Chemical

Processing
Industries

Thermal Ceramics
Hydrocarbon Processing Industries
Thermal Ceramics, a world force in heat management, has provided innovative, engineered solutions for reducing energy
usage and maintenance costs for more than 75 years. With manufacturing sites and sales/marketing offices in more than
30 countries, we are uniquely positioned to supply the global petrochemical market with the optimal system of refractory and
insulation products for the job, anywhere around the world. Thermal Ceramics can also provide the necessary engineering
support to go with our world-class products to fill customer needs in all kinds of petrochemical projects, from hot spot repairs
to major turnarounds and new unit constructions.
Whether the application is in fired heaters, sulfur recovery units, FCCU or boilers, we can supply the Hydrocarbon Processing
industries with the worlds leading brands including: Kaowool®, Cerablanket® and Cerachem® ceramic fibre bulk and blan-
ket, Superwool® products, Pyro-Bloc® fibre modules, K®, JM™ and TJM™ brand insulating firebrick, SR® and Moral®
dense firebrick, Kaolite®, Firelite® and Tri-Mor® insulating castables, Kaocrete® /Firecrete®/Tri-Mor/Kao-Tab®/Kao-Tuff®
dense and special duty castables. We offer the following features and benefits:
• Superior insulating value = Lower fuel costs
• Quick material installation = Shorter downtimes
• Excellent resistance to high temperatures and mechanical stresses = Extended service life
• Fast deliveries around the world = Shorter order lead times
• Responsive service = Satisfied customers worldwide

Radiant Arch/Transition

4 6

Transition/Convection Section

Pyro-Bloc
Radiant
Wall

1
Fired Heaters-Process Heaters, Reformers, Pyrolysis
The fired heater is the "central processing unit" in many refineries and petrochemical plants.
Thermal Ceramics offers a total package of insulation linings for use in fired heaters, from the
floor to the walls to the convection section to the stack and any ductwork in between.
• Our conventional insulating materials - K/JM/TJM insulating firebrick and
Kaowool/Cerablanket layered constructions, are true worldwide industry standards
with more than 30 years of service.
• High quality castable products such as Kaolite/Firelite/Tri-Mor insulating castables
offer superior heat savings and long service life in heater floors, walls, convection
sections, ductwork and stacks.
• Easy-to-install insulation designs like Pyro-Bloc and our folded module systems
offer an unparalleled combination of thermal efficiency and quick installation.
Several other innovative products for fired heaters are also available from Thermal Ceramics
like Pyro-Log™ log insulation for easily applied floor insulation, high thermal efficiency BTU-
BLOCK™ microporous insulation in radiant walls and specially engineered Pyro-Bloc and vac-
uum formed shapes for burner blocks and peepsites. Radiant Wall with Pyro-Bloc
Burner Blocks

1 Radiant Floor 4 Radiant Arch

• Dense Castables (Kaocrete, Firecrete) • Pyro-Bloc and Folded Module Systems
• Insulating Castables (Kaolite, Firelite, Tri-Mor) • Kaowool Layered Blanket Systems
• Pyro-Log Floor System • Kaowool Board/Blanket Systems
• Blok 607®, TR-19™ and TR-20™ Insulating Block • Insulating Castables (Kaolite, Firelite, Tri-Mor)
• K, JM and TJM Insulating Firebrick • K, JM and TJM Insulating Firebrick
• Microporous BTU-BLOCK
5 Tubeseals
2 Radiant Walls
• Kaowool/Kao-Tex™ Engineered Systems
• Pyro-Bloc and Folded Module Systems
6 Convection Section
(Pyro-Fold™, Unibloc, Pyro-Stack™, Z-Blok®)
• Kaowool Layered Blanket Systems • Blok 607, TR-19 and TR-20 Insulating Block
• Kaowool Board/Blanket Systems • Pyro-Bloc and Folded Module Systems
• K, JM and TJM Insulating Firebrick • Kaowool Layered Blanket Systems
• Blok 607, TR-19 and TR-20 Insulating Block • Insulating Castables (Kaolite, Firelite, Tri-Mor)
• Insulating Castables (Kaolite, Firelite, Tri-Mor) • K, JM and TJM Insulating Firebrick
• Microporous BTU-BLOCK 7 Corbels
3 Burner Blocks/Peepsites • Pyro-Bloc and Folded Module Systems
• Kaowool and Detrick™ Vacuum Formed Shapes • Insulating Castables (Kaolite, Firelite, Tri-Mor)
• Pyro-Bloc and Folded Module Systems • K, JM and TJM Insulating Firebrick
• Pre-Cast Shapes (Kaocrete, Firecrete, Kaolite, Firelite) 8 Stack
• K, JM and TJM Insulating Firebrick Shapes
• Pyro-Bloc and Folded Module Systems
• Dense Castables (Kaocrete, Firecrete)
• Insulating Castables (Kaolite, Firelite, Tri-Mor)

