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In this Issue:
- Sale of the Month: Petrochemical Application in The Gulf Coast
- Stellar Announces New Product Formula 28-S
- Stellar Spotlight: Jim Knicley, Plant Manager
- Application Report: Burner Face Repair in Power Plant, ramming
Testimonial from a customer in the aluminum industry:
Thermbond Formula 2104-L was installed as a repair to the most severe wear furnace hearth. Formula 2104-L has provided "amazing" ability to withstand the abrasion and mechanical abuse that no other refractory has been able to provide.
Thermbond Application in The Gulf Coast
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Lifting mortar box to work platform. |
Stellar Materials has been supplying high quality Thermbond refractory for transfer line applications in Olefin units worldwide since 2001. During a recent installation of Formula 16-L at a large plant located in the Gulf Coast, external vibrators were used to insure a homogenous lining throughout the entire length of the transfer line. This was a revamp to an existing design to improve unit performance.
Stellar Materials supplied 576 units of Formula 16-L for the quench header linings and 48 units of Formula 6-P for the inlet and outlet headers during this revamp. Thermbond technology delivered the desired strengths and excellent insulating properties without need for refractory thermal dry out prior to unit start up. This was critical to the long term integrity of the high alloy transfer lines as it eliminated premature hot spots and thermal stress cracking due to metal fatigue. Thermbond continues to provide great value in numerous applications throughout the petrochemical and olefins market.
For additional information regarding this application, please contact Stellar's Sales Manager for the Gulf Coast, Jamie Cambetta: Direct: (561) 558-5815, Email: jamie.cambetta@thermbond.com
Testimonial from a Customer in the Petrochemical Industry, in the Gulf Coast:
"We have successfully used Thermbond Formula 6-B for ethylene cracking furnace burner tile for over 15 years. A great improvement in tile life was a very positive result."
New Formula Product 28-S
Stellar Materials, manufacturer of Thermbond Refractories is pleased to announce a new Formula product called Formula 28-S.
Formula 28-S is a coating material that is mixed with Thermbond's Formula Activator. The dry material ships in a 38lb pail and uses two jugs of activator. The coating provides non wetting properties against molten aluminum and protects surfaces in furnaces against slags and ash build up. Formula 28-S has a long working time and sets under heat during furnace start up at roughly 200°F.
Formula 28-S can be used in any industry with ceramic fiber lined furnaces to rigidize the fiber surface and protect the fiber from high wind velocities and abrasion from particle load in the furnace. It can also convert a conventional refractory surface into a non-wetting surface and protect a surface from slag infiltration. The sprayed layer has a thickness between 100 and 300 microns.
Formula 28-S is scheduled to be installed in an Ethanol plant in the near future. The material will be applied with a texture sprayer to seal the cracks around the burners, providing an extra layer of protection to the refractory. This customer is very excited about the new product and the benefits it will provide them. Formula 28-S is superior to the current coating material they use, thanks to the additional protection of the refractory, the dry out method, the consistency of the material and the bonding capabilities.
Look for more information on this application in a future bulletin.
Testimonial from a Engineering Specialist in the Petrochemical Industry:
"We have seen very good results with Formula 12-L in our FCCU cracking risers, flue gas line downstream of our quench water sprays, tertiary separator inlet plenum, and tertiary separator cyclones since 2003."
Stellar Spotlight: Jim Knicley, Plant Manager
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Plant Manager, Jim Knicley |
This month’s spotlight shines on Stellar’s Plant Manager, Jim Knicley. Jim began his employment with Stellar Materials in 1998 as a production worker and spent time working in all of the departments at the plant: shipping, manufacturing, maintenance and quality control. He was rewarded for his hard work and diligence in 2004 when he was promoted to Plant Manager.
Jim’s character, dedication, and extensive experience within all departments give him a unique insight and sound judgment.
As the plant manager, it is Jim’s job to ensure that all of the departments run efficiently and harmoniously. He is responsible for overseeing production, maintenance, and building operations, along with shipping and receiving. Jim keeps the plant operating at peak performance.
“What I love most about working for Stellar Materials is our ability to preserve the small business ambiance. Success has not altered our ideals. Every customer is still just as important as the next, regardless of size. Each employee is treated like family. It is a wonderful place to work” says Jim Knicley.
In addition to running the plant, Jim has four boys all under the age of nine to keep him on his toes. In comparison, managing the plant is a piece of cake! J
Stay tuned for next month’s Stellar Employee spotlight!
Testimonial from a Customer in the Gulf Coast
"We plan to include Thermbond products on our approved refractory materials list for a long time to come."
Application Report
Burner Throat Repair
Industry: Coal Fired Power Plant
Description of Equipment: Coal fired power plant burner face
Problem: The maintenance manager and mechanical supervisor at the power plant needed to repair the refractory in burner throats to improve burner performance. Their desire was to repair the existing refractory rather than take the time to tear out and replace it in its entirety. Conventional refractory could not be dried out effectively and there was concern about conventional refractory bonding to the existing refractory.
Solution: Install Thermbond Formula 15-R, which requires no curing or lengthy dry out. This formula eliminates the thermal dry out restrictions for the start up of the furnace.
Product Being Replaced: Conventional 85% alumina plastic refractory
Benefit Using Thermbond: Thermbond ramming materials bond to existing refractories and require little or no dry-out. These two features address the customer’s initial concerns plus, because dry-out is minimized, down time is also reduced.
The maintenance manager and mechanical supervisor were so impressed with the ease of installation for Thermbond, they expanded the scope of work. The additional scope of work was done within the original shutdown schedule.
Products Applied: Thermbond Formula 15-R, a 60% alumina ramming material.
Scope of Work: Thermbond Formula 15-R was mixed in a Holbart mixer and then rammed around the outside of 42 burner throats, feathered out to five inches thick.
Equipment Used: A 30-quart Hobart mixer and Ingersol-Rand pneumatic bench rammers
Installation Date: February 2009
Follow Up: Inspection scheduled during outage in November
For additional information regarding this application report, please contact Stellar's Sales Manager, Jamie Cambetta: Direct: (561) 558-5815, Email: jamie.cambetta@thermbond.com
To view this application report in a printable format, please click here.
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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 6/23/2009 4:01 PM by Ashley Garcia
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