Think Thermbond. Experience the Difference.

 

In this Issue:

• Application Report: Reducing Dry-out time on Power Plant Burner Installation
• Stellar Materials' Record Sales Year!
• New Director of Technical Services, Jeff Pchola
• *Clarification: Thermbond Tip: Durasorb Wrap (Vol. 3, Issue 12)

APPLICATION REPORT

Reducing Dry-out time on Power Plant Burner Installation 

 

Industry: Power industry

 

Description of Equipment: Coal fired burners, OFA, and auxiliary equipment

 

Problem: The burner manufacturer and power plant were in the process of retrofitting and repairing existing burners.  A long dry-out schedule is typical with this type of project.  In this case the customer could not afford the additional down time required for the long dry out. They needed to get back up and running as soon as possible.

Solution: Use Thermbond gunning and castable materials to eliminate the long and expensive dry-out schedule.  Thermbond provides fast and easy gunning and casting in the required equipment. 

 

Product Being Replaced:  Conventional, water-based refractories

 

Savings Using Thermbond: The unit was powered up on schedule with Thermbond offering the desired time and cost savings for both gas consumption and days of outage.

Products Applied: Thermbond Formula 6-AG and Thermbond Formula 9-L

 

Method of Installation: Gunning and slobber nozzle

 

Equipment Used: Reed LOVA machine, horizontal mixer, Stellar gunning nozzle

 

Scope of Work:  All existing refractory was removed from the burners and related equipment.  Any necessary steel repairs were made to the exposed surfaces in preparation for Thermbond refractory installation.  The burner throats and burner windows were gunned using Thermbond Formula 6-AG.  The Over Fire Air Boxes (OFA) were “slobber nozzled” using Thermbond formula 9-L. Slobber nozzling is a method used for placing Thermbond in applications other than vertical and overhead via a special gunning nozzle with lower air pressure and a slightly modified wet:dry ratio. All installation work was completed on time.

Installation Date:  October 2010

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

For additional information regarding this application report, please contact Stellar's Power Generation Industry Specialist Brendan Gallagher, at brendan.gallagher.com

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.

Stellar Materials’ Record Sales Year

2010 was a record breaking year for Stellar Materials, with total sales surpassing any previous year in company history!  This data validates Thermbond Refractories’ worldwide acceptance as a valuable refractory product.

The use of Thermbond continues to grow in our cornerstone industries: petrochemical, aluminum, and power. The benefit of time savings, proven performance, and fast repairs to damaged refractory all contribute to Thermbond’s success across all industries. Customers recognize Thermbond’s superior service not only for repairs but also for extensive refractory projects.

Thermbond is gaining recognition in specific applications for other industries too, including cement and steel. Our advanced technology offers many benefits but time savings is Thermbond’s leading selling point for first time users. Thermbond can deliver valuable refractory solutions from reheat furnace repairs to burner pipes.

Phoscrete, our concrete repair material, used in industrial flooring applications for over 20 years worldwide, is now gaining acceptance in departments of transportation, military applications, and other public works projects.

Stellar Materials continued success would not be possible without our dedicated employees, strategic partners, and our growing list of satisfied customers. Our employees and strategic partners are knowledgeable about Thermbond’s extensive product formulations and recognize their responsibility in meeting our customers’ expectations. Our customers appreciate Thermbond’s exceptional performance and work closely with us to ensure its use in applications that derive maximum benefit. It is a winning combination.

In summarizing the record results of 2010, Stellar Materials President, David Mintz, stated:

“It