable gunite equipment. The gun grade material should bepredampened uniformly with approximately:- Kaolite 2000-LI 8-10%- Kaolite 2300-LI 8-10%- Kaolite 2500-LI 6-8%

by weight of clean water in a mechanical mixer before placing intogun. This will reduce rebound and dust. Add required water atnozzle for effective placement. Suggested air pressure at the nozzleis 20 to 35 psi.

PrecautionsStore bagged monolithics in a dry place, off the ground and, whenpossible, with the original shrink wrapping intact. Normal shelf life is 12 months if properly stored.

Watertight forms must be used when placing material. All poroussurfaces that will come in contact with the material must bewaterproofed with a suitable coating or membrane. For maximumstrength, cure 24 hours under damp conditions before initial heat-up.Keep freshly placed monolithic warm during cold weather, ideallybetween 70°F and 80°F. New monolithic installations must beheated slowly the first time.

Freshly placed lightweight monolithics 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 environment.Under these conditions, the monolithics should be force-dried soonafter placement to help retard the possible deterioration effects.

Insu la t ing Our Wor ld

Tri-Mor® Kaolite® LI Monolithics

Insu la t ing Our Wor ld

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Physical Properties32000 - LI 2300-LI 2300-LI Gun 2500-LI 2500-LI Gun 2600-LI 2600-LI Gun

Method of installation6 cast/gun cast gun cast gun cast gunRecommended use limit, °F (°C)1 2000 (1093) 2300 (1260) 2300 (1260) 2500 (1371) 2500 (1371) 2600 (1427) 2600 (1427)Avg. lb req. to place one cubic ft2, (kg)

45 (20) 61 (28) 63 (29) 69 (31) 71 (32) 83 (38) 84 (38)Density, fired, pcf (kg/m3)9@ 1500°F (816°C) 40 - 48 55 - 66 56 - 68 62 - 74 63 - 75 78 - 88 79 - 89

(641 - 769) (881 - 1057) (897 - 1088) (993 - 1184) (1008 - 1200) (1250 - 1410) (1265 - 1424)@ use limit 41 - 48 55 - 66 56 - 68 64 - 76 64 - 76 80 - 89 80 - 89

(657 - 768) (881 - 1056) (897 - 1088) (1026 - 1216) (1026 - 1216) (1282 - 1424) (1282 - 1424)Recommended Water Ranges, % by weight3casting (by vibrating) 65 - 75 46 - 54 - 38 - 47 - 28 - 35 -pouring 78 - 85 - - - - - -Pounds per bag (kg) 25 (11) 40 (18) 40 (18) 50 (23) 50 (23) 50 (23) 50 (23)Shelf life, months 12 12 12 12 12 12 12Modulus of rupture, psi (MPa) ASTM C 133, castdried 18-24 hrs @ 220°F (104°C)

110 - 220 120 - 200 100 - 180 200 - 300 150 - 250 300 - 500 300 - 500(0.76 - 1.52) (0.83 - 1.38) (0.68 - 1.24) (1.38 - 2.07) (1.03 - 1.72) (2.07 - 3.45) (2.07 - 3.44)

fired 5 hrs @ 1500°F (816°C) 100 - 200 110 - 250 110 - 250 150 - 300 120 - 250 225 - 400 250 - 400(0.68 - 1.38) (0.80 - 1.72) (0.80 - 1.72) (1.03 - 2.07) (0.83 - 1.72) (1.55 - 2.76) (1.72 - 2.76)

fired 5 hrs @ use limit 100 - 200 150 - 300 135 - 350 200 - 350 250 - 400 500 - 900 500 - 900(0.68 - 1.38) (1.03 - 2.07) (0.93 - 2.41) (1.38 - 2.41) (1.72 - 2.75) (3.45 - 6.21) (3.45 - 6.21)

Cold Crushing strength, psi (Mpa) dried 18-24 hrs @ 220°F (104°C) 325 - 600 350 - 600 350 - 600 500 - 800 450 - 650 800 - 1200 800 - 1500

