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In this Aluminum Issue:
· Meet our Aluminum Industry Specialist: Jeff Pchola
· Application Report: 90 ton Aluminum Round Melter
· Aluminum Industry Testimonials
· Application Report: Aluminum Melting Holding Pouring Furnace
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A brief message from
Jeff Pchola,
Aluminum Industry Specialist
for Thermbond Refractories
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As the Aluminum Industry Specialist for Stellar Materials, I will draw on my experience obtained from working for nearly 15 years in the refractories and molten metal equipment side of the aluminum industry, to provide solutions to your refractory problems.
With our great team of salesmen, installation support personnel, technical staff, customer service, strategic partners, and a phenomenal line of products, I am confident the Stellar Materials Team can help you maximize the value Thermbond delivers to your operation.
Thank you,
Jeff Pchola
Sales Director and Aluminum Industry Specialist
Stellar Materials Incorporated
jeff.pchola@thermbond.com
(561) 504.8332 Direct
(561) 330.9300 Main Office
(267) 295.1777 Fax
Stellar-Jeff Skype
www.thermbond.com
Testimonial from a Casting Coordinator in the Aluminum Industry
Thermbond formula 2104-L was installed by the contractor as a repair to the most severe wear in the furnace hearth. Refractory repairs to this hearth area have been very unsatisfactory in the past. The failure has been at the bond to the existing sub hearth. Complete hearth refractory repairs have not lasted very long due to the extreme abrasion from loading and cleaning operations making repairs to the hearth surface a frequent necessity. Formula 2104-L was installed and has provided "amazing" ability to withstand the abrasion and mechanical abuse that no other refractory has been able to provide.
APPLICATION REPORT
90 ton Aluminum Round Melter - Permanent Cast Veneer Hot Face Repair
Industry: Secondary Aluminum
Equipment/Location: 25' diameter round, top charge melter
Problem: Conventional refractory sidewalls were worn out and repairs were required. Normally the repairs would be a full rebuild of sidewalls requiring 4 weeks of downtime. Customer could not afford 4 weeks of downtime.
Solution: Leave existing conventional floor alone and tear out sidewalls. Repair complete circumference of sidewall using Thermbond Formula 4-L from belly band to floor. The repair would be a 9 inch, full thickness, installation. Formula 4-L would be used in the ramp4-Land floor area of Flue. 4-L Steel Forms were used to achieve a smooth finish. 4-L
Product Being Replaced: Conventional ultralow cement, aluminum resistant, castable refractory
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Thermbond Formula 4-L in ramp. |
Thermbond Formula 4-L in floor area of flue |
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Section of lower sidewall cast with Formula 4-L |
General configuration of inside of furnace. Left side shows forms
removed with one section of Formula 4-L cast |
Savings Using Thermbond:
Initial savings were substantial because the furnace did not require complete tear-out and downtime for repairs was reduced substantially. Additional saving were obtained because the remaining conventional refractory lining could be salvaged and operational for an estimated two more years.
Products Applied: Formula 4-L in 16 unit "super sacks"
Method of Installation: Cast
Equipment Used: 2 ton horizontal mixer, two fork lifts, large mortar box, painted steel forms, and 3" pencil vibrator
Scope of Work: Removed old conventional refractory lower sidewalls. Placed steel forms (pre painted) around entire furnace circumference and blocked at 6' intervals with removable form boards. Mixed "16 unit" super sacks (1,264 lbs) of Formula 4-L for two minutes, dumped material into mortar box and transported into furnace by fork lift. Mixing time for Formula 4-L was slightly longer than normal because of the large volume of material being mixed. The Formula 4-L was poured behind forms and vibrated into place taking care to vibrate the material into a homogenous mass with no "rat holes". Every other 6’ section was cast. Once the cast sections set, the form boards between sections were removed and the remaining sections cast. Since Thermbond bonds to itself this method of installation works well and eliminates joints. Over 30,000 pounds of Formula 4-L was cast in four hours.
Installation Date: April 2008
Follow-Up: August 2008- Everything was fine, furnace operating properly, and customer pleased with the Thermbond installation.
Testimonial from a Maintenance Manager in the Aluminum Industry:
“I have been using the Thermbond products for several years. Since we do most of the work in house we find the product easy to use because everything is premeasured. I have been very satisfied with the performance of the material and like the fact that it can be heated up quickly because down time is very expensive. Over all it is a great product when we need to get back up quickly.”
Application Report
Aluminum Melting Holding Furnace
Industry: Aluminum
Description of Equipment: Aluminum Furnace
Problem: Because of high operating temperatures (+ 1600 F) dross builds up very badly and reduces furnace capacity.
Solution: Perform a total reline using Thermbond products extensively.
Product Being Replaced: Conventional Refractory
Products Applied: Thermbond Formula 3-L, 4-L, 5-L, Thermbrake 403, Formula 5-P
Method of Installation: Casting
Equipment Used: Mortar mixer, plastic pails, 2” pencil vibrator, and a plastic garden sprayer
Scope of Work: Knockout old refractory. Repair furnace steel work. Place insulating board on floor and side walls. Place brick anchors on wall above metal line. Form up lower and upper walls. Form ceiling. Cast Thermbrake 403 on floor as insulating layer. Cast Formula 4-L on floor. Cast conventional castable and ramp. Cast Formula 5-L on lower walls. Cast Formula 3-L on upper walls. Repair ceiling between holding area and outside well area with Formula 5-P to fix any minor damage.
Installation Date: February 2006
Follow Up: After 6 months, the furnace is running great, customer just set an all time month production record. No dross built up, operators state it is very easy to keep clean.
For additional information regarding this application report, please contact Stellar’s Director, Aluminum Industry, Jeff Pchola Direct: (561) 504-8332, Email: jeff.pchola@thermbond.com
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Stellar Materials Incorporated is a privately-held corporation headquartered in Boca Raton, FL with manufacturing facilities in Whitmore Lake, MI, stocking warehouses worldwide, and wholly-owned subsidiaries in Rotterdam NL and Abu Dhabi UAE., and Mongaguá -SP Brasil. |
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Stellar Materials Incorporated
7777 Glades Road, Suite 200
Boca Raton, Florida 33434 USA
(561) 330-9300 |
Stellar Materials International, LLC
Nieuw Mathenesserstraat 39 - 41 Unit 1 B
3029 AV Rotterdam
The Netherlands
+31 (10) 2460264 |
Stellar Materials M.E. FZE
P.O.Box No 10559
Ras Al Khaimah
United Arab Emirates
+971506891327 |
Stellar Materials do Brasil
Avenida São Paulo
1380 sala 07 - Centro
Mongaguá - SP Brasil
11730-000
+55-13-3448-6516 |
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