THERMBOND: Experience The Best.

 

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In this Issue:

• New Product: Thermbond Formula 4-R
• Only 6 Weeks Until our Summer Workshop! Space is Filling Up Fast!
• Stellar Spotlight: Alan Kirsch, Assistant Controller
• Visit Us at NPRA next month!
• Application Report: Launder Casting

 

Stellar Materials Announces New Product, Thermbond Formula 4-R

Stellar Materials, manufacturers of Thermbond Refractories and Phoscrete Concretes is pleased to announce Thermbond Formula 4-R.

Brendan Gallagher, Stellar Materials Power Industry Specialist was the driver for this new material. His customer required a product similar in characteristics to Thermbond Formula 4-AG that could be applied by ramming. Brendan contacted Stellar's Vice President of Engineering, Jens Decker and the development process began.

The new high temperature product can be used at intermittent temperatures up to 3100°F (1700°C); however, the long term operating temperature should not exceed 2600°F (1425°C). Abrasion resistance is very good as well, testing at 7 cc loss.

Formula 4-R was created primarily for cyclone boiler applications in the Power Industry. We recommend the use of this product in high temperature ramming applications where good abrasion resistance and high strengths are required.

As with all Thermbond products extensive standard testing was performed. This product is currently available for purchase.

Questions or comments regarding this product, please contacts Stellar’ s Power Industry Specialist, Brendan Gallagher at brendan.gallagher@thermbond.com.  

For a printable version of the Technical Data Sheet, please click here.

Maintenance Manager in an Arizona Aluminum Foundry

"We have been using the Thermbond products for several years. Since we do most of the work in house we find the product easy to use because everything is pre-measured. We are very satisfied with the performance of the material and like the fact that it can be heated up quickly because down time is very expensive. Over all it is a great product when we need to get back up quickly."

Testimonial from a Thermbond Workshop Attendee:

“This was the best workshop I have ever attended. I never lost interest and I learned so much. I feel I will retain what I learned and I feel more confident about sharing what Thermbond can offer.”

 

Stellar Spotlight:   Alan Kirsch Assistant Controller

It is with both sadness and great expectations that we bid farewell to Alan Kirsch. Our Assistant Controller for nearly three years is moving to Chicago to attend Northwestern University’s accelerated law program.

Alan came to work for Stellar upon graduation from The University of Washington with a Bachelor’s degree in economics to experience a two year apprenticeship in a business environment.  He used his education, skills and strong drive to contribute significantly to our company’s growth and benefit. Alan designed and implemented our corporate travel program and contributed tremendously in the development of our newly implemented Human Resources benefits program.

His outstanding performance in the workplace is a reflection of the standards of excellence upheld by every employee of Stellar Materials. We are proud of the environment our organization provided Alan during his apprenticeship. We look forward to watching him pursue his potential and make good use of his “Stellar” experience.

     

Testimonial from a Maintenance Manager at a Gulf Coast Power Generation Facility:

"We have had a local contractor gunite 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."

 

Reliability and Maintenance Conference   San Antonio, Texas

Come and Visit Us at NPRA Reliability and Maintenance Conference! 25-28 May 2010 Stop by our booth 104 to visit Director Business Development, Ted Hagberg and Sales Manager Jamie Cambetta. We hope to see you there!

  

Testimonial from a Customer in the Petrochem Industry: 

"I have used Thermbond successfully in TLE's and different applications where conventional refractories were failing. Thermbond has performed as promised, and I will continue to use Thermbond in the future."

Application Report 

 Launder Casting at Galvanizing Factory

Industry: Steel Strip Continuous Galvanizing

Description of Equipment: 2.7m (8.8’) and 1.7m (5.6’) long sections of the launder. The launder connects the induction melting pot and the induction holding pot.

Problem: Conventional refractory launder was cracked, worn and penetrated by molten metal (55% Al, 43.4% Zn and 1.6% Si). The slag build-up caused clogging and molten metal overflow.  As a result, the equipment was damaged and production was stopped. Staff was also concerned about safety.

Solution:  The customer tried two units of Thermbond Formula 2104-L to repair a small part of the launder. They were very pleased with all the characteristics of Thermbond, especially wear-resistance, thermal shock resistance, and non-wetting features. The customer subsequently specified Thermbond to rebuild two sections of the launder.

Conventional Castable Launder	Form Setting
Insulation Back-up	Launder casting with Thermbond Formula 2104-L
Thermocouple Sensor Setting	Temperature monitored dry-out

Product Being Replaced: Conventional low cement castable refractory

Savings Using Thermbond: High wearing and thermal shock resistance delivers longer service life. The non wetting feature allows for easy cleaning and prevents overflowing. Two years service life is expected, compared to 6-12 months for conventional refractory.

 Products Applied: 26 units of Thermbond Formula 2104-L

 Method of Installation: Cast

Equipment Used: Paddle Mixer, 35mm air pencil vibrator, two form vibrators and assorted hand tools.

Scope of Work: Remove all damaged conventional refractory and insulation materials. Install new insulation materials. Set two K-Type temperature sensors on the insulation materials to monitor the side wall and the bottom temperature of the insulation back up for Formula 2104-L. Place steel forms (wrapped with card paper).

Because the ambient temperature was 32°C (90°F), the Thermbond Liquid Activator was iced to extend the working time. Each batch mixed four units of Formula 2104-L for 30-45 seconds. Formula 2104-L was then vibrated into place.

One hour later, the Formula 2104-L was fully set and the form was removed. The surface was in good condition, with only a few small air pockets.

The following day, two K-Type temperature sensors were set on the surface of Formula 2104-L to monitor the side wall and the bottom temperature.

After the burner was set, a heating rate of 50°C (122°F) per hour was used to fire in the 65mm (2.5”) thick launder lining. A five-hour hold was taken to ensure full heat saturation and then the temperature was raised to 650°C (1200°F), the daily operating temperature of the launder. Both ends of the launder were open during drying out to proper ventilation and positive airflow.

Installation Date: November 2009

Follow Up: Customer is satisfied with the results. The installation continues to be monitored. The customer has 21m (69’) long launder sections on three additional production lines, and is considering re-casting them all with Formula 2104-L.

We thank our Strategic Partner, U-Zone, for this excellent application report and their willingness to share it with others. If you have an application you would like shared please forward it to ashley.garcia@thermbond.com.

For additional information regarding this application report, please email info@thermbond.com

To view this application report in a printable format, please click here.

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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