Tri-Mor Kaolite 2200-HS, 2500-HS, 2500 EXHS

Datasheet Code US: 3-14-102 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 2200-HS and Kaolite 2200-HS Gun are medium

weight, high strength monolithics that resists thermal shock,

and has excellent volume stability. They possess the best

thermal conductivity-to-weight ratio in the industry.

Kaolite 2500-HS and Kaolite 2500-HS Gun are medium

weight, high-strength, insulating monolithics for use where

strength and thermal stability are required.

Kaolite 2500 EXHS is an extra high-strength gun grade

monolithic designed for temperatures up to 2500F (1371C).

It has excellent thermal stability throughout its temperature use

range.

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

Steam flood generator convection sections and target walls

Cat cracker regenerator linings

Petrochemical applications

Features 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.

Instructions For Using

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. A mechanical mixer

is required for proper placement (paddle-type mortar mixers

are best suited). After achieving a ball-in-hand consistency,

mix for 6 minutes. Place material within 30 minutes after

mixing.

Gunning

Use suitable gunite equipment. Material should be

predampened uniformly with approximately

- Kaolite 2200-HS Gun 7-9%

- Kaolite 2500-HS Gun 5-7%

- Kaolite 2500 EXHS 6-8%

by weight of clean water in a mechanical mixer before placing

into gunite applications at gun. This will reduce rebound and

dust. Add required water at nozzle for effective placement.

Suggested air pressure at the nozzle is 25 to 40 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 or

coated with Kao-Seal to help retard the possible deterioration

effects.

Insu la t ing Our Wor ld

Tri-Mor Kaolite 2200-HS, 2500-HS, 2500 EXHS

Insu la t ing Our Wor ld

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Physical Properties1

2200-HS 2200-HS Gun 2500-HS 2500-HS Gun 2500-EXHS

Method of installation6 cast gun cast gun gun

Recommend use limit, F (C) 2200 (1204) 2200 (1204) 2500 (1371) 2500 (1371) 2500 (1371)

Avg. lb req. to place one cubic ft2, (kg) 73 (33) 76 (34) 83 (38) 84 (38) 86 (39)

Density, fired, pcf (kg/m3)

@ 1500F (816C) 68 - 78 69 - 79 79 - 89 79 - 89 82 - 91

(1090-1250) (1105 - 1265) (1265-1425) (1265 - 1425) (1313 - 1458)

@ use limit 68 - 78 72 - 80 80 - 88 76 - 88 84 - 94

(1090-1250) (1153 - 1282) (1282-1410) (1218 - 1410) (1346 - 1506)

Recommended Water Ranges, % by weight3

Casting (by vibrating) 37 - 44 - 28 - 35 - -

Pounds per bag (kg) 50 (23) 50 (23) 50 (23) 50 (23) 50 (23)

Shelf life, months 12 12 12 12 12

Modulus of rupture, psi (MPa) ASTM C 133, cast

Dried 18-24 hrs. @ 220F (104C) 250 - 400 300 - 550 250 - 400 250 - 400 400 - 600

(1.72 - 2.76) (2.06 - 3.79) (1.72 - 2.76) (1.72 - 2.75) (2.75 - 4.13)

Fired 5 hrs. @ 1500F (816C) 175 - 350 250 - 450 225 - 375 250 - 500 325 - 550

(1.21 - 2.41) (1.72 - 3.10) (1.55 - 2.59) (1.72 - 3.44) (2.24 - 3.79)

Fired 5 hrs. @ use limit 200 -300 300 - 600 350 - 600 400 - 650 450 - 700

(1.38 - 2.07) (2.07 - 4.14) (2.41 - 4.14) (2.75 - 4.48) (3.10 - 4.83)

Cold Crushing strength, psi (Mpa)

Dried 18-24 hrs. @ 220F (104C) 850 - 1400 900 - 1500 700 - 1200 700 - 1200 1000- 1600

(5.86 - 9.66) (6.20 - 10.34) (4.83 - 8.27) (4.82 - 8.27) (6.89 - 11.03)

Fired 5 hrs. @ 1500F (816C) 750 - 1400 900 - 1600 850 - 1600 900 - 1600 1000 - 1700

(5.17 - 9.66) (6.20 - 11.03) (5.86 - 11.03) (6.20 - 11.03) (6.89 - 11.72)

Fired 5 hrs. @ use limit 700 - 1200 900 - 1600 900 - 1500 900 - 1600 1100 - 1800

(4.83 - 8.28) (6.20 - 11.03) (6.21-10.34) (6.20 - 11.03) (7.58 - 12.41)

Permanent linear change, % (ASTM C 113)4

Dried 18-24 hrs. @ 220F (104C) 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2 0 to -0.2

Fired 5 hrs. @ 1500F (816C) -0.1 to -0.5 -0.2 to -0.55 -0.1 to -0.4 -0.2 to -0.5 -0.2 to -0.5

Fired 5 hrs. @ use limit -0.3 to -1.0 -0.6 to -1.5 -1.5 to +1.5 -0.5 to +0.5 -0.6 to +0.5

Chemical Analysis, %, Weight basis after firing5

Alumina, Al2O3 43 41 44 42 42

Silica, SiO2 28 31 35 38 37

Ferric oxide, Fe2O3 3.2 3.0 2.0 2.2 2.2

Titanium oxide, TiO2 1.2 1.2 1.2 1.2 1.3

Calcium oxide , CaO 25 (18) 23 (16) 17 (13) 15 (11) 16 (11)

Magnesium oxide, MgO 0.2 0.2 0.2 0.2 0.2

Alkalies, as, Na2O 0.5 0.5 0.9 0.9 0.8

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

mean temperature

@ 500F (260C) 1.90 (0.27) 1.90 (0.27) 2.8 (0.40) 2.8 (0.40) 2.8 (0.40)

@ 1000F (538C) 2.02 (0.29) 2.02 (0.29) 3.0 (0.43) 3.0 (0.43) 3.0 (0.43)

@ 1500F (816C) 2.11 (0.30) 2.11 (0.30) 3.2 (0.46) 3.2 (0.46) 3.2 (0.46)

@ 2000F (1093C) 2.19 (0.32) - 3.4 (0.51) 3.4 (0.51) 3.4 (0.51)

@ 2500F (1371C) - - 3.5 (0.53) 3.5 (0.53) 3.5 (0.53)1. Properties indicated are for vibratory cast materials only unless specified otherwise.2. Gunite installation requires 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 2200-HS and Kaolite 2500-HS may be guntied 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 technicalservice 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 toobtain current information.