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Tri-Mor Kaolite LI Monolithics

Datasheet Code US: 3-14-103

MSDS Code US: 103, 153

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

Product Description

Features

Kaolite 2300-LI and Kaolite 2300-LI Gun are 2300F (1260C)

lightweight monolithics which incorporates a high-purity binder for
applications where hydrogen or reducing atmospheres are present.

Instructions For Using

Kaolite 2000-LI is a lower density cast/gun 2000F (1093C)

monolithic traditioinally used to reduce the amount of supporting
furnace steel work required and provide more insulation with a
thinner lining.

Kaolite 2500-LI and Kaolite 2500-LI Gun are high-strength

lightweight monolithics that contains an intermediate purity calciumaluminate cement. Total iron oxide contents of 0.9% enables use
where hydrogen or reducing atmospheres are present. Its low
thermal conductivity and density produces the most economical
2500F (1371C) insulating monolithic on a per cubic foot basis.

Kaolite 2600-LI and Kaolite 2600-LI Gun are designed especially

for use in petrochemical applications. They incorporate a cement of
sufficient purity for low iron content and high-intermediate
temperature strengths.
Carbon Monoxide Disintegration Test - Kaolite 2300-LI

The special low-impurity materials were formulated especially for oil

refinery and chemical units as well as other applications operating in
hydrogen or highly reducing atmospheres. In order to test, a 700
hour carbon monoxide disintegration test was conducted. ASTM C
288-62 procedure was followed, with the exception that the samples
tested were dried rather than fired. The lack of firing of the samples
tends to hasten the attack of carbon monoxide attack. Firing at
2300F before testing in carbon monoxide atmospheres is specified
by ASTM procedure to lessen the carbon monoxide attack. This was
omitted because it is not reasonable from a practical standpoint, as
no monolithic, will be subjected to 2300F throughout its structure.
The samples were rated merely as Affected because of slight
cracking which occurred between 500 and 700 hours in one of the
two samples. At the end of 500 hours, which is the specified testing
time of ASTM, no effect was shown by either sample. As a result of
this severe test, it is recommended that Kaolite 2300-LI be used in
applications where carbon monoxide or other reducing atmospheres
are present.

Applications

Backup insulation in two component linings in petrochemical

process units
Hot face lining in ductwork from waste heat recovery boilers and
process 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

Light weight and low thermal conductivity reduce both the quantity
of heat storage and heat transfer producing significant savings in
furnace fuel consumption
Lower densities reduce the amount of supporting furnace steelwork
required and provide more insulation with a thinner lining.
Casting
Highest strength is obtained with monolithic refractory by using the
least amount of clean mixing water that will allow thorough working
of material into place by vibrating or rodding. A mechanical mixer is
required for proper placement (paddle-type mortar mixers are best
suited). Mix for 6 minutes to achieve a good ball-in-hand
consistency. Place material within 30 minutes after mixing.

Gunning
Use suitable gunite equipment. The gun grade material should be
predampened 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 into
gun. This will reduce rebound and dust. Add required water at
nozzle for effective placement. Suggested air pressure at the nozzle
is 20 to 35 psi.
Precautions
Store bagged monolithics in a dry place, off the ground and, when
possible, with the original shrink wrapping intact. Normal shelf life is
12 months if properly stored.

Watertight forms must be used when placing material. All porous

surfaces that will come in contact with the material must be
waterproofed with a suitable coating or membrane. For maximum
strength, cure 24 hours under damp conditions before initial heat-up.
Keep freshly placed monolithic warm during cold weather, ideally
between 70F and 80F. New monolithic installations must be
heated slowly the first time.
Freshly placed lightweight monolithics are prone to a deteriorating
condition called alkali hydrolysis when they are kept in a non-dried
state for a sustained period of time in a warm, humid environment.
Under these conditions, the monolithics should be force-dried soon
after placement to help retard the possible deterioration effects.

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Insula t ing Our Wor ld

Tri-Mor Kaolite LI Monolithics

Physical Properties3

2000 - LI
Method of installation6
cast/gun
Recommended use limit, F (C)1 2000 (1093)
Avg. lb req. to place one cubic ft2, (kg)
45 (20)
Density, fired, pcf (kg/m3)9
@ 1500F (816C)
40 - 48
(641 - 769)
@ use limit
41 - 48
(657 - 768)
Recommended Water Ranges, % by weight3
casting (by vibrating)
65 - 75
pouring
78 - 85
Pounds per bag (kg)
25 (11)
Shelf life, months
12
Modulus of rupture, psi (MPa) ASTM C 133, cast
dried 18-24 hrs @ 220F (104C)
110 - 220
(0.76 - 1.52)
fired 5 hrs @ 1500F (816C)
100 - 200
(0.68 - 1.38)
fired 5 hrs @ use limit
100 - 200
(0.68 - 1.38)
Cold Crushing strength, psi (Mpa)
dried 18-24 hrs @ 220F (104C) 325 - 600
(2.24 - 4.13)
fired 5 hrs @ 1500F (816C)
275 - 550
(1.90 - 3.79)
fired 5 hrs @ use limit
200 - 400
(1.38 - 2.76)
Perm. linear change, % (ASTM C 113) 4
dried 18-24 hrs @ 220F (104C) 0 to -0.2
fired 5 hrs @ 1500F (816C)
-0.6 to -1.3
fired 5 hrs @ use limit
-1.5 to -2.0

