Testimonial from a Casting Coordinator in the Aluminum Industry:
"Thermbond Formula 2104-L 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 2104-L was installed and has provided amazing ability to withstand the abrasion and mechanical abuse that no other refractory has been able to provide."

Thermbond Autumn Workshop 2009, a Great Success!

Customers from all over the world, including Brasil, Canada, Mexico, Indonesia, Taiwan, UAE, and of course the United States, traveled to Whitmore Lake, Michigan to attend our sold out Thermbond Autumn Workshop in October. A valuable technical education on refractories, installation, and applications were delivered by a very well prepared Thermbond team.
We received positive feedback from all who attended:
"I found this seminar/workshop very informative and an eye opener for a great technology that makes you so eager to try and use in so many applications."
"You have done a great job guys, looking forward to the next one!"
"This was the best Workshop I attended. Never lost interest, learned so much and feel I will retain what I learned and feel more confident about sharing what Thermbond can offer."
"Hospitality of Stellar was excellent; organization and flow of Workshop and Activities were great. Wonderful Accommodations."
The workshop was an excellent opportunity for all attendees to share knowledge and experiences. Plus, we all had great fun getting to know each other better during our evening activities in Ann Arbor.
Many guests were repeat attendees from a previous Thermbond Workshop, and most of those surveyed indicated they plan to attend a future Workshop. Stay tuned for advance registration information for our next Workshop!

Testimonial from an Engineering Specialist in the Petrochemical Industry:
"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... 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.... 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."

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Stellar Spotlight:
Peter Billi |
This month's spotlight shines on Stellar's Installation and Services Specialist, Peter Billi. Peter began his career with Stellar Materials in 2002. Prior to his employment at Stellar, Pete worked for Frontier Foundries for sixteen years, Weaver Materials for seven years, and ran his own company for four years.
As the Installation and Services Specialist, Peter is directly responsible for installation support, training installation personnel, and the maintenance of the gunning equipment Stellar provides to customers.
Peter reports to Vice President of Engineering, Jens Decker. "The performance of a furnace lining is determined by the composition of the material but also to a great extent by the installation of the refractory materials and the engineering of the furnace lining. In this regard Peter Billi has a very important role within our company. He supports our customers on-site to obtain the best installation results and long lasting furnace lining. He trains installation personnel with the right techniques and makes sure that Thermbond is installed according to our installation guidelines. Peter works out of our plant in Whitmore Lake. He has continuously developed and improved the gunning equipment used for installing Thermbond. As a result of his hard work, gunning Thermbond is a very reliable and efficient process. Peter is also a crucial part of our R&D team in Whitmore Lake and helps with installation tests to make sure that our materials are user-friendly. Peter is a dedicated and loyal employee who goes above and beyond. I am happy to have him on my team," says Jens.
Peter has been recognized publicly by customers for his “stellar” service during installations. After a recent installation at Petrobras (see testimonial below), the company contacted our VP of Sales to tell him how impressed they were with Peter.
Another Contractor who did not have experience gunning Thermbond requested Peter's technical support. This contractor was reluctant to gun-repair a furnace until Peter trained the contractor on the gunning equipment, and directed them how to properly clean the furnace before the start of the job. Now he is confident using Thermbond as a gunning material. After Peter left, the plant maintenance manager said that the job could not have been started, much less completed without Peter’s assistance. He stated that he intended to gun veneer both of the other two furnaces at the plant as required. The plant manager was very pleased to bring the unit back on line faster than the two-plus weeks they anticipated.
When Peter is not traveling to job sites providing his expert support, he enjoys fishing, golfing and hunting with his sons.

Testimonial from a Customer in the Petrochemical Industry:
"We have used Thermbond refractory quite extensively for a number of years mostly in our Sulfur Recovery Units within the furnaces. The Thermbond refractory provided the quick application, high temperature capabilities, chemical resistant properties, and quick curing capabilities that allowed us to have a quick turnaround time on our damaged furnaces."

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Petrobras Testimonial
Stellar Materials is recognized not only for their unique product line, but also for their excellent support! Below is the translated version of a recently published company bulletin from Petrobras, the largest oil company in Brasil. Installation Specialist, Peter Billi received special praise for his tremendous support, installation knowledge, and professionalism on the job. |
A preliminary assessment was conducted today for the refractory of the secondary reformer for the ammonia unit. The technical team, composed of specialists in the fabrication and utilization of the material, will determine the most efficient method in using the product, which is a pioneering intervention of this magnitude in all the Petrobras system.
A refractory material named "Thermbond" will be used for these purposes. Thermbond, imported from the United States, provides excellent adhering characteristics to the older refractories. This product provides a quicker drying process, which reduces the application period thus optimizing results.
The implementation of this new technology also allows for the reduction of production waste. The refractory is a mechanism used for temperature abatement, with the purpose of not damaging the shell of the equipment. "This will increase dependability of the operation of this equipment, since the current refractory is partially degraded, " states shutdown manager Wellington Medeiros, who is confident in the successful outcome of this intervention.
To see a copy of the original bulletin, please click here.
Testimonial from a Plant Manager in the Power Industry:
"There are 96 gas fired burner throats that we have repaired as well as new installation of burner throats using Thermbond Formula 6-AG for gunning an overlay and new throat linings. We have also used Thermbond Formula 15-R for overlay repairs, installed by hand-packing that have bonded to the existing refractory and has lasted over 18 months and is still in service."

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Stellar Materials do Brasil is Now Open for Business! |
Tom Atkins, Stellar's Vice President of Worldwide Sales noted “We have been looking to hire someone in Brazil for some time now. The Brazilian industrial market holds real promise and with our growing presence there, Stellar Materials needs an employee working directly for us to support our strategic partners and key end-users. With Alex and Bill working together, the potential for continued growth is significant.”
Contact Information:
Alexandre Leme, Sales Manager
Email: alexandre.leme@thermbond.com
Celular: 55-13-8115-8187
Stellar Materials do Brazil
Av. Sao Paulo, 1380- sala 07 Centro-
Mongagu- SP 11730-000
Fone/Fax: 55-13-3488-6516

Testimonial from a Customer in the Power Generation Industry, in Southern California:
"We like the fact that Thermbond does not need any outside heat source to attain good strengths. We would normally have to completely replace the top 2 to 3 feet of the ash hopper in each unit every other year. When we switched to Thermbond in most cases we only needed to flash over the top 2 to 3 feet. This has saved us a lot of time and money by not having to tear out and replace the refractory over and over again."

Application Report
Industry: Steel Industry
Description of Equipment: Blast Furnace Stove
Products Applied: Thermbond Formula 6-L, Formula 6-P, Formula 6-A
Problem: Bricks in burner chamber of blast furnace stove crushed due to improper expansion allowance. To repair with brick it was determined:
- Project estimated to take 45 days to complete, equating to around $20 million in production losses.
- Demolition of existing brick lining could cause further damage to the end wall lining and extend the shutdown even further.
- Using conventional castable refractory to repair damaged brick would not provide a permanent bond to the remaining brick lining.
Solution: Use Thermbond cast and patch grade materials to repair remaining brick lining. To support the proposed solution:
- Customer tests showed Thermbond bonds to existing refractory with an effective long lasting bond.
- Thermbond has the advantage to withstand very rapid heat-up and cooling down cycles typical in blast furnace stoves.
With restricted working space within the stove gas slot, making the repairs by casting would be more practical than re-bricking.
Savings Using Thermbond: Customer estimated their savings of $444,000 Australian dollars per day over a 45-day production period, an overall savings estimate of AUD$20 million. This calculation is the comparison to re-bricking the burner in the blast furnace stove.
Material Being Repaired: Andalusite brick
Method of Installation: Cast
Equipment Used: Pan mixer, electric vibrators
Installation Date:
December 2000
Scope of Work: January-August 2000: Customer identified a problem with their blast furnace stove in reaching and maintaining dome temperatures. A pyro-camera confirmed brick spalling and holes in the end-walls of burner allowing air to enter gas slot, causing pre-ignition.
Early October 2000: The customer thoroughly tested Thermbond in mock-up repairs and laboratory testing. In testing, the customer determined that Formula Six-L was very similar to the andalusite brick regarding chemical content, expansion, strengths, and thermal shock resistance. The customer performed bond strength tests, thermal cycling tests, hot strength testing, and installation mock-ups.
Late October 2000: The customer’s Refractory Services Group placed an order for 6.1 tons of Thermbond. The customer’s cost-benefit analysis determined a rapid repair was important enough to have the material shipped via airfreight.
Early December 2000: Thermbond was installed with the assistance of Refractech, a Thermbond strategic partner and a Thermbond Installation Specialist. The loose portions of the andalusite brick lining were removed, form boards were placed and Thermbond Formula 6-L was cast on to the damaged andalusite brick bringing the lining back to the original thickness and sealing the holes in the walls.
December 14th: Blast furnace stove went back on-line. The customer’s Refractory Services Group reported the Thermbond Formula 6-L installation went according to plan and the stove was operating at optimal rates.
Follow-up 2008:
Thermbond has been in service since December 2000 without any problems. The customer has since expanded their use of Thermbond in other areas of the plant with great success.
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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Copyright 2009 Stellar Materials Incorporated. All Rights Reserved.
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