Harbison-Walker Insulating Castables

H-W Insulating Castables for the Environmental, Energy and Chemical Markets
KAST-O-LITE 16 PLUS A 1600F (871C) insulating castable with outstanding low density and very low thermal conductivity that can be applied by casting or gunning. KAST-O-LITE 19L PLUS A 1900F (1038C) insulating castable. It exhibits greater crushing strengths than traditional mineral wool block insulation. It is used as a back-up lining behind hot face linings to reduce shell temperatures. KAST-O-LITE 20 PLUS (Formerly VSL-35) A 2000F (1093C) insulating castable usable in direct contact with hot gases under continuous or intermittent operation without loss of thermal efficiency. KAST-O-LITE 20 LI ADTECH (Formerly H-W LT WT CASTABLE 20) A low iron insulating castable with a maximum service temperature of 2000F (1093C). KAST-O-LITE 20-45 G PLUS A 2000F (1093C) insulating castable with low density, good strengths, and low shrinkage. Can be cast or gunned. KAST-O-LITE 22 PLUS (Formerly CASTABLE INSULTION #22) A lightweight castable for temperatures to 2200F (1205C). It features low thermal conductivity and good strength for such a lightweight material. KAST-O-LITE 22 G PLUS (Formerly H-W LT WT GUN MIX 22) A 2200F (1205C) insulating castable developed for gunned applications. Predampening with 10% water is suggested. Characterized by good volume stability, low gunning rebound loss, and good resistance to thermal shock. For cast applications, use KAST-O-LITE 22 PLUS. KAST-O-LITE 23 LI PLUS (Formerly VSL-50) KAST-O-LITE 23LI PLUS is a 2300F (1260C) maximum service temperature insulating castable. It contains low iron to resist detrimental reducing furnace conditions. Typical applications are: flues, stacks, breechings, controlled atmosphere furnaces, petroleum transfer and riser back-up linings, catalytic reformer linings behind stainless steel shroud and waste heat boilers. This product can be cast or gunned. KAST-O-LITE 23 ES ADTECH (Formerly H-W LT WT ES REFRACTORY) An intermediate strength insulating castable with a maximum service temperature of 2300F (1260C). This product can be cast or gunned. KAST-O-LITE 26 LI PLUS (Formerly KAST-O-LITE 25) A low iron insulating castable with a maximum service temperature of 2600F (1427C). This product can only be cast. KAST-O-LITE 26 LI G ON-LINE A high performance gun mix designed especially for applications where its combination of insulating ability and high temperature strength enables it to perform as a one shot lining. Predampening with 8 to 10% water is recommended. KAST-O-LITE 26 LI G ON-LINE can be heated after taking a hard set typically within 2-4 hours after installation to greatly minimize downtime. Uses: A maximum service temperature of 2600F (1427C). KAST-O-LITE 30 LI PLUS (Formerly KAST-O-LITE 30) A lightweight insulating castable with high purity cement and a high strengh aggreate. The maximum service temperature 3000F (1649C). This product can only be cast. KAST-O-LITE 30 LI G (Formerly KAST-O-LITE 30 GR) Is a high alumina, ligthweight, 3000F (1649C) maximum service temperature insulating gunning castable/ It exhibits moderate density, excellent strengths, low iron, low thermal conductivity, and low rebound. Typical applications are petrochem heaters, sulphur recovery unit backup linings, air heaters, and catalytic reformer backup lining. KAST-O-LITE 97 L PLUS (Formerly GREENCAST-97-L) A 3300F (1815C) maximum service temperature insulating castable. It contains bubble alumina for high strength and moderate density. It has a very low silica content to resist detrimental hydrogen atmospheres. Typical applications are secondary ammonia reformer back-up linings, carbon black reactor back up linings, very high temperature back-up linings, waste heat boiler tube sheets, and controlled atmosphere furnace linings. GREENLITE CASTABLE 22 (Formerly LITECAST 2200) GREENLITE CASTABLE 22 is a 2200F (1203C) maximum service temperature castable that can be cast, gunned, or pumped. It has a moderate density, good strengths, and a low permanent linear change after heating to 1500F (816C).

