Aluminum

Industry

Thermal Ceramics
Aluminum Industry
Thermal Ceramics offers the aluminum industry the widest selection of refractories and high-temperature insulating materi-
als on the market. Products that can increase your production efficiency, as well as lower energy and maintenance costs at
your plant. With our extensive product line and advanced manufacturing capabilities, we can provide you with the exact prod-
uct or engineered system of products that is right for your specific application. Our major product groups are:
• Superwool® - Thermal Ceramics Superwool products are available in various product forms: from blanket and strip
to modules, papers, and moldable. Our low biopersistent Superwool products are produced from specific alkaline
earth-silicate raw materials. The non-wetting characteristics of Superwool products help make them an excellent
choice for aluminum contact applications.
• Kaowool® and Cerablanket® Blanket/ Strip - Available in a wide range of roll widths, as well as temperature and
density compositions, these refractory ceramic fiber products feature low thermal conductivity, and low-heat stor-
age capacity.
• Boards/Block - Thermal Ceramics offers an entire temperature range of insulating boards in a wide array of
thicknesses and sizes. TR-19™, TR-19HS, V-1100AL™, V-1200AL™ and Blok® 607® block products are strong,
cut to size materials used as backup insulation in electrolytic pots, carbon bake furnaces, melter/holding furnaces,
and launders.
• BTU-BLOCK™ - BTU-BLOCK microporous insulation products feature superior thermal conductivity values, good
compressive strength, and low shrinkage at high temperatures. These superior insulating products are ideal for
backup in launders and filter boxes as well as carbon bake furnaces and melter/holder furnaces.
• Kaowool TBM™ - Kaowool TBM 2230 products feature high strength, are lightweight, resist thermal shock and
molten aluminum, and offer improved machinability. They are used to produce excellent casting tips.
• Paper - Thermal Ceramics paper products, produced from Kaowool ceramic fibers or Superwool® amorphous wool,
are noted for outstanding handling characteristics and high insulating value at high temperatures. These versatile
materials are used as expansion joint filler or backup insulation.
• Bulk Fiber - Thermal Ceramics complete line of refractory bulk fibers is produced by varying composition, fiber
length, compressed density, fiber content, fiber diameter, and lubricity to serve a wide range of customer needs
including stuffing joints in carbon bake furnace walls.
• Pyro-Bloc® Modules - This modular insulation is manufactured from a monolithic slab of Pyro-Log™ fiber in den-
sities ranging from 8 pcf (128 kg/m3)to 15 pcf (240 kg/m3). It combines the insulating advantages of ceramic fiber
with fast, easy installation. Ideal uses are in holder furnace doors and roofs.
• Dense and Insulating Castables - Thermal Ceramics has engineered a full line of castables that meet the
specific property requirements of aluminum furnace operators. The Kaocrete® and Tri-Mor® line are general
purpose, refractory castables that can be cast or gunned. High-performance castables, Kaocrete HPM™, Alcast
and Albond are non-wetted by molten aluminum and offer superb resistance to mechanical impact and thermal
shock. These properties make them an ideal choice below the melt line in holding and melting furnaces.
Kaolite®/Firelite® castables feature low thermal conductivity which can result in significant savings in fuel
consumption in carbon bake furnaces.
• K® and JM™ Insulating Firebrick - Our K and JM grade lightweight insulating firebricks offer low heat conduc-
tivity, hign hot strengths plus the ability to withstand the most demanding reducing atmospheres. They are used as
backup insulation in pot cell floors and carbon bake furnace tub walls and floors.
• Vacuum Formed Shapes - Vacuum formed shapes are available in a wide range of organic-free, temperature
related compositions. They offer superior insulating performance and excellent aluminum resistance, as well as
good hardness and strength over a broad range of uses. They are available in a wide variety of sleeve and shape
configurations including tap-out cones, launders, and header boxes.
• Moldable/Pumpables - Superfil® 607® Moldable is a ready-to-use insulating putty that adheres well to a wide
variety of surfaces, is non-wetting to aluminum, and has excellent strength on drying and firing. Kaofil® Pumpables
and Therm-O-Hot Patch™ are designed for spray filling of refractory joints and cracks, such as in carbon baking
pit corners.
Carbon Bake Furnace
Thermal Ceramics insulating firebrick and block insulation stand up to
the reducing atmospheres, high and long-temperature cycles, and
mechanical abuse that exist in carbon bake furnaces. These prod-
ucts, along with our insulating castables and fibers provide the bene-
fits associated with long, consistent service life and low-maintenance
requirements: high quality anodes, trouble-free furnace operation, and
low operating costs. New products such as BTU-Block microporous
insulation provide increased energy efficiently and the capacity for
thinner linings.

Tubwalls*
K and JM-23, 25, 26 IFB
Kaolite 1800 Super Lightweight Insulating Castable
Kaolite 2000-HS Insulating Castable
Kaolite 2600-LI Insulating Castable
TR-19/V-1100 Insulating Block
BTU-Block Board/Panel Microporous Insulation

Floor*
K and JM-23, 25, 26, TC-140 and 140-HS Insulating Firebrick (IFB)
Kaolite 2000-HS Insulating Castable
BTU-Block Board/Panel Microporous Insulation

Floor Leveling
Kao-Tuff® C Abrasion-Resistant Castable
Kaocrete HS Dense Castable

Flue Port Blocks

Kaocrete 26 Precast Shapes
Tri-Mor Fused Silica Shapes

Flue Wall Caps

Kaocrete 250-C, 28-LI Dense Castables
Tri-Mor Medium-weight Castable
Tri-Mor Morflo 160 Castable

Expansion Joints
Cerablanket Strip
Cerawool Bulk
Superwool 607 MAX and HT Strip/Bulk
Therm-O-Hot Patch
Superfil 607 Moldable

*Backup

Kaolite insulating castable K and JM series insulating firebrick Superwool bulk

Electrolytic Reduction Cell
Our insulating firebrick and vermiculite block insulation are proven
performers in the reduction cell, providing consistent and reliable,
long service life. In combination with an organized maintenance
program, these products help provide benefits you can depend on:
• high-quality aluminum
• reduced energy consumption
• trouble-free operation.

Floor/Lower Wall Insulation

TR-19, TR-19 HS, V-1100AL, V-1200AL Insulating Board
TR-2000 SL Board
Blok 607 Block Insulation
K and JM-20, 23 IFB
Kaolite 2200 Insulating Castables

Upper Walls
Morsil® Nitride Bonded Silicon Carbide Brick
Superfil 607 Moldable
Barrier Lining insulating mastic
Moral® BRO Brick

Pot Cell Start-Up Cover

Superwool 607 Blanket (aluminum faced)

Collector Bar Area

Kaofil Moldable
Superfil 607 Moldable
Kaolite 2200 Castable
Kaocrete 26 Castable
Tri-Mor Morflo 160

Thermal Ceramics TR-19 and V-1100AL

insulating boards
Holding/Melting Furnace
Thermal Ceramics gunning and casting plastics, our family of non-wet-
ting to molten aluminum castables, and our backup insulation boards
and blocks offer an alternative to conventional brick or plastic-lined
holding and reverb furnaces. These products are designed to handle
harsh service conditions, such as thermal shock and mechanical
abuse, as well as attack from corrosive agents. In combination with
our backup castable and insulating boards, our products lower energy
costs, and help ensure long service life.

Roof
Kao-Plas C, Plascast Castables1
Kaogun® 30, Kao-Plas G Castables1
Midcast® Castable1
Kaolite 2200/2300-LI Castables2

Upper Walls
Kao-Plas C, Plascast Castables1
Kao-Plas G, Guncrete 160 Castables1
Midcast Castable1
TR-19/V-1100 Board2
BTU-BLOCK Board and Panel2

Lower Walls
Alcast Extra HS and Albond Castables1
Kaocrete HPM 80AL and HPM 65Al Castables1
Kaocrete HS Castable2
Morbond Castables
Superwool 607 Board, Blok 607 Board2
TR-19/V-1100 Insulating Board2

Floor
Alcast Extra HS and Albond Castables1
Kaocrete HPM 80AL and HPM 65Al Castables1
Kaocrete HS Castable2

Door
Pyro-Bloc Modules1
Kaolite, Insulite Castables1

Door Jamb
Kaocrete 250C, Morflo 165 Castables1
Kaocrete HPM 80AL and HPM 65Al Castables1

Maintenance Gunning
Kao-Plas G, Plasgun Castables1
Higun1
1
Hot Face 2
Backup

Pumpable castable application

Pyro-Bloc module and hardware Alcast Extra Castable
Casting Process
Molten aluminum retains its heat and filters well in launders that are
either lined with our non-wetting castables and vacuum formed
shapes or formed with our specially formulated moldables. Casting
tips manufactured with our TBM board technology can produce alu-
minum sheet and foil with low defect rates, which can improve your
production yields and product quality.

Launders
Alcast Extra HS and Alcast 70FS Castables1
Kaocrete HPM 80AL and HPM 65AL Castables1
Kaofil Moldable2
Superfil 607 Moldable1,2
Alfibond® Shapes1
TR-19 Insulating Board2
BTU-Block Board/ Panel2
Superwool 607 Paper2
Blok 607 Board2

Degassing, Filtration and Head Boxes

Alcast Extra HS and Alcast 70FS Castables1
Kaocrete HPM 80AL and HPM 65AL Castables1
TR-19 Insulating Board2
Kaowool Board/Blanket2
Superwool 607 Board/Blanket/Paper2
BTU-BLOCK Board/Panel2
BTU-BLOCK microporous insulation
Casting Tips
Kaowool TBM 2230 Boards
CT Boards
Superwool Boards

1. Metal contact / hot face

2. Back up insulation / expansion joint

Kaowool TBM® Board casting tip

Homogenizing Furnace
Thermal Ceramics has several lining options for homogenizing furnaces,
depending on your finished product requirements. Each system installs
quickly, reducing downtime, and is thermally efficient with a rapid ther-
mal response. Our linings are also designed to withstand high air veloc-
ity and furnace vibration. Some lining materials in board or low shot
blanket and module form are extremely clean, minimizing contamination
from airborne particulate matter. This, in turn, results in final aluminum
products with fewer defects and higher yields.

Furnace Lining
Pyro-Bloc Modules
Kaowool M-Board
Superwool 607 Modules/Board
TR-19/V-1100 Insulating Board
Kaomat 2000-SL/SL Silica Blanket/Modules

Ceramic fiber blanket roll and strip

Pyro-Bloc Ceramic Fiber Module and Stud

Gun
 Global Headquarters
Thermal Ceramics Global
L'Européen - Bât. C
2, rue Joseph Monier
92859 Rueil-Malmaison Cedex, France
T: +33 (0)1 47 16 22 23
F: +33 (0)1 47 16 22 40
E-mail: info@tc-global.com

Global Marketing 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

#18 Kang an Road
Pudong, Shanghai • 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

Global Aluminum Industry Sales Office Locations

Americas Europe Asia
North America United Kingdom Australia
Canada T: +44 (0) 151 334 4030 T: +61 (8) 8243 05300
T: +1 (905) 335 3414 F: +44 (0) 151 334 1684 F: +61 (8) 8243 0571
F: +1 (905) 335 5145 Italy Middle East
United States T: +39 (02) 822 8171 T: +971 (4) 8833 807
T: +1 (706) 796 4200 F: +39 (02) 824 3815 F: +971 (4) 8833 083
F: +1 (706) 560 5841 South Africa China
T: +27 (11) 815 6820 T: +86 (21) 6812 2200
South America F: +27 (11) 362 4673 F: +86 (21) 5812 3529
Brazil Singapore
T: +55 (21) 2418 1366 T: +65 6733 6068
F: +55 (21) 2418 1205 F: +65 6733 3498
Venezuela
T: +58 (241) 858 2192
F: +58 (241) 858 9562

www.thermalceramics.com
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