Trouble viewing this page? click here.
In this Issue:
Aluminum Application in the West Coast
Thermbond Always Thinking Safety!
Stellar Spotlight: Shipping Supervisor, Jonathan Thomas
Stellar Trade Show Schedule
Application Report: Down Draft Calciner Cement Installation
Aluminum Application Success Story
Because of our many years of refractory experience in the aluminum industry, Stellar Materials was approached by a major aluminum wheel manufacturer who was frustrated with the service life of conventional refractories on their #1 melter. Spinel growth at the top of the belly band and upper walls had become a serious problem, forcing them to take the melter down for cleaning every six months. The cleaning process caused even more damage to the refractory lining. After only 18 months the conventional refractory needed to be replaced.
Thermbond was the solution. In December of 2007 the contractor installed several hundred units of Thermbond Formula 2104-L. This was cast in the belly band and lower walls. Several hundred units of Thermbond Formula 3-L was cast in the upper walls. With its quick setting and rapid start-up, Thermbond also saved them several days of down time.
The furnace operated 24/7 for the first year due to production schedules and lack of another furnace. Their maintenance plan called for taking the melter down every six months for inspection and repair as needed.
Upon inspection after the first 6 months, zero spinel growth was detected. After the furnace was drained and cleaned, it revealed minor wear of only 1 ½ inches on the belly band area. This area was gunned back to full thickness with Thermbond Formula 4-AG and the melter was quickly returned to service.
Since then the melter is taken down every 6 months for maintenance and inspection. To date, no spinel growth has been reported. The upper walls look brand new, still showing the wood grain from the form boards. The lower walls look excellent as well. They continue to maintain the belly band area gunning with Formula 4-AG as necessary.
The melter has been in constant use for nearly three years and the refractory is performing beyond their expectations. The customer expects to meet or exceed the projected five year campaign and beyond.
For additional information on this application, please contact our Industry Specialist, Brendan Gallagher at brendan.gallagher@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."
Thermbond Thinking Safety: Dura Sorb Wraps
|
|
|
|
DuraSorb Wraps, designed and created by EDI Solutions, L.L.C. |
Stellar Materials takes safety very seriously. "The safety of our employees and our customers is one of our top priorities. We are committed to providing our customers and employees with the tools and training to ensure their safety" says C.O.O. Neil Mintz.
We are now pleased to offer our customers the DuraSorb Wraps, a hydrophobic absorbent pad with outer tarpaulin backing for activator leak prevention. When using Chicago fittings during gunning applications, small leaks can occur at the couplings. The DuraSorb Wraps are a safe way to ensure the leaks are minimized and properly contained. Replacing all rubber washers in Chicago fittings prior to gunning also minimizes the risk of leaks. The DuraSorb wraps are now part of Stellar Materials’ rental gunning equipment.
Our Installation Specialists and Sales Team are trained on the proper use and installation of our products. Necessary precautions are taken in all situations to avoid any potential hazards. Installation support is always available and our Installation Guide can be found on our website. If you are not familiar with Thermbond, we ask that you please reference our Installation Guide before handling any of our products.
If you are interested in purchasing DuraSorb Wraps for use with your own gunning equipment, please contact your local Sales Representative or Peter Billi, our Installation and Service Specialist for additional information. Pete can be reached at peter.billi@thermbond.com.
Testimonial from an 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:
Shipping Supervisor,
Jonathan Thomas
|
This month’s spotlight shines on Stellar Materials’ Shipping Supervisor, Jonathan Thomas. Jonathan began his career with Stellar in 2002. He originally hired in as a Maintenance worker. Through his hard work and dedication he earned his promotion to Shipping Supervisor in 2006.
“As Shipping Supervisor, Jonathan is directly responsible for providing logistics for outbound orders, as well as receiving and recording inbound raw materials. In addition, he creates and maintains records vital to our quality control tracking process and performs the final quality checks on all outbound loads” says Plant Manager Jim Knicley.
Our Shipping Department is always available for after-hours emergencies. Many of our team members give up their weekends or stay well after business hours to ensure that our customers are satisfied.
“Stellar Materials is a wonderful company to work for” says Jonathan.
Outside of work Jonathan enjoys camping and dirt biking with his wife and four children.
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."
|
25 August 2010 |
Stellar Materials is exhibiting at ARIPPA 2010 in Hershey, PA this August.
Stop by our booth #8 to visit Vice President Jens Decker, Sales Director Brendan Gallagher and Sales Manager Dave Ernst.
Jens Decker is presenting a paper on New Developments in the Refractory Industry at 3:00 PM in Salon CDE. If you are interested in receiving a copy of this technical paper, please click here. |
|
Cat Cracker Seminar 24-25 August 2010 |
Stellar Materials is exhibiting at NPRA's Cat Cracker Seminar in Houston, TX this August.
Stop by our table to visit Business Director Ted Hagberg and Sales Manager, Jamie Cambetta . |
|
14-16 September 2010
Essen, Germany |
Stellar Materials is exhibiting at
Aluminium 2010 in Essen, Germany.
Stop by our booth 2B04 and visit with Executive Management and Sales Representatives from Stellar Materials. |
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.
Application Report
Cement Installation
Industry: Cement
Description of Equipment: Down Draft Calciner
Problem: Prior to a planned shutdown in May 2009 a hot spot was observed in the burner bonnet of the down draft calciner. A similar problem occurred in 2006 and it resulted in a complete demolition and reline of the bonnet section. After tearing out the damaged area, which exceeded 50% of the bonnet, the decision was made to remove the entire refractory lining down to the steel, perform steel repairs and reinstall the lining.
In addition to the repairs in the burner bonnet, it was also 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.
Solution: Due to the lack of temperature control 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.
|
|
|
|
|
Steel repairs prior to gunning. |
Finished sidewall. |
Finished lining. |
Product Being Replaced: Conventional water-based refractory.
Products Applied: Thermbond Formula 8-G and Thermbond Formula 6-AG
Method of Installation: Gunning
Equipment Used: Allentown rotary machine with horizontal mixer.
Scope of Work: Formula 8-G was gunned in as the insulating lining and Formula 6-AG was gunned in as the hot-face lining. Both products were pre-dampened in order to reduce rebound while gunning overhead and on an angle. Installation time was 6 hours for the Formula 8-G and 12 hours for the Formula 6-AG.
Installation Date: May 2009
For additional information regarding this application report, please contact Stellar's Sales Manager, Ken Hoyt at ken.hoyt@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 The Netherlands, UAE., Brazil, and Mexico. |
|
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 |
|
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 |
Subscribe to Thermbond Bulletins
Unsubscribe from Thermbond Bulletins
Contact Stellar Materials
Previous Bulletins
Access our web site
Thermbond and Phoscrete are registered trademarks of Stellar Materials Incorporated.
Copyright 2010 Stellar Materials Incorporated. All Rights Reserved