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Thermbond Bulletin Vol 1 Issue 6

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Thermbond News, Hot off the press!

September 2008
Volume 1, Issue 6
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 Previous Issues

 
In this Issue:
  • Thermbond Team Members (and Product) are safe following Hurricane Ike
  • New Thermbond Formula: Formula 2125 G
  • Updated Thermbond Products: Formula 12 L & 12 W
  • Come Visit Us in Essen at the Aluminium 2008 Show!
  • Application Report:90 ton Aluminum Round Melter - Permanent Cast Veneer Hot Face Repair

Think Thermbond!

Thermbond Team Members (and Product) are safe following Hurricane Ike
 
           
Jamie Cambetta's House
Jamie Cambetta's House
Jamie Cambetta's House
Tree on Jamie's House
and another one...
and another one!
 
Hurricane Ike plowed its way through Houston and surrounding areas on Sunday. Thermbond's Houston-based employees, Ted Hagberg and Jamie Cambetta and their families weathered the storm although as of Wednesday Sept. 17, their homes (and millions of others) are still without power. Former employee Oscar Thackery has also reported that he and his family are safe.
 
All product stored in our Houston warehouse is safe although they too are without electricity, so deliveries may need to be routed from an alternative warehouse.
 
Both Ted and Jamie have cell phone service and can be reached at their direct numbers. If you are unable to get in touch with them and require immediate assistance, please call Stellar's Administrative Offices at (561) 330-9300
 
Testimonial from a Customer in Hungary
 
"We are always looking for better solutions for our customers. In summer 2006 we decided to cast a one-piece aluminum tank with F 5-L. After 8 months life-time now we have best result:
 -  no sticking of aluminum to the sidewalls
 -  less corundum
Within the next months we will realize the same Thermbond application again. We hope that this method will become standard for all plants of our customer worldwide. Thanks for your support and help to use Thermbond as a better solution."
 
Stellar Materials Announces New Product Formula 2125 G
                                            
Samples cut from a gunned panel show the
material is free of laminations and separation.
Cross section of gunned sample that shows a
dense matrix with no voids.

 

Stellar Materials Incorporated, manufacturers of Thermbond® Refractories, has released a new gun grade refractory ideally suited for refinery applications where high strength and abrasion resistance are desired.

Formula 2125 G has a fired density below 130 pcf, and is recommended for FCCU and Fluid Coker applications including reactor risers, overhead flue gas lines, strippers, 3rd stage separators, combustion risers, and seal pots. 

“I’m extremely excited about the release of our Formula 2125 series (cast and gun) mixes.  We targeted the ExxonMobil “Type 3” classification for applications where high strength and abrasion resistance were needed, but also achieved desirable insulating properties to minimize mechanical stress concerns.  Formula 2125 meets those needs, and should be considered in any critical path application or where thermal shock problems exist,” comments Ted Hagberg, Director of Business Development.

As with all Thermbond products, Formula 2125 G provides exceptional thermal shock resistance and rapid heat up capabilities.  Formula 2125 G has undergone extensive gunning and abrasion resistance testing.

 Complete technical data information can be found on our website at www.thermbond.com.

 

Think Thermbond!

Testimonial from a Casting Coordinator in the aluminum industry: 

"Thermbond formula 2104L was installed as a repair to the most severe wear furnace hearth. Refractory repairs to this hearth area have been very unsatisfactory in the past.  Formula 2104L was installed and has provided "amazing" ability to withstand the abrasion and mechanical abuse that no other refractory has been able to provide."

Think Thermbond!

 
Stellar Materials Announces Product Update: Formula 12 L & 12 W

Stellar Materials Incorporated, manufacturers of Thermbond® Refractories announces significant improvements to the following products: Formula 12-L and Formula 12-W

Vice President of Engineering, Jens Decker recently made raw material changes that significantly improve the physical properties and bonding capabilities of these high strength abrasion resistant products. 

“Due to the raw material changes we lowered the wet to dry ratio of Formula 12 L and Formula 12-W which resulted in dramatic improvements in cold crushing strengths and abrasion resistance.  The workability is still the same even though the drop in the wet to dry ratio was significant”, says Decker.

Formula 12-L and 12-W are primarily used in the Refining/Petrochem industry. These products are recommended in hot wall and cold wall applications in FCC Units where abrasion and/or thermal stress resistance is required. Formula 12-L is a ramming material for full thickness linings (eg; reactor risers/cyclones) whereas Formula 12-W is a wash coat material developed to extend the life of existing eroded areas.

Formula 12-W has a higher wet to dry ratio then Formula 12-L, and will provide exceptional bond strengths to existing substrate materials. Formula 12-W is perfect for trowelling or smear coating.

 

Think Thermbond!
Testimonial from a Contractor in the Aluminum Industry:
 
 "Thermbond's use at this facility has grown over the past 10 years. We first used Thermbond for small emergency repairs and now use it for full maintenance applications. Thermbond has given us the confidence that it will perform where others have failed in the past."
Think Thermbond!
 
Stellar Exhibiting at Aluminum 2008 in Essen
 
Don't forget to visit us in Essen at the Aluminium 2008 show. We looking forward to seeing you there!
 
Visit Stellar at Booth B 40 in Hall 2!
 
September 23-25, Stellar is Exhibiting at Aluminium 2008 in Essen, Deutschland.
 
Visit us at Booth B 40 in Hall 2!
 
For more information, contact Paula Schell at paula.schell@thermbond.com
 
Think Thermbond!
 

Testimonial from a customer in the aluminum industry: 

 

"Thermbond in all equipment since approx. 1999. Second melting furnace purchased in 2003 and the refractory lining was specified as “Thermbond no substitutions” only because of Thermbond’s performance in the first furnace. The heated launder system was originally lined with Thermbond and lasted 5 years.  After the original 5 years, a conventional non-wetting refractory was installed as a cost saving.  This replacement non-wetting material lasted 1 year was taken out and the complete launder relined with Thermbond.  Five times the service life!!!" 

Think Thermbond!

Application Report
 
Industry: Secondary Aluminum
 
Description of Equipment25' 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 side wall. Repair complete circumference of sidewall using Thermbond Formula 4L from belly band to floor.  Formula 4L would be a 9" full thickness hot face refractory lining.

 

Formula 4L was used in ramp.

Formula 4L was used for floor area of Flue.

Section of lower sidewall cast with Formula 4L. Steel
Forms were used to achieve smooth finish.
General configuration of inside of furnace. Left side
shows forms removed with one section of Formula
4L cast.
 
Product Being Replaced: Conventional ultra low cement, aluminum resistant, castable refractory 
 
Savings Using Thermbond: Initial savings were substantial because furnace did not require complete tear-out and reducing the downtime for repairs substantially. Additional saving will be obtained because the remaining conventional refractory lining could be salvaged and operational for an estimated two more years. 
 
Products Applied: Formula 4L in 16 unit "super sacks"

Method of Installation: Cast.

Scope of Work: Removed old conventional refractory lower sidewalls. Placed steel forms (pre painted) around entire furnace circumference and blocked at 6' intervals. Mixed each "16 unit" super sac (1,264 lbs) of Formula 4L for two minutes, dumped material into mortar box and transported hopper into furnace by fork lift. Mixing time for Formula 4L was slightly longer than normal because of the large volume of material being mixed. The Formula 4L was poured behind forms and vibrated into place taking care to vibrate the material into a homogeneous mass with no "rat holes". Looking down at the furnace every other 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. Thermbond also bonds to the existing conventional refractory floor. Over 30,000 pounds of Formula 4L was cast in four hours.
 

Installation Date: April 2008
 
Follow Up: August 2008- Everything is fine, furnace operating properly, and customer pleased with the Thermbond installation.
 
Think Thermbond!

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.

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
 
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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 9/18/2008 5:00 PM  by Ashley Garcia