Click here for printer friendly version of this techncial bulletin.
Stellar Materials Incorporated, manufacturers of Thermbond® Refractories announces significant improvements to the following products, effective immediately:
Formulas 3-P, 4-P, 5-P, 6-P, Formula 12, Formula 8, and Formula 15-R
|
|
|
Thermbond Formula 6-P: Old (left) and New (right) |
Technical Director Jens Decker recently identified a new raw material that improves refractory performance in certain Thermbond formulations. Decker substituted the new material in these existing formulas and found it to improve strength and density.
As a side benefit, the new formulations are now off-white in color as opposed to black. The color change adds value, as patching and repairs with these Thermbond products now closely matches the color of the existing refractory shape or lining. Repairs are now more aesthetically pleasing to the customer.
In addition to the formulation/color change for the patch products, the color change also affects Formula 12 (hex mesh ramming material primarily for the refining industry), Formula 8 (insulating mix primarily for the petrochemical industry and backup linings for the aluminium industry) and Formula 15-R (rammable material primarily for burner tiles).
Customers that order new material may still have some of the old material in stock. If both materials are delivered to the same job site, the finished patch may resemble a Holstein cow. Because the raw material substitution has no significant impact on the chemistry of the product there is no problem installing both formulations. Because the chemical composition is virtually the same, new testing certificates and new material safety data sheets are not required. However, since the material properties have improved, and the wet-to-dry ratios have changed, revised Technical Data Sheets are posted at www.thermbond.com.
Please note on the new data sheets that some materials now have different unit weights to account for the change in wet-to-dry ratios. This change is also reflected in unit pricing for the affected products.
All new materials starting with Batch #722208 use the modified formulation. The updated Thermbond refractories are already successfully installed across all industries supported by Stellar Materials.
Application Report: Anchorless, Permanent Veneer Repair
Industry: Aluminum
Description of Equipment: Melting Furnace
Problem: Operational difficulties and frequent ramp-ups caused the conventional refractory surface of this holding furnace to become badly impregnated with corundum growth. The refractory failed prematurely because of damage from mechanical cleaning, use of aggressive cleaning fluxes, moisture pickup and frequent cycling from hot to cold. The customer contacted Stellar looking for an alternative to a complete furnace reline that would reduce material costs and excessive furnace down-time.
Solution: Overlay a veneer of Thermbond to the clean solid surface after removal of all traces of existing refractory oxidation. The Thermbond veneered lining would allow the customer to avoid the capital expenditure of a new lining. Thermbond would also protect against corundum growth and eliminate the need for aggressive cleaning fluxes, provide longer lining life that required less maintenance. Thermbond would not require an extended thermal heat cure so the furnace could be brought online quickly.
Furnace is prepped and formed prior
to Thermbond installation. |
Finished Thermbond veneer floor,
wall, and ramp areas. |
Product Being Replaced: Conventional monolithic refractory
Production's Required Turnaround Time: 5 days
Actual Turnaround Time Using Thermbond: 5 days
Products Applied: Thermbond Formula 5-L
Method of Installation: Vibration casting
Equipment Used: Chipping hammers, pan mixer, two 2" diameter pencil vibrator
Scope of Work: Prepare floor, ramp, and lower sidewall areas by removing all contaminated refractory using chipping guns. Install forms to prepare for casting. Install Thermbond veneer to restore areas to original lining thickness.
Installation Date: October 2005
Follow Up: February 2008 Furnace still in good operating condition. No visible corundum penetration.