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THERMBOND: Experience The Best. > StellarPublicWiki > Thermbond Bulletin Vol 2 Issue 1
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Thermbond Bulletin Vol 2 Issue 1
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In this Issue:
- THERMBOND: Delivering Value in Difficult Times
- Stellar Presents a paper at TMS
- Happy New Year from Stellar!
- Application Report: Cement Industry, Formula 4-L and Formula 2104-L – Cast
Testimonial from an engineering manager at a west coast refinery:
"I have been specifying and engineering Thermbond installations since 1996 for many different applications. The various Thermbond formulations are very unique and well suited for the refinery industry. They can be the refractory material of choice in quite a number of installations where time or longevity of service is critical. I am happy to spread the word."
THERMBOND: Delivering Value in Difficult Times
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by Tom Atkins, Vice President Worldwide Sales
Part one in a series. |
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The global recession has affected every industrial market to a substantial degree. From aluminum to steel to petroleum products, no one is immune. Even in this economic malaise, Thermbond continues to deliver value to its users. Over the next few bulletins, we will explore how Thermbond is still the right refractory choice.
At first glance, it would seem that lower cost refractories would be the smart choice for repairs or relines. How many times have we heard maintenance or production personnel lament, “We really want to use Thermbond but we don’t have the money today.” If Thermbond provided value to a customer in the past, it will continue to provide it in the future. The parameter that has changed is the immediate available budget.
Does it make sense to repair or reline a furnace with products that knowingly will not perform as well as Thermbond? Does it make sense to spend $ 15,000 on labor and conventional refractories today, and again in 3 months, when one could spend $ 30,000 on labor and Thermbond today and not worry about it for 9 months? On the other hand, doesn't it make sense to consider what is really the best overall decision and champion the right choice to decision makers with budget making authority?
We have very smart customers and within their organizations, someone has the capability of creating the budget for Thermbond if they are presented with the facts. The hard part is finding that person and allowing them to uncover the truth for themselves. In other words, someone does have the budget authority to choose Thermbond if they conclude it still delivers better value.
My challenge to anyone who is thinking about using Thermbond but does not have the immediate budget, think again. If Thermbond is the right choice, find someone in your organization that does have the budget making authority and present your case for the value of Thermbond. The worst that can happen is they say, “No, there just isn't any money.” The best that can happen is they say “Yes” and you are a hero!
Testimonial from a maintenance manager at a gulf coast power generation facility:
"We have had a local contractor gunnite 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."
Stellar is Presenting a Paper at TMS on Energy-Saving Refractories
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Jens Decker
goes GREEN at TMS
16 December 2009 |
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Learn how Thermbond Refractories can help you save energy! Come and listen to our Vice President of Engineering, Jens Decker at the TMS show in February. He will be presenting his paper, "Energy Savings Through Phosphate-Bonded Refractory Materials" with all of the details. The presentation will take place on Monday, February 16 at 10:15 a.m. in room 2102, at the Moscone West Convention Center in San Francisco. The key points in this paper were included in our December bulletin.
Testimonial from a plant manager at a secondary aluminum melter:
"We have been utilizing Thermbond Refractories in our furnaces for over 3 years now with great success. The Formula 4-L is used below the metal line in critical areas such as the hearth. The Formula 5-L is used above the metal line and the Formula 3-L is used in the furnace roof. Thermbond has saved us in the scope of repair work due to its unique bonding to existing refractory and in down time due to Thermbonds rapid heat up capabilities."
Happy New Year from Stellar Materials!
Another year is here, Happy 2009! We look forward to another productive year working together. With wonderful people like you by our side, this year will be even better than the last.
We wish you and your families a very Happy New Year! We hope this year is filled with love and happiness for you.
Testimonial from a sales engineer in the aluminum industry:
"As a refractory contractor-installer in the aluminum industry, we have achieved great results utilizing THERMBOND products. We have found that the combination of high alumina, non-wetting characteristics and rapid set-up allow us to install durable, long-lasting working linings in a time-saving manner. We strongly believe that THERMBOND materials give us and our customers a solid competitive edge in the aluminum industry."
Application Report
Cement Industry, Formula 4-L and Formula 2104-L – Cast
Location: France
Description of Equipment: Burner pipe and outlet rings on satellite coolers
Problem: Abrasion by the clinker and thermal shock leads to cracks and wear in the refractory outlet rings. Thermal shock and alkali attack shorten the life of the burner pipe.
Solution: Selectively place Thermbond in areas to increase overall life.
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Satellite Coolers |
Burner lance (new) - tip cast with Formula 4L |
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Formula 4L burner lance after 18 months |
Outlet rings inside rotary kiln |
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Forms set in preparation for casting |
Formula 2104-L cast in outlet ring |
Product Being Replaced: Conventional high alumina castable with stainless steel fibers
Savings Using Thermbond: Less cracking because of Thermbond’s good thermal shock properties and less erosion because of Thermbond’s excellent abrasion resistance
Products Applied: Thermbond Formula 2104-L and Thermbond Formula 4-L
Method of Installation: Cast in place behind steel forms with 1.5 % steel fibers
Equipment Used: pan mixer and pencil vibrator
Scope of Work: Cast a 60-degree section on all ten outlet rings using Formula 2104-L with each section taking 1 hour to form and pour. The replaced sections are where the clinker discharges out the kiln. The first 2 meters of the burner tip were cast in the shop using Formula 4-L. One 180-degree section was formed and cast. The tip was rotated and the next 180-degree section was cast. Total installation time was approximately 3 hours.
Installation Date: December 2008
Follow Up: Initial Formula 4-L burner lance has been running for more than 18 months !! This exceptional performance is what made the customer to decide to do a second lance and install Thermbond in the outlet rings. Other plants within the group will be installing Thermbond in severe wear areas too.
If you would like additional information regarding this application report, please contact Stellar's Installation Manager for 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 2009 Stellar Materials Incorporated. All Rights Reserved.
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Last modified at 1/22/2009 10:54 AM by Brian Mintz
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