2300-LI
2300-LI Gun
cast
gun
2300 (1260) 2300 (1260)

2500-LI
cast
2500 (1371)

2500-LI Gun
gun
2500 (1371)

2600-LI
cast
2600 (1427)

2600-LI Gun
gun
2600 (1427)

55 - 66
(881 - 1057)
55 - 66
(881 - 1056)

56 - 68
(897 - 1088)
56 - 68
(897 - 1088)

62 - 74
(993 - 1184)
64 - 76
(1026 - 1216)

63 - 75
(1008 - 1200)
64 - 76
(1026 - 1216)

78 - 88
(1250 - 1410)
80 - 89
(1282 - 1424)

79 - 89
(1265 - 1424)
80 - 89
(1282 - 1424)

120 - 200
(0.83 - 1.38)
110 - 250
(0.80 - 1.72)
150 - 300
(1.03 - 2.07)

100 - 180
(0.68 - 1.24)
110 - 250
(0.80 - 1.72)
135 - 350
(0.93 - 2.41)

200 - 300
(1.38 - 2.07)
150 - 300
(1.03 - 2.07)
200 - 350
(1.38 - 2.41)

150 - 250
(1.03 - 1.72)
120 - 250
(0.83 - 1.72)
250 - 400
(1.72 - 2.75)

300 - 500
(2.07 - 3.45)
225 - 400
(1.55 - 2.76)
500 - 900
(3.45 - 6.21)

300 - 500
(2.07 - 3.44)
250 - 400
(1.72 - 2.76)
500 - 900
(3.45 - 6.21)

61 (28)

46 - 54
40 (18)
12

350 - 600
(2.41 - 4.13)
350 - 1000
(2.41 - 6.90)
400 - 950
(2.76 - 6.55)

63 (29)

40 (18)
12

38 - 47
50 (23)
12

71 (32)

50 (23)
12

83 (38)

28 - 35
50 (23)
12

84 (38)

50 (23)
12

350 - 600
(2.41 - 4.13)
350 - 900
(2.41 - 6.20)
400 - 900
(2.75 - 6.20)

500 - 800
(3.45 - 5.52)
600 - 1200
(4.14 - 8.28)
800 - 1400
(5.52-9.65)

450 - 650
(3.10 - 4.48)
550 - 1000
(3.79 - 6.89)
600 - 1000
(4.13 - 6.89)

800 - 1200
(5.52 - 8.28)
750 - 1300
(5.17 - 8.96)
1200 - 1800
(8.28-12.41)

800 - 1500
(5.51 - 10.34)
850 - 1500
(5.86 - 10.34)
1000 - 2000
(6.89 - 13.79)

38
41
0.9
1.4
17 (9)
0.2
1.1

43
36
0.9
1.6
17 (11)
0.2
1.3

42
37
0.9
1.8
17 (11)
0.2
1.3

47
36
1.0
1.5
13 (10)
0.2
0.8

45
38
1.0
1.8
13 (10)
0.2
0.8

1.86 (0.27)
2.05 (0.30)
2.25 (0.32)
2.46 (0.35)

1.86 (0.27)
2.05 (0.30)
2.25 (0.32)
2.46 (0.35)

2.7 (0.39)
2.9 (0.42)
3.0 (0.43)
3.2 (0.46)

2.9 (0.42)
2.9 (0.42)
3.0 (0.43)
3.2 (0.46)

0 to -0.2
0 to -0.2
-0.1 to -0.55 -0.2 to -0.6
-1.0 to -2.0
-1.0 to -2.0

Chemical Analysis, %, Weight basis after firing5

Alumina, Al2O3
34
40
Silica, SiO2
40
38
Ferric oxide, Fe2O3
1.6
0.9
Titanium oxide, TiO2
1.1
1.4
Calcium oxide , CaO
19
18 (10)
Magnesium oxide, MgO
0.3
0.2
Alkalies, as, Na2O and K2O
4.0
1.1

69 (31)

Thermal Conductivity, BTUin./hrft2F (W/(mk)), ASTM C 417

mean temperature
@ 500F (260C)
1.22 (0.18)
1.46 (0.21)
1.46 (0.21)
@ 1000F (538C)
1.49 (0.22)
1.65 (0.24)
1.65 (0.24)
@ 1500F (816C)
1.74 (0.26)
1.82 (0.26)
1.82 (0.26)
@ 2000F (1093C)
2.00 (0.30)
2.00 (0.30)

0 to -0.2
-0.1 to -0.4
-0.5 to -1.5

0 to -0.2
-0.2 to -0.5
-0.5 to -1.5

0 to -0.2
-0.1 to -0.4
-0.5 to -1.5

0 to -0.2
-0.2 to -0.5
0 to -1.5

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 change
without notice. Therefore, the data contained herein should not be used for specification purposes. Check with your Morgan Thermal Ceramics office to obtain current information.

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