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Chemical

Processing

Industries

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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

Hydrocarbon Processing Industries

Radiant Arch/Transition 1 2 3 4 7 5 6 Pyro-Bloc Radiant Wall Transition/Convection Section

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1 Radiant Floor

• Dense Castables (Kaocrete, Firecrete) • Insulating Castables (Kaolite, Firelite, Tri-Mor) • Pyro-Log Floor System

• Blok 607®, TR-19™ and TR-20™ Insulating Block • K, JM and TJM Insulating Firebrick

• Microporous BTU-BLOCK 2 Radiant Walls

• Pyro-Bloc and Folded Module Systems (Pyro-Fold™, Unibloc, Pyro-Stack™, Z-Blok®) • Kaowool Layered Blanket Systems

• Kaowool Board/Blanket Systems • K, JM and TJM Insulating Firebrick

• Blok 607, TR-19 and TR-20 Insulating Block • Insulating Castables (Kaolite, Firelite, Tri-Mor) • Microporous BTU-BLOCK

3 Burner Blocks/Peepsites

• Kaowool and Detrick™ Vacuum Formed Shapes • Pyro-Bloc and Folded Module Systems

• Pre-Cast Shapes (Kaocrete, Firecrete, Kaolite, Firelite) • K, JM and TJM Insulating Firebrick Shapes

4 Radiant Arch

• Pyro-Bloc and Folded Module Systems • Kaowool Layered Blanket Systems • Kaowool Board/Blanket Systems

• Insulating Castables (Kaolite, Firelite, Tri-Mor) • K, JM and TJM Insulating Firebrick

5 Tubeseals

• Kaowool/Kao-Tex™ Engineered Systems 6 Convection Section

• Blok 607, TR-19 and TR-20 Insulating Block • Pyro-Bloc and Folded Module Systems • Kaowool Layered Blanket Systems

• Insulating Castables (Kaolite, Firelite, Tri-Mor) • K, JM and TJM Insulating Firebrick

7 Corbels

• Pyro-Bloc and Folded Module Systems • Insulating Castables (Kaolite, Firelite, Tri-Mor) • K, JM and TJM Insulating Firebrick

8 Stack

• Pyro-Bloc and Folded Module Systems • Dense Castables (Kaocrete, Firecrete) • Insulating Castables (Kaolite, Firelite, Tri-Mor)

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

Corbels - Pyro-Bloc Module

Corbels -Refractory

Pyro-Fold Module

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Secondary Ammonia Reformer

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)

Dome

• High alumina dense firebrick (SR-99)

Inside view of Transfer Line

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.

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)

Waste Heat Boiler

• Bubble alumina high strength insulating castable (Kaolite 3300)

• High alumina special duty castable (Firecrete, Kao-Tab, Tri-Mor)

Top of Catalyst Bed

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

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Sulphur Recovery Unit

Inlet Nozzle

• Insulating castables (Kaolite, Firelite, Tri-Mor)

Burner Block • Dense castable

(Kaocrete, Firecrete, Tri-Mor)

Main Body Brick option

• High Alumina dense firebrick (SR-90) backed up with high temperature insulating firebrick (K, JM & TJM) or high temperature insulating castable (Kaolite, Firelite) Castable option

• Dense high alumina castable (Firecrete, Kao-Tab) backed up with high strength low iron insulating castable (Kaolite, Firelite, Tri-Mor)

Transition Section Brick option

• High Alumina dense firebrick (SR-90) backed up with high temperature insulating firebrick (K, JM & TJM) or high temperature insulating castable (Kaolite, 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)

Waste Heat Boiler Tubesheet

• 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 Choke Ring/Checker Wall

• High alumina, high density firebrick (SR-90, SR-99)

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

Sulphur Recovery Unit - Head

Ceramic Fiber Paper SR-90 Firebrick

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Flue Gas Lines Dual Component

• Special duty abrasion resistant castable (Kao-Tuff) backed with high strength insulating castable (Kaolite)

Single Component

• Special duty abrasion resistant insulating castable (Kao-Tuff 110)