(2.24 - 4.13) (2.41 - 4.13) (2.41 - 4.13) (3.45 - 5.52) (3.10 - 4.48) (5.52 - 8.28) (5.51 - 10.34)fired 5 hrs @ 1500°F (816°C) 275 - 550 350 - 1000 350 - 900 600 - 1200 550 - 1000 750 - 1300 850 - 1500

(1.90 - 3.79) (2.41 - 6.90) (2.41 - 6.20) (4.14 - 8.28) (3.79 - 6.89) (5.17 - 8.96) (5.86 - 10.34)fired 5 hrs @ use limit 200 - 400 400 - 950 400 - 900 800 - 1400 600 - 1000 1200 - 1800 1000 - 2000

(1.38 - 2.76) (2.76 - 6.55) (2.75 - 6.20) (5.52-9.65) (4.13 - 6.89) (8.28-12.41) (6.89 - 13.79)Perm. linear change, % (ASTM C 113)4dried 18-24 hrs @ 220°F (104°C) 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2fired 5 hrs @ 1500°F (816°C) -0.6 to -1.3 -0.1 to -0.55 -0.2 to -0.6 -0.1 to -0.4 -0.2 to -0.5 -0.1 to -0.4 -0.2 to -0.5fired 5 hrs @ use limit -1.5 to -2.0 -1.0 to -2.0 -1.0 to -2.0 -0.5 to -1.5 -0.5 to -1.5 -0.5 to -1.5 0 to -1.5

Chemical Analysis, %, Weight basis after firing5Alumina, Al2O3 34 40 38 43 42 47 45Silica, SiO2 40 38 41 36 37 36 38Ferric oxide, Fe2O3 1.6 0.9 0.9 0.9 0.9 1.0 1.0Titanium oxide, TiO2 1.1 1.4 1.4 1.6 1.8 1.5 1.8Calcium oxide , CaO 19 18 (10) 17 (9) 17 (11) 17 (11) 13 (10) 13 (10)Magnesium oxide, MgO 0.3 0.2 0.2 0.2 0.2 0.2 0.2Alkalies, as, Na2O and K2O 4.0 1.1 1.1 1.3 1.3 0.8 0.8

Thermal Conductivity, BTU•in./hr•ft2•°F (W/(m•k)), ASTM C 417mean temperature@ 500°F (260°C) 1.22 (0.18) 1.46 (0.21) 1.46 (0.21) 1.86 (0.27) 1.86 (0.27) 2.7 (0.39) 2.9 (0.42)@ 1000°F (538°C) 1.49 (0.22) 1.65 (0.24) 1.65 (0.24) 2.05 (0.30) 2.05 (0.30) 2.9 (0.42) 2.9 (0.42)@ 1500°F (816°C) 1.74 (0.26) 1.82 (0.26) 1.82 (0.26) 2.25 (0.32) 2.25 (0.32) 3.0 (0.43) 3.0 (0.43)@ 2000°F (1093°C) - 2.00 (0.30) 2.00 (0.30) 2.46 (0.35) 2.46 (0.35) 3.2 (0.46) 3.2 (0.46)

1 Properties indicated are for vibratory cast materials only unless specified otherwise.2 Gunite installation may require 10 - 30% more material due to compaction and rebound loss.3 Water requirements indicated are offered as a guide. Actual water required may be subject to field conditions. Consult your Thermal Ceramics sales representative for assistance. 4 Fired linear change values reflect samples taken from a dried to fired state.5 Chemical analysis % for CaO in parentheses indicates the % of reactive CaO present if less than the total. The balance is calcia from the anorthite aggregate. 6. Standard grade Kaolite 2300-LI, Kaolite 2500-LI, and Kaolite 2600-LI may be gunited with care but the rebound will be significantly higher and the difficulty greater than with the respective gun grades.

The values given herein are typical average values obtained in accordance with accepted test methods and are subject to normal manufacturing variations. They are supplied as a technical service and are subject to changewithout notice. Therefore, the data contained herein should not be used for specification purposes. Check with your Morgan Thermal Ceramics office to obtain current information.