Harbison-Walker Insulating Castables for the Environmental, Energy and Chemical Markets
Limited Data
Max Temp (F) Density After 1500F Cold Crushing After 1500F (Psi) Permanent Lin. Change After 1500F (%) Thermal Conductivity (Btu-in/hr-ft-F) At Mean 1500F Chemical Analysis (%) Silica (SiO2) Alumina (Al203) Iron Oxide (Fe203)
*After 1000oF **At Mean 1000oF

KAST-O-LITE 16 PLUS Cast Gunned 1600 1600 25 40 80* -1.6 115* -1.5

KAST-O-LITE 19L PLUS Cast 1900 19 40 -0.6

KAST-O-LITE 20 PLUS Cast 2000 31 90 -0.3

KAST-O-LITE 20 LI ADTECH Cast 2000 36 300 -0.7

KAST-O-LITE 20-45 G PLUS Cast Gunned 2000 2000 27 42 67 -0.6 250 -0.5

KAST-O-LITE 22 PLUS Cast 2200 53 550 -0.5

KAST-O-LITE 22 G PLUS Gunned 2200 73 700 -0.4

KAST-O-LITE 23 LI PLUS Cast Gunned 2300 2300 53 73 325 -0.5 600 0.4 -

KAST-O-LITE 23 ES ADTECH Cast Gunned 2300 2300 80 94 1,600 -0.2 4,100 -0.2

KAST-O-LITE 26 LI PLUS Cast 2600 86 1,660 -0.2

KAST-O-LITE 26 LI G ON-LINE Gunned 2600 105 1,475 -0.3

KAST-O-LITE 30 LI PLUS Cast 3000 90 1,950 -0.2

0.8** 34.5 34.0 5.0

1.1**

1.0** 27.9 31.6 6.9

1.5 31.5 33.1 3.2

1.45 43.9 39.3 0.6

1.3 40.8 30.8 3.8

1.6

2.2 36.8 37.2 4.2

2.7 34.1 41.2 3.3

2 56.1 32.7 0.7

2.2

2.9 39.0 36.3 5.1

3.4

3.7 39.1 46.3 1.3

5.03 44.6 44.5 1.0

4.2 35.3 56.6 0.9

Limited Data
Max Temp (F) Density After 1500F Cold Crushing After 1500F (Psi) Permanent Lin. Change After 1500F (%) Thermal Conductivity (Btu-in/hr-ft-F) At Mean 1500F Chemical Analysis (%) Silica (SiO2) Alumina (Al203) Iron Oxide (Fe203)

KAST-O-LITE 30 LI G Gunned 3000 98 1,500 -0.2

KAST-O-LITE GREENLITE GREENLITE GREENLITE 97 L PLUS CASTABLE 22 23 LI PLUS DS -23-LI ON-LINE Cast Cast Gunned umped Cast Gunned P Gunned 3300 2200 2200 2200 2300 2300 2300 84 61 65 60 51 61 62 900 -0.2 525 850 400 -0.1 285 -0.3 700 -0.2 550 -0.3

GREENLITE -45-L PUMP Pumped 2500 74 2,300 -0.2

GREENLITE -45-L PLUS Cast 2500 70 2,300 -0.2

GREENLITE -45-L GR ON-LINE Gunned 2500 77 2,000 -0.15

GREENLITE 26 LIG PLUS Gunned 2600 91 1,900 -0.2

GREENLITE 75LI G PLUS Gunned 2500 78 1,800 -0.2

GREENLITE 75-28 PLUS Cast 2800 77 2,250 -0.2

GREENLITE 75-28 G PLUS Gunned 2800 85 3,000 -0.2

+0.3 +0.1

4.2 35.8 55.7 0.9

6.0 0.3 94.4 0.1

2.3

2.4 54.5 32.9 1.4

2.3

2.2 57.9 31.0 1.1

2.9

2.9 56.5 32.6 0.9

42.2 44.8 1.2

2.9 39.3 44.6 1.3

3.1 45.5 38.1 1.5

5.03 34.0 50.0 1.3

3.1 46.6 44.0 1.1

2.97 38.8 51.6 1.2

3.08 40.0 50.5 1.8

GREENLITE 23 LI PLUS DS and GREENLITE 23 LI G ON-LINE These are 2300F (1260C ) rated insulating products for cast/gun or fast cure gun installations. Both products are medium-weight low-iron products. Ideal for back-up lining material for ducts carrying hot gases, even in a CO-rich atmosphere. GREENLITE 26 LIG PLUS A 2600F (1427C) gunning insulating castable. It exhibits high strengths, moderate density, and low shrinkage. It should only be gunned. It is suitable for one shot linings in the petrochemical industry. GREENLITE-45-L PLUS (Formerly GREENCAST 45-L) A 2500F (1371C) insulating castable with moderate density, low shrinkage, and high strengths. It can be only be cast.

GREENLITE-45-L GR ON-LINE (Formerly GREENLITE45-L GR PLUS).

A 2500F (1371C) gunning insulating gun mix. It exhibits high strengths, moderate density, and low shrinkage. GREENLITE-45-L GR ON-LINE can be heated after taking a hard set typically within 2-4 hours after installation to greatly minimize downtime. GREENLITE-45-L GR ON-LINE contains the PLUS additive for faster heatups and can be ordered with DS additive to minimize dusting. GREENLITE 45 L PUMP A 2500F (1370C) insulating castable containing GREENLITE AGGREGATE, which imparts extraordinary strength and features excellent insulating properties. It can be installed by pump cast or shortdrete (Activator LP). Typical applications are backup linings fired oil heater stacks, carbon monoxide boiler duct linings, olefins cracking furnace stacks, boilers and incinerator backup linings, and fluid catalytic cracking unit (FCCU).

GREENLITE 75LI G PLUS A 2500F (1370C) low iron, insulating gun mix containing GREENLITE AGGREGATE, which imparts extraordinary strength and features excellent insulating properties. Typical applications are Fluid Catalytic Cracking Unit (FCCUs), Fluid Coking Units and any industrial lining requiring low densities and high strengths GREENLITE 75-28 PLUS (Formerly LITECAST 75-28) A lightweight, super-duty, hydraulic setting castable with high strength. GREENLITE 75-28 is rated to 2800F (1538C). This product can only be cast. GREENLITE 75-28 G PLUS (Formerly LITECAST 75-28 G) A 2800F (1538C) gunning insulating castable. It exhibits high strengths, moderate density, and low shrinkage. It should only be gunned.

HPV 110 CASTABLE A 2400F (1316C) abrasion-resistant, castable mix with 110 pcf density. Typical applications range from chemical processing and refining, such as fluid catalytic cracking unit cyclones and transfer lines, to regenerator and reactor linings. Appropriate for any application requiring high abrasion resistance and low thermal conductivity. HPV 110 GUN MIX The orginal 110pcf high-strength, abrasion resistant gun mix. Can be use in wide-range of refinery and furnace applications,

1/2012

Harbison-Walker Insulating Castables for the Environmental, Energy and Chemical Markets

Limited Data

Max Temp (F) Density After 1500F Cold Crushing After 1500F (Psi) 10,750 Permanent Lin. Change After 1500F (%) -0.2 C-704 Abrasion Resistance (cc loss) After 1500OF <10 Thermal Conductivity (Btu-in/hr-ft-F) At Mean 1500F 5.3 Chemical Analysis (%) Silica (SiO2) Alumina (Al203) Iron Oxide (Fe203)

HPV 110 CASTABLE Vib-Cast Self-Flow 2400 2400 110 105 7,750 -0.2 <15 4.8 48.8 39.0 1.8

HPV 110 GUN MIX Gunned 2400 110 8,750 -0.2 <13 5.3 42.7 40.9 1.2

Three steps to follow to minimize and prevent the potential for the alkali hydrolysis reaction in insulating castables are: 1) Cast and cure material at warmer temperatures to develop stable cement hydrates, which are more resistant to alkali hydrolysis above 70F is preferred. 2) Dry the material out as soon as possible after the 24 hour cure. The dryout temperature should be in the 500-750F range on the hot face to allow heat to penetrate the material and obtain at least 230F part way into the lining. 3) Keep the material dry by covering it with plastic. Do not use surface sealants because they will breakdown over time and trap water inside the lining. The trapped water can act as a catalyst to promote the hydrolysis reaction.

The data given in this brochure are based on averages of test results on samples selected from routine plant production by standard A.S.T.M. procedures where applicable. Variation from the above data may occur in individual test. These results cannot be taken as minima or maxima for specification purposes. All statements, information, and data given herein are believed to be accurate and reliable but are presented without guarantee, warranty, or responsibility of any kind, expressed or implied. Statements or suggestions concerning possible use of our products are made without representation or warranty that any such product is fit for such use or that such use is free of patent infringement of a third party. The suggested use assumes that all safety measures are taken by the user.

Harbison-Walker Refractories Company 400 Fairway Drive Moon Township, PA 15108 www.hwr.com 2012 Harbison-Walker Refractories Company. All rights reserved. Phone: (412) 375-6600 Fax: (412) 375-6783 Cat. # HW 120 R (1/12)