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THERMBOND: Experience The Best. > StellarPublicWiki > Thermbond Bulletin Vol 1 Issue 4
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Thermbond Bulletin Vol 1 Issue 4
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In this Issue:
- New Thermbond Formula: Formula 18 R
- Product Names and Suffixes
- Thermbond Tips: Proper Vibration of Thermbond Products
- Application Report: Australian Copper Smelter- Phoscrete 602– Castable Repair
Interview with Stellar's Vice President of Engineering, Jens Decker:
New Product Formula 18 R
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Jens Decker
Vice President, Engineering |
Stellar Materials Incorporated, manufacturers of Thermbond® Refractories developed a new Formula product for applications in the Hydrocarbon Processing Industry.
In this interview, Vice President of Engineering, Jens Decker explains the reasons why this product was developed, and presents a couple of applications for its use.
Why was Formula 18 R developed?
Jens Decker: In our Formula 18 Series product line we had one component missing: ramming. Usually in an application where casting is not possible, for ex: overhead position, gunning is preferred. In some applications the area is so small that there is no value in bringing all of the equipment for gunning. So we developed ramming as an alternative, when casting and gunning cannot be applied conveniently.
What applications would you recommend this product for?
Jens Decker: Mainly for all applications where low iron and low silica (SiO2) is required in the refractory. It is also best used in highly reducing atmospheres such as hydrogen transfer lines in ammonia plants and sulfur recovery units. This product should be used where ramming or hand packing is required. One significant benefit of this product is its suitability in highly reducing atmospheres based on pure tabular alumina raw material used without any silica (SiO2).
What independent testing has been done on Formula 18 R?
Jens Decker: Standard pre-testing has been done as with all Thermbond products.
 Testimonial from a plant manager in the aluminum industry:
"We have been utilizing Thermbond Refractories in our furnaces for over three years now with great success. Thermbond has saved us in the scope of repair work due to its unique bonding to existing refractory and in down time to due to Thermbond's rapid heat up capabilities."
Product Names and Suffixes
Thermbond product suffixes, when used, are consistent throughout the product line, and designed to convey certain characteristics of the products. Below is a listing of the suffixes currently in use and their meaning:
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"A" |
Higher Abrasion Resistance |
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"B" |
Contains poly fibers to facilitate even faster initial firing |
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"E" |
Extended working and setting times specially suitable for pumping applications
(even longer than "L" mixes) |
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"F" |
Finer grain sizing |
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"G" |
Gunning Grade. Should be applied by gunning |
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"J" |
More flowable consistency |
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"L" |
Longer working and setting times |
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"P" |
Patch and repair mix may be applied by troweling, hand packing, or casting |
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"Q" |
Super Quick Setting |
| "R" |
Ramming grade. Should be applied with pneumatic hammer. |
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"W" |
Designed to be applied in thin sections as a washcoat |
Suffixes follow the numeric product formulation. For example, Formula 4-A would be Formula 4 with a higher abrasion resistance. Multiple suffixes may be used, and are typically stacked alphabetically. For instance, Formula 6-AG would be a gunning grade higher abrasion resistant version of Formula 6.
Testimonial from a maintenance manager in Southern California:
"I have used Thermbond for seven years in my melting and casting furnaces. It is a great material for repairs because it bonds so well to the existing refractory and can be heated up quickly to get my furnaces back in service. I have used Thermbond in troughs where the non-wetting characteristics made for easy maintanence. I have used it in floors, upper and lower walls where time and time again it has saved money by providing a fast turn around and superior service life.”
Thermbond Tips from Engineering & Installation Manager, Oscar Thackery:
Proper Vibration of Thermbond Products
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Engineering & Installation
Manager, Oscar Thackery |
- Vibration of the material is necessary to ensure sound placement, and eliminate voids and air pockets.
- External form vibrators are highly recommended for the best material placement and should be used whenever possible.
- If using a probe vibrator, a 2" diameter with a minimum of 12,000 VPM is recommended to efficiently move the material.
- As probe vibrators can generate substantial heat which can accelerate the hardening of Thermbond products, extra caution should be taken to avoid leaving "rat holes" in the material.
- Alternate the use of probe vibrators so that the heat they generate can dissipate when not in use
- When casting Thermbond on horizontal surfaces as a repair to existing fired refractories, vibration is still recommended to ensure good contact between the surfaces by vibrating or tamping.
Testimonial from a customer in the aluminum industry:
"We have been using Thermbond products for several years to do our repairs. This is a great material for repairs because it allows us to get full life out of the launder without having to replace it."
Application Report: Annode Casting Floor Repair
Industry: Non-Ferrous Metal Casting
Description of Equipment: Cooper Smelter Annode Casting Floor
Problem: Thermal degredation and heavy traffic caused damage to conventional concrete floor.
Solution: Use Phoscrete 602 Concrete to rapidly repair floor
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Installing Phoscrete as on overlay on
existing refractory. |
Waiting for final pour in the area to be
repaired.
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Installer finishing surface as Phoscrete
material is poured. |
Completed area of Phoscrete 602
repair. |
Product Being Replaced: Conventional Concrete
Savings Using Thermbond: Quick Installation, only two hours down time. Floor ready for plant traffic within two hours.
Products Applied: Phoscrete 602 (formerly Phoscrete Hot Floor) and Thermbond Formula 18 B (Castable)
Method of Installation: Poured
Equipment Used: Paddle Mixer, Vibrator
Scope of Work: The floor was well prepared by scarifying, providing an average depth of 60mm of rough textured concrete. Some old steel reinforcing bar remained in the old concrete and exposed to the Phoscrete repair. A small quantity of Thermbond Formula 18 B castable was installed into deep crevices near the Anode casting wheel (the hottest area of the floor) prior to the Phoscrete 602 overlay. Internal vibration was used with the TBF18B castable to move into the deep crevices and ensure full contact with the concrete substrate. Using a paddle mixer, the Phoscrete Hot Floor mixed one unit at a time and the overlay was poured without formwork. The entire repair was completed in one hour and floor was fully set shortly after completion. The ambient temperature for this repair was 26°C.
Installation Date: 30 June 2006
Follow Up: July 2008- still in operation.
Special thanks to John Pulbrook, Sales Manager, Refractech Pty. Ltd. for this application report. John and Refractech have been a successful Stellar Materials International partner for nearly 10 years.
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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. |
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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 |
Thermbond and Phoscrete are registered trademarks of Stellar Materials Incorporated.
Copyright 2008 Stellar Materials Incorporated. All Rights Reserved.
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Last modified at 7/15/2008 9:50 AM by Ashley Garcia
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