CO Boiler

• Special duty abrasion resistant insulating castable (Kao-Tuff 110) • Dense, low iron castable

(Kaocrete, Firecrete, Tri-Mor) backed with high strength, low iron insulating castable (Kaolite, Firelite, Tri-Mor)

Seal Tanks

• Dense thermal shock resistant castable (Kaocrete, Firecrete)

Regenerated Catalyst Line • Special duty abrasion resistant

insulating castable (Kao-Tuff 110)

“Y” Section

• Kaocrete HPM 90TR

• Special duty abrasion resistant castable (Kao-Tuff, Morflow) • Kaowool ceramic fiber paper Spent Catalyst Line

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

Slide Valves

• Kaocrete HPM 90TR

Riser Line External

• Special duty abrasion resistant castable (Kao-Tuff, Morflow) Internal

• Kaocrete HPM 90TR

Stripper

• Kaocrete HPM 90TR

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

• High strength insulating castable (Kaolite)

• Special duty abrasion resistant castable (Kao-Tuff 110) Reacted Vapor Line

• High strength insulating castable (Kaolite)

• Special duty abrasion resistant insulating castable (Kao-Tuff 110) • Kaocrete HPM 90TR Cyclones • Kaocrete HPM 90TR Air Ring • Kaocrete HPM 90TR Regenerator

• High strength insulating castable (Kaolite) • Pyro-Bloc HS

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 linlin-ings, Pyro-Bloc HS offers the heat savlin-ings and thermal shock resistance of fiber with the strength required in the application.

Pumping application

Gunning application

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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 • 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

• High strength, high temperature castable

• Offers superior resistance to thermal shock and spalling

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 vboil-ersatile 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)

• Fast setting to approximately 11/

2times its

origi-nal volume

Kaofil Pumpable, XTP being pumped to repair hot spot.

Therm-O-Hot Patch Product Group

Cease Fire 2000 and pump

Structural Steel Enclosure

Above Ground Storage Tank Cable Tray

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www.thermalceramics.com

Hydrocarbon Processing Industries Sales Offices Global Marketing Communications Offices

Thermal Ceramics Americas

2102 Old Savannah Road Augusta • Georgia • 30906

T: +1 (706) 796 4200 F: +1 (706) 560 5841

E-Mail: tceramics@thermalceramics.com

Thermal Ceramics Asia Pacific

28 Jalan Kilang Barat Kewalram House Singapore • 159362

T: +65 6273 1351 F: +65 6273 0165

E-mail: thermalceramics@tcasia.com.sg

Thermal Ceramics China

No. 18 Kang An Road • Kangqiao Industrial Zone Pudong • Shanghai • 201315 • People’s Republic of China

T: +86 (21) 6812 2200 F: +86 (21) 5812 3529 E-mail: info@morgantcs.com.cn

Thermal Ceramics Europe

Tebay Road • Bromborough • Wirral CH62 3PH • England T: +44 (0) 151 334 4030 F: +44 (0) 151 334 1684

E-mail: marketing@thermalceramics.co.uk

08.07/I255/1M

Global Marketing Offices

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

Asia

Thermal Ceramics Asia Pacific 28 Jalan Kilang Barat

Kewalram House Singapore 159362 T: +65 6273 1351 F: +65 6273 0165 E-mail: thermalceramics@tcasia.com.sg Europe CIRIA Thermal Ceramics

Milanofiori Palazzo F/2 20094 Assago (Milano) T: +39 (02) 822 171 F: +39 (02) 824 3815 E-Mail: ciria@thermal-ceramics.com North America Thermal Ceramics Inc. 2102 Old Savannah Road

Augusta, Georgia 30906 T: +1 (706) 796 4200 F: +1 (706) 796 4398 E-Mail: tceramics@thermalceramics.com South America Morganite Brasil Ltda. Thermal Ceramics Division

Rua Darcy Pereira 83 Distrito Industrial de Santa Cruz 23565-190 Rio de Janeiro - RJ, Brazil

T: +55 (21) 2418 1366 F: +55 (21) 2418 1205

E-Mail:

References

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