THERMBOND: Experience The Best.

 

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A brief message from Brendan Gallagher, Power Industry Specialist for Thermbond Refractories

 

Hello and Happy New Year!

<Intro Sentence> because our business is solving problems related to refractory installation, tear-out, maintenance, and service life.

My company, Stellar Materials is the manufacturer of Thermbond Refractories, a unique and patented material in use worldwide for twenty years. We developed special formulations for power boiler linings and ash hoppers that get our customers online faster and keep them running longer than conventional refractories.

Thermbond is not the appropriate refractory for every customer or for every application, but if refractory is ever a bottleneck in your operation, there is a good possibility I can help.

Please scroll down to read some testimonials from satisfied customers, and review a selection of our Power Industry Application Reports.

If you are willing to invest 20 minutes of your time to meet with us, we’ll both learn if we can solve some of your refractory problems. <Sales rep>, your area Stellar sales representative will contact you later this month to request that brief meeting.

Please feel free to forward this email to any associates who might also benefit from Thermbond Refractories.

If you require more immediate assistance, please contact me directly.

Thank you for your time and consideration. We look forward to speaking with you.

Sincerely,

Brendan Gallagher
Sales Director and Power Industry Specialist
Stellar Materials Incorporated
brendan.gallagher@thermbond.com
(520) 906.2407 Direct
(561) 330.9300 Main Office
(267) 295.1777 Fax
Stellar-Brendan Skype
 www.thermbond.com

 

In this Power Issue:

·         Meet our Power Industry Specialist: Brendan Gallagher

·         Application Report: Burner Throats-1300 MW Power Station

·         Power Industry Testimonials

·         Application Report: Coal Fired Power Boiler: Gunned & Slobber-nozzled

 

 

 Testimonial from a Maintenance Manager in the Power Industry: 

"We have had a local contractor gunite Thermbond Formula 6-AG for 2 years now to do all of our burner throat repairs as well as new refractory throats. Thermbond Formula 6-AG holds up better than any other refractory to our knowledge because of its bonding capabilities and the ability to start the unit up rapidly."

APPLICATION REPORT

Burner Throats- 1300 MW Power Station

Industry: Power Generation

 

Description of Equipment: 650 MW Coal Fired Generating Unit

 

Problem: Clinker and ash buildup on the top sections of the burner quarls created an eyebrow, resulting in localized hot spots and inconsistent flame patterns.  Conventional plastic refractory installed in the 68 burner quarls deteriorated to such an extent that they required full thickness replacement.

 

Solution:  Find a refractory product that provides longer service life and minimizes downtime for installation and heat-up. Thermbond was chosen because it has little or no cure time and can withstand rapid and uncontrolled ramp-up to operating temperature without damage. Thermbond also resists thermal cycling and has proven to resist surface penetration of clinker, ash, and coke buildup.

 

 

Product Being Replaced: Conventional Plastic Refractory

 

Products Applied: Thermbond Formula 15-R

 

Method of Installation: Hand-packing and ramming

 

Equipment Used: Pneumatic ramming hammers, 250 lb paddle mixer

 

Scope of Work:  Thermbond was rammed and hand-packed to replace the plastic refractory in the burner throat areas. No form-work was required. Thermbond chemically etches to the metal surfaces, creating a chemical bond. All 68 burner throats were installed at full thickness.

 

Installation Date:  April 2007

 

Follow Up: In April 2008, upon inspection a light coating of ash was found on the refractory, but this is not a criteria for replacement. In this difficult environment, conventional products sometime only last for a few weeks before the product falls off. The most critical area for refractory is in the burner throat, because it affects the efficiency of the flame. All of the Thermbond that was rammed in the throat looked excellent in the burners and had not fallen out, and that is extremely important.

 

To view this application report in a printable format, please click here

Testimonial from a Contractor in the Power Industry: 

 

"As far as the installation, we successfully installed the Thermbond materials using the tools recommended in the Installation Guide. With the fast setting of the Formula 6-P it really helped us to finish the job on time. GREAT PRODUCT."

Application Report

Coal Fired Power Boiler - Gunned and slobber-nozzled

Industry:  Power Generation-Illinois

 

Description of Equipment: Coal fired burners and OFA or Overhead Fired Air Ports

Problem: New Low Nox burner technology being retrofitted into existing burners. Much of the old refractory needed to be replaced and OFA ports needed to be installed. Overhead Fired Air Ports recirculate hot air and help reduce NOx in new burner technology. Conventional refractory could not be dried out effectively in the burners or OFA without a very costly forced air dry-out company and the addition of several more days on to an already tight schedule. 

 

Solutions Using Thermbond: Time/Cost Savings- Gunning and slobber nozzleing the Thermbond products provided an extremely fast and easy installation. Because Thermbond chemically bonds to existing refractory and requires no curing or lengthy dry out the plant was able to bring the boiler back up saving gas consumption and extra outage days.

 

Time Savings- Our unique binder system allows for much faster start up rates than any alternative refractory without affecting material properties and long-term performance. Thermbond will not be adversely affected by an uncontrolled start up.

 

Performance- The integrity of the burner flame is critical in maintaining Low Nox burner performance. Thermbond's binder system is naturally non-wetting and minimizes the buildup of slags and coking  which is an important aspect of long-term efficiency and burner performance.

 

 

Products Being Replaced:  Conventional Refractory

Products Applied: Formula 6-AG and Formula 9-L

Method of Installation: Gunning and Slobber nozzle

Equipment Used: Reed LOVA machine, Horizontal mixer, Stellar gunning nozzle, 2- 375 air compressors 

Scope of Work: Most of the existing old refractory needed to be removed for this retrofit. Thermbond Formula 6-AG was gunned in and around the burner throats and Formula 9-L was slobber nozzled into the OFA boxes. All the work was completed on time and the boiler was back in operation without any problems. The customer was very pleased with the material selection, installation, and time/money savings on start-up..

Installation Date:  11-04-2008

Follow-up: The customer confirmed in a September 2009 phone conversation that the burners were performing well with little or no slag/coke, or “eyebrow” build-up observed.

For additional information regarding this application report, please contact Stellar’s Director, Power Industry, Brendan Gallagher Direct: (520) 906-2407, Email: brendan.gallagher@thermbond.com

To view this application report in a printable format, please click here. 

Testimonial from a Plant Manager in the Power Industry

"There are 96 gas fired burner throats that we have repaired as well as new installation of burner throats using Thermbond Formula 6-AG for gunning an overlay and new throat linings. We have also used Thermbond Formula 15-R for overlay repairs installed by handpacking that have bonded to the existing refractory and has lasted over 18 months and is still in service."

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.
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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