Doris Gold Retires after 20 years of loyal service
Application Report: Coal Fired Power Boiler, Gunned and Slobber nozzled
Cement Installation
Prior to a planned shutdown in May 2009 a hot spot was observed in the burner bonnet of the down draft calciner at a major US cement producer. In this instance, after tearing out the damaged area, which exceeded 50% of the bonnet, it was agreed to remove the entire bonnet to the steel, perform steel repairs, and reinstall the refractory lining. A similar problem occurred in 2006 that resulted in a complete demolition and reline of the bonnet section, causing many days of downtime.
Due to the lack of temperature control on start-up in this area and its proximity to the burner itself, Thermbond products were installed in order to eliminate the need for a controlled and prolonged dry-out. Formula 8-G was gunned in as the insulating back-up lining and Formula 6-AG gunned in as the hot-face lining. Both products were pre-dampened in order to reduce rebound while gunning overhead and on an angle.
In addition to the repairs in the burner bonnet, it was discovered that the wall directly below the firing hood doors had lost most of the refractory lining and the steel was in need of repairs. Thermbond Formula 6-AG and Formula 8 were used to make those repairs as well.
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Bonnet side wall hot-spot area |
Finished Lining |
For additional information regarding this installation, please contact Ken Hoyt, ken.hoyt@thermbond.com
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Thermbond 2009 Autumn Workshop
SOLD OUT! |
Stellar Materials is proud to announce that our Autumn Workshop is sold out!
The response to our Thermbond Workshop was tremendous. Customers from all over the world will be traveling to attend our Autumn Workshop. Even with the tough economic conditions our customers, contractors and strategic partners clearly see the value Thermbond Refractories provide their businesses.
Thermbond’s Autumn Workshop will provide attendees with key technical knowledge and installation techniques to help them to not only weather this economic storm but come out on top!
Thank you for your interest and we hope to see you at our next Workshop.
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Welcome Baby Luke!
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Luke Robert Niedrach |
Please join us in congratulating Thermbond Sales Manager (Midwest US), Jim Niedrach, and his wife Amanda, on the birth of their baby boy. Luke Robert Niedrach was born on Sunday August 30 at 3:51 PM. He came into the world at 8 lbs 6 oz, 20 1/2 inches long.
Congratulations Jim and Amanda!
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Doris Gold,
Office Manager,
Retires
After 20 Years
of Loyal Service |
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After decades of loyal, dedicated, and outstanding service, our Office Manager, Doris Gold has retired. Doris began working for Stellar Materials the very first day that we opened in Detroit Michigan and then relocated with the corporate headquarters to Boca Raton, Florida in 1998. She has played a very important role in the growth of Stellar Materials. We are extremely grateful to Doris for her esteemed contribution.
“We will miss Doris greatly. It just won’t be the same without her. Especially on fall Monday mornings after a Michigan football weekend! We’ll never be able to replace Doris. She’s leaves a legacy behind,” said David Mintz, President of Stellar.
Doris says farewell, “After all these years it is time for me to say Goodbye. What a journey with Stellar! It’s been a wonderful and fulfilling adventure. The sales, plant, and office personnel have been the best team to work with and I wish all of you continued success in keeping Stellar a growing company.
She will be missed. We wish Doris a long and enjoyable retirement, she certainly earned it!
Application Report
Industry: Power Generation-Illinois
Description of Equipment: Coal fired burners and OFA or Overhead Fired Air Ports
Problem: New Low Nox burner technology being retrofitted into existing burners. Much of the old refractory needed to be replaced and OFA ports needed to be installed. Overhead Fired Air Ports recirculate hot air and help reduce NOx in new burner technology. Conventional refractory could not be dried out effectively in the burners or OFA without a very costly forced air dry-out company and the addition of several more days on to an already tight schedule.
Solutions Using Thermbond: Time/Cost Savings- Gunning and slobber nozzleing the Thermbond products provided an extremely fast and easy installation. Because Thermbond chemically bonds to existing refractory and requires no curing or lengthy dry out the plant was able to bring the boiler back up saving gas consumption and extra outage days.
Time Savings- Our unique binder system allows for much faster start up rates than any alternative refractory without affecting material properties and long-term performance. Thermbond will not be adversely affected by an uncontrolled start up.
Performance- The integrity of the burner flame is critical in maintaining Low Nox burner performance. Thermbond's binder system is naturally non-wetting and minimizes the buildup of slags and coking which is an important aspect of long-term efficiency and burner performance.
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Burner wall with most of the old refractory
removed. |
Gunned material around burner throat with
top hat form in place. |
Finished burner throat. |
Products Being Replaced: Conventional Refractory
Products Applied: Formula 6-AG and Formula 9-L
Method of Installation: Gunning and Slobber nozzle
Equipment Used: Reed LOVA machine,, Horizontal mixer, Stellar gunning nozzle, 2- 375 air compressors
Scope of Work: Most of the existing old refractory needed to be removed for this retrofit. Thermbond Formula 6-AG was gunned in and around the burner throats and Formula 9-L was slobber nozzled into the OFA boxes. All the work was completed on time and the boiler was back in operation without any problems. The customer was very pleased with the material selection, installation, and time/money savings on start-up..
Installation Date: 11-04-2008
Follow-up: The customer confirmed in a September 2009 phone conversation that the burners were performing well with little or no slag/coke, or “eyebrow” build-up observed.
For additional information regarding this application report, please contact Stellar’s Director, Power Industry, Brendan Gallagher Direct: (520) 906-2407, Email: brendan.gallagher@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., and Mongaguá -SP Brasil. |
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 |
Stellar Materials do Brasil
Avenida São Paulo
1380 sala 07 - Centro
Mongaguá - SP Brasil
11730-000
+55-13-3448-6516 |
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Thermbond and Phoscrete are registered trademarks of Stellar Materials Incorporated.
Copyright 2009 Stellar Materials Incorporated. All Rights Reserved.
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