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In this Issue:
- Stellar Materials Announces New Product, Formula 2102
- Thermbond Shows its True Color: Green!
- Happy Holidays from Stellar!
- Application Report: Boiler Installation, Formula 15 R- Ram
Maintenance Manager in Aluminum foundry in Arizona
"We 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 every thing is pre-measured. We are 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."
Stellar Materials Announces New Product, Formula 2102
Thermbond Formula 2102 Series has been developed for applications in the aluminum industry where resistance against chemical attack from aluminum alloys, wear resistance and insulating properties are required. Transfer launders and ladles are two applications where Formula 2102 would be of benefit.
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Pic 1: Over the road ladle lined with Thermbond |
Pic 2: Alcoa Cup Test |
Formula 2102 possess a significantly lower thermal conductivity than Formula 5L which is the Thermbond formulation typically used in these applications. This improved heat flow allows the transport of metal with much less metal overheating and reduces metal temperature losses during transport. Picture 1 shows an over the road ladle lined with Thermbond.
Besides the low thermal conductivity, Formula 2102 shows excellent non wetting properties and in fact was rated “Excellent” in Alcoa’s aluminum cup test. Picture 2 shows Formula 2102 after 72 hours exposed to a 7075 alloy at 1500F. Although the density of Formula 2102 is only 120– 125 lbs/ft3 the abrasion resistance is still very good with less than 15cc loss. The strengths of Formula 2102 are higher than many conventional products in this density range. Formula 2102 is available in casting and gunning grades.
The updated Technical Data Sheet has been posted on our website.
Engineering Specialist of Petrochemical Facility in Texas
""We have successfully used Thermbond Formula 6B for ethylene cracking furnace burner tile for over 15 years. A great improvement in tile life was a very positive result... We have seen very good results with Formula 12L in our FCCU cracking risers, flue gas line downstream of our quench water sprays, tertiary separator inlet plenum, and tertiary separator cyclones since 2003.... We appreciate all the guidance and technical help you have given us over the years to help us improve performance in our facility. We plan to include Thermbond products on our approved refractory materials list for a long time to come."
Therrmbond Shows its True Color: Green!
Environmental stewardship is something industrial companies are embracing more than ever before. Besides being good for the environment, it is also good for business. Three basic principles of environmental stewardship are Reduce, Reuse, Recycle. Thermbond refractories help our customers in two out of three ways, reduce and reuse. Stellar Materials will be presenting a paper at two upcoming trade shows in 2009 to inform and educate people in the ways that Thermbond can help reduce energy costs and reduce refractory waste.
Vice President of Engineering, Jens Decker will be presenting a paper with the details at TMS in 2009. He will present a similar paper at another Aluminum Conference in 2009. Below we have highlighted the key points in the paper:
The primary furnace design objective is to keep furnace conditions stable over time in order to avoid interruptions of the production process. Interruptions such as additional door openings, furnace maintenance downtime, or changes in the thermal profile, change the heat containment conditions and increase total energy consumption. The features of Thermbond refractories described below either decrease or eliminate these issues resulting in energy savings and less refractory waste.
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Non-Wetting to Molten Aluminum and Aluminum Alloys: Liquid phosphate-bonded materials do not show corundum build up and therefore eliminate the related problems like production capacity losses and wall deterioration which result energy losses, due to additional down time.
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Chemical Bond to Existing Refractory: Liquid phosphate-bonded materials allow veneer repairs that have monolithic properties. This reduces maintenance downtime and stops corundum build up on old conventional monolithic materials after the repair. The outcome is less refractory waste because up to 80% of existing linings can be maintained indefinitely rather than torn out and disposed of repeatedly.
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Fast Firing Properties: This property leads to faster maintenance turnaround with reduced downtime. This increases metal output verses energy input.
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High Strength, Abrasion Resistance and Extremely Thermal Shock Resistant: Due to the very flexible polymer-like bonding system, even high alumina materials can with stand direct flame impact without pre-drying, which allows faster maintenance turnaround. In addition, the high strengths and abrasion resistance of the material can extend the life of the furnace, which reduces downtime.
These factors contribute to energy savings because of the improved furnace efficiency.
Testimonial from a Customer in the Petrochemical Industry, in the Texas:
"We have successfully installed Thermbond products in many areas of our Ethylene furnaces since 2001.We are very pleased with its unique benefits, including cure out, which we usually base on a standard heat-up procedure,we have used a variety of Thermbond materials with the ability to withstand thermal cycling better than previous used convectional refractory."
Happy Holidays from Stellar Materials
In the Spirit of the Season we would like to take this opportunity to wish you and your families a very Happy Holiday Season and New Year. This is the time of year to slow down and appreciate all of the wonderful people in our lives. In this distressed economy, we are particularly thankful for the relationships that we have been fortunate enough to build. Our success would not be possible without you and we wish to thank you from the bottom of our hearts.
Like most businesses around the world, we are doing our best to weather this storm and during the Holiday Season more than ever, we are reminded of those who have not been as lucky. So in the true giving spirit of the Season, in lieu of sending you yet another box of candy or nuts, we have decided to make a donation to a very worthy cause: Direct Relief International.
Since 1948, Direct Relief International has worked to improve the quality of life for people in need. Direct Relief provides medical assistance to improve the quality of life for people victimized by poverty, disaster, and civil unrest at home and throughout the world. Direct Relief is a non-political and non-sectarian organization that provides assistance without regard to race, ethnicity, political or religious affiliation, gender, or ability to pay. Since its inception, Direct Relief has provided appropriate and specifically requested medical resources to community-based institutions and organizations in over 140 countries including the United States.
Once again, we thank you for your business. We appreciate all that you have done to help our company grow, and we look forward to another successful year together.
Wishing you a wonderful Holiday and Happy New Year!
The Stellar Family
If you are interested in making a donation to the Direct Relief International charity or learning more about them, please click here to be directed to their site.
Testimonial from a Customer in the Power Generation Industry, in Hawaii:
"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 6P it really helped us to finish the job on time. GREAT PRODUCT."
Application Report
Industry: Major European Refinery
Description of Equipment: Industrial boiler
Problem: Installing new burners, burner throats, and refractory lining on the sidewall.
Solution: Ramming Formula 15 R for the burner throats and sidewall refractory
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Burner Situation |
Ramming Formula 15 R |
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| Sidewall partly finished |
Formula 15 ready mixed |
Product Being Replaced: Conventional Refractory
Savings Using Thermbond: A reduction in downtime because of Thermbond's ability to be heated up very rapidly and longer life because of Thermbond superior thermal shock resistance.
Products Applied: Formula 15 R
Method of Installation: Ramming with pneumatic hammers.
Scope of Work: Install Formula 15 R in eight burner throats and over 18 square meters of finned tube sidewalls.
Installation Date: April 2007
Follow Up: The same type of installation was performed at the refinery in August 2007. An inspection of both installations in November 2008 boiler revealed the burners and sidewalls of Formula 15 R were still in excellent condition.
If you would like additional information regarding this application report, please contact Stellar's Installation Manager of Europe, Burckhard Vitt @: Mobile: +49 (178) 4 10 38 19, Email: burckhard.vitt@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. |
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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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The Stellar Binder System™ is our patented process used in the technology of Thermbond® Refractories and Phoscrete® Concretes. Thermbond and Phoscrete are registered trademarks of Stellar Materials Incorporated. Copyright
© 2010 Stellar Materials Incorporated. All Rights Reserved.
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Last modified at 12/19/2008 2:44 PM by Ashley Garcia
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