The ever-increasing cost for energy has continued to fuel new product development at Thermal Ceramics. Most ultra-lightweight castables on the market have low densities and good thermal conductivity (k) values, but very low crushing strengths. This combination of features creates a very low strength-to-density ratio material in the range of 1.3 to 1.6 psi/pcf, which becomes a problem when high-performance castable and brick hot face linings require more substantive physical strengths from the backup insulation to meet the application requirements.

The newly developed Kaolite 2000-LI castable meets both the strength and thermal properties needed for these high-performance linings. The strength-to-density ratio of the Kaolite 2000-LI product is in the range of 11 to 12 psi/pcf, which is 10 times higher than the typical super-lightweight castable. The low k values of Kaolite 2000-LI, along with high cold crushing strengths (450 psi at densities of 38 to 41 pcf), translates into a superior insulating castable that design engineers can use to substantially strengthen the refractory lining and at the same time provide the thermal efficiency to lower energy costs. Kaolite 2000-LI castable also has low iron oxide content so it can be used in carborizing furnaces or where high concentrations of CO gas are present.

Field testing of the Kaolite 2000-LI product as installed by gunning has shown its ease of installation while providing low densities in the range of 43 to 45 pcf with crushing strengths in excess of 500 psi (as confirmed by an independent refractory testing lab). In addition, this product can be cast at water contents from 55 to 85% to create a large range of densities (from 49 to 37 pcf) with small variations in permanent linear change, and can provide superior crushing strengths (850 to 300 psi) at all water content levels.

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