Corbels - Pyro-Bloc Module Pyro-Fold

Module

Corbels -
Refractory
Secondary Ammonia Reformer
Hydrogen transfer lines and secondary ammonia reformers present very tough
service conditions for refractory materials due to the high pressure, high hydro-
gen environments. Thermal Ceramics has high purity/low silica hot face lining
materials that are well suited for these harsh conditions including high alumina
composition Kao-Tab 95/Firecrete 95/Tri-Mor 1800 special duty castables and
Kaolite 3300 bubble alumina insulating castable. For backup insulation where
very low iron products are necessary, Kaolite/Firelite castables are well suited to
do the job. And in catalyst support domes and checkers, high alumina compo-
sition SR-99 brick offers ultra-high purity, excellent dimensional tolerances and
fired strengths.

Transfer Lines
• High alumina special duty castable (Firecrete, Kao-Tab, Tri-Mor)
backed with high strength, low iron insulating castable (Kaolite,Firelite)
• Bubble alumina high strength insulating castable (Kaolite 3300)

Main Vessel
• High alumina special duty castable (Firecrete, Kao-Tab,
Tri-Mor) backed with high strength, low iron insulating
castable (Kaolite,Firelite)
• Bubble alumina high strength insulating castable
(Kaolite 3300)

Top of Catalyst Bed

• High alumina tile (SR-99, Kao-Tab 95,
Firecrete 95)

Dome
• High alumina dense
firebrick (SR-99)

Waste Heat Boiler

• Bubble alumina high strength insulating
castable (Kaolite 3300)
• High alumina special duty castable
(Firecrete, Kao-Tab, Tri-Mor)

Inside view of
Transfer Line
Sulphur Recovery Unit
Sulfur recovery units (SRUs) operate under severe conditions
of high temperatures and corrosive atmospheric conditions.
Thermal Ceramics offers products that have exhibited long
service life in both standard fired and the more severe oxygen-
enriched SRU applications. For hot face use, high alumina,
high hot strength SR-90 and brick can do the job. For backup
insulation, K, JM and TJM insulating firebrick present a good
combination of structural strength and low thermal conductivity.

Sulphur Recovery Unit

Inlet Nozzle
• Insulating castables Choke Ring/Checker Wall
(Kaolite, Firelite, Tri-Mor) • High alumina, high density firebrick Waste Heat Boiler Tubesheet
(SR-90, SR-99) • Dense high alumina castable (Firecrete, Kao-Tab, Tri-Mor)
• Kaocrete HPM 90TR
• Bubbled alumina high strength insulating castable
(Kaolite 3300)
• Ferrules wrapped with Kaowool paper

Transition Section
Brick option
Burner Block Main Body • High Alumina dense firebrick (SR-90) backed up with
• Dense castable Brick option high temperature insulating firebrick (K, JM & TJM) or high
(Kaocrete, Firecrete, Tri-Mor) • High Alumina dense firebrick temperature insulating castable (Kaolite, Firelite, Tri-Mor)
(SR-90) backed up with high Castable option
temperature insulating firebrick • Dense high alumina castable (Firecrete, Kao-Tab) backed
(K, JM & TJM) or high temperature up with high strength low iron insulating castable (Kaolite,
insulating castable (Kaolite, Firelite) Firelite, Tri-Mor)
Castable option
• Dense high alumina castable
(Firecrete, Kao-Tab) backed up
with high strength low iron insulating
castable (Kaolite, Firelite, Tri-Mor)

Sulphur Recovery Unit - Head

SR-90 Firebrick
Ceramic Fiber Paper
Fluid Catalytic Cracking Unit
A fluid catalytic cracking unit (FCCU) has many different operating parameters
and thus refractory lining requirements vary throughout the entire unit. High
thermal efficiency Kaolite insulating castables from Thermal Ceramics are well
proven for use in regenerators and reactors. They are easy-to-install products
whether by casting, pumping, traditional or wet gunning. Kao-Tuff 110, avail-
able in both cast and gun versions is ideal as a single component, semi-insu-
lating refractory for applications in spent catalyst lines, regenerated catalyst
and flue gas lines. It is a best of class product with an unparalleled combina-
tion of strength, abrasion resistance and insulating value. Lastly, a unique lin-
ing for regenerator linings, Pyro-Bloc HS offers the heat savings and thermal
shock resistance of fiber with the strength required in the application.

Regenerator Reacted Vapor Line

• High strength insulating castable (Kaolite) • High strength insulating castable (Kaolite)
• Pyro-Bloc HS • Special duty abrasion resistant insulating castable (Kao-Tuff 110)
• Kaocrete HPM 90TR

Flue Gas Lines

Dual Component Riser Line
• Special duty abrasion resistant castable Cyclones
External
(Kao-Tuff) backed with high strength • Kaocrete HPM 90TR
• Special duty abrasion resistant
insulating castable (Kaolite) castable (Kao-Tuff, Morflow)
Single Component Internal
• Special duty abrasion resistant insulating • Kaocrete HPM 90TR
castable (Kao-Tuff 110)
Reactor
• High strength insulating
castable (Kaolite)
CO Boiler • Special duty abrasion resistant
• Special duty abrasion resistant castable (Kao-Tuff 110)
insulating castable (Kao-Tuff 110)
• Dense, low iron castable
(Kaocrete, Firecrete, Tri-Mor) backed
with high strength, low iron insulating Air Ring
Stripper
castable (Kaolite, Firelite, Tri-Mor) • Kaocrete
• Kaocrete HPM 90TR
HPM 90TR
• Special duty abrasion resistant
insulating castable (Kao-Tuff110)

Spent Catalyst Line

• Special duty abrasion resistant
insulating castable (Kao-Tuff110)

“Y” Section
• Kaocrete HPM 90TR
• Special duty abrasion resistant
Regenerated Catalyst Line castable (Kao-Tuff, Morflow)
Seal Tanks • Special duty abrasion resistant • Kaowool ceramic fiber paper
• Dense thermal shock resistant insulating castable (Kao-Tuff 110)
castable (Kaocrete, Firecrete)
Slide Valves
• Kaocrete HPM 90TR

Gunning
application

Pyro-Bloc HS Module

Pumping application
Hot Spot Repairs
Thermal Ceramics offers a complete line of pumpable repair products to eliminate hot spots in furnaces, vessels and boil-
ers from deteriorated backup insulation. These versatile products can be used while the unit is in-service or off, which pro-
vides high flexibility in planning the repair and can save significant money by not necessarily having to bring the unit off-line.
Kaofil® and Cer-Wool® Pumpables
Therm-O-Hot Patch™/Therm-O-Hot Patch HS
• Ready to use premium mixture for hot or cold repairs
• Excellent insulating properties
• Continuous use limits up to 2400°F (1316°C)
• Therm-O-Hot Patch has unlimited shelf life
• Economical and highly insulating repair products
Cease Fire® 2000 Insulating Foam
• Two component refractory foam
insulation that flows to fill voids
• Rated to 2000°F (1093°C) Therm-O-Hot Patch Product Group
• Fast setting to approximately 11/2 times its origi-
nal volume

Kaofil Pumpable,
XTP being pumped
to repair hot spot.
Cease Fire 2000
and pump

Fire Protection Applications

Thermal Ceramics FireMaster® line of products are dedicated to the fire protection mar-
ket. These products were developed to meet industry needs for high quality, reliable, true
fire protection materials. FireMaster systems provide fire protection for:
• Cable Trays Cable Tray
• Tanks and Vessels
• Pipework
• Structural Steel
The products used in these fire protection applications meet strict manufacturing toler-
ances and rigorous quality control inspections in order to ensure conformance and certi-
fication capability to national testing laboratory standards. These procedures ensure that the outstanding fire performance
properties of each FireMaster product are maintained for all life safety applications.
FireMaster Blanket
• Lightweight, non-combustible, high-temperature fiber
blanket
• Can be used as fireproof covering or pipe wrap
• Unaffected by oil or water
FireMaster Encapsulated/Faced Blanket
• Reduces risk of physical damage
• Protects against weathering
FireBarrier® 135 and 110 Structural Steel Enclosure
• High strength, high temperature castable
• Offers superior resistance to thermal shock and spalling
Above Ground Storage Tank
 The Hydrocarbon Processing World Organization
is a team of highly qualified specialized engineers and technicians who operate inside Thermal Ceramics.
They will produce technically and economically optimized refractory linings to meet your special require-
ments. Our experienced installation supervisors will also control the erection of the lining on site.
Operating in over 30 countries worldwide and manufacturing in 25 of these, we have the capability to design
the best engineering solutions to fit customers needs, offering a complete and effective service in:
Refinery
Petrochemical
Recovery Unit Sectors

Your benefits of work with Thermal Ceramics Petrochemical Team

Worldwide mobilization:
• Lowest Costs – Material, Transportation; Local Currencies
• Taxes / Duties; Thermal Ceramics Quality (ISO 9002)
• Thermal Ceramics Support, Before, During and After the Sale
Turnkey Job Responsibility:
• Engineering Design
• Material Supply
• Supervision
• Installation

Global Marketing Offices

Global Marketing Communications Offices Thermal Ceramics China
Thermal Ceramics Americas No. 18 Kang An Road • Kangqiao Industrial Zone
2102 Old Savannah Road Pudong • Shanghai • 201315 • People’s Republic of China
Augusta • Georgia • 30906 T: +86 (21) 6812 2200
T: +1 (706) 796 4200 F: +86 (21) 5812 3529
F: +1 (706) 560 5841 E-mail: [email protected]
E-Mail: [email protected]
Thermal Ceramics Europe
Thermal Ceramics Asia Pacific Tebay Road • Bromborough • Wirral
28 Jalan Kilang Barat CH62 3PH • England
Kewalram House T: +44 (0) 151 334 4030
Singapore • 159362 F: +44 (0) 151 334 1684
T: +65 6273 1351 E-mail: [email protected]
F: +65 6273 0165
E-mail: [email protected]

Hydrocarbon Processing Industries Sales Offices

Asia Europe North America South America
Thermal Ceramics Asia Pacific CIRIA Thermal Ceramics Thermal Ceramics Inc. Morganite Brasil Ltda.
28 Jalan Kilang Barat Milanofiori Palazzo F/2 2102 Old Savannah Road Thermal Ceramics Division
Kewalram House 20094 Assago (Milano) Augusta, Georgia 30906 Rua Darcy Pereira 83
Singapore 159362 T: +39 (02) 822 171 T: +1 (706) 796 4200 Distrito Industrial de Santa Cruz
T: +65 6273 1351 F: +39 (02) 824 3815 F: +1 (706) 796 4398 23565-190 Rio de Janeiro - RJ, Brazil
F: +65 6273 0165 E-Mail: E-Mail: T: +55 (21) 2418 1366
E-mail: [email protected] [email protected] F: +55 (21) 2418 1205
[email protected] E-Mail:
[email protected]

08.07/I255/1M www.thermalceramics.com