In this Issue:
- Application Report: Aluminum Scrap Melter Repair
- Thermbond Tip: Durasorb Wrap
- Come Visit Thermbond at EGC 2011!
- Happy New Year from Stellar Materials!
APPLICATION REPORT: Aluminum Scrap Melter Repair
Industry: Secondary Aluminum
Description of Equipment: 45 Ton Scrap Melting Furnaces
Problem: The plant runs the scrap melting furnaces very hard. They melt scrap in the furnaces and move molten metal via crucibles to another process furnace. Because of aggressive melting, fluxing, and cleaning practices, the scrap melting furnaces have to be repaired extensively on an annual basis.
Thermbond Formula 4-AG was installed in the past for sidewall repairs. Although it holds up well, the customer expressed an interest in trying another Thermbond product if it can provide even longer service life. The customer was not specific in how long they wanted to increase service life, but willing to try an alternative material and conduct a return on investment review once performance results are known.
Solution: A partner company suggested they try Thermbond Formula 2104-G, the gunning version of high strength casting product Thermbond Formula 2104-L, that provides superior service in high abrasion applications. After reviewing the technical data sheet and receiving feedback on the tremendous success of the casting product, the customer decided to gun Thermbond Formula 2104-G on the sidewalls.
An experienced and highly qualified contractor performed the gunning installation. The material thickness of the areas gunned varied from three to 16 inches.
Materials Installed: Thermbond Formula 2104-G – 11 pallets
Product Being Replaced: Conventional materials and Thermbond Formula 4-G
Savings Using Thermbond: To be determined on next inspection in summer 2011
Method of Installation: Gunning
Equipment Used: Thermbond pump and nozzle set, Allentown gunite machine with a 12 pocket feed wheel, paddle mixer for pre-dampening, and hand tools. Pre-damping ratio was one jug to three bags. The nozzle mixing chamber length was modified to 12 inches.
Installation Date: September 2010
Follow Up: The next inspection and outage for the furnaces is scheduled for early summer 2011. The furnaces will be inspected and evaluated to determine if Thermbond Formula 2104-G provided an acceptable return on investment.
To view this report in printable format, please click here.
For additional information regarding this application report, please contact Stellar's Aluminum Industry Specialist Jeff Pchola, at jeff.pchola@thermbond.com
Testimonial from a Customer in the Petrochemical Industry, on 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."
Thermbond Tip: Durasorb Wrap
When properly outfitted with bronze or stainless steel Chicago fittings and rubber washers at all connections, Activator hose leaks rarely occur.
As an added measure Stellar Materials highly recommends the use of Durasorb Wraps, a hydrophobic absorbent pad with outer tarpaulin backing, to minimize the safety and housekeeping issues in the event l leak occurs.
Durasorb Wraps are included in Stellar Materials’ rental gunning equipment sets.
If you are interested in purchasing Durasorb Wraps for use with your own gunning equipment, please contact your local Thermbond Sales Representative or Peter Billi, our Installation and Service Specialist for additional information. Pete can be reached at peter.billi@thermbond.com
Testimonial from a Customer in Hungary
"We are always looking for better solutions for our customers. In summer 2006 we decided to cast a one-piece aluminum tank with [Thermbond Formula] 5-L. After 8 months life-time now we have best result:
- no sticking of aluminum to the sidewalls
- less corundum
We hope that this method will become standard for all plants of our customer worldwide. Thanks for your support and help to use Thermbond as a better solution."
Come Visit Us at EGC 2011!
Stellar Materials will be co-exhibiting with PTS Power at the Energy Generation Conference in Bismarck, North Dakota. Come visit us at booth #821.
Stellar Materials Sales Director, Brendan Gallagher and Stellar Materials Sales Manager, Ken Hoyt will be on site. For additional information regarding this show, please contact Ken at ken.hoyt@thermbond.com.
Testimonial from a Petrochemical Customer on the U.S. Gulf Coast
"We plan to include Thermbond products on our approved refractory materials list for a long time to come."
Happy New Year from Stellar Materials!
As another year comes to a close, we find ourselves gratefully thinking of those who contribute to our success. To our good friends worldwide, thank you from the bottom of our hearts for your friendship, good will and loyalty.
We look forward to another successful year together!
May the New Year bring you much love, happiness and prosperity. Wishing you and yours a very Happy New Year!
HAPPY NEW YEAR!
The Stellar Materials Family
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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 The Netherlands, UAE., Brazil, and Mexico. |
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Stellar Materials Incorporated
7777 Glades Road, Suite 200
Boca Raton, Florida 33434 USA
(561) 330-9300 |
StellarMaterials 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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Stellar Materials International, LLC
Nieuw Mathenesserstraat 39 - 41 Unit 1 B
3029 AV Rotterdam
The Netherlands
+31 (10) 2460264 |
Stellar Materials International,
S. de R.L. de C. V.
Av. Batallon de San Patricio 109 Sur.
Piso 19 Col. Valle Oriente, San Pedro
Garza Garcia, N.L. C.P. 66260 Mexico
(52) 81 4780 2312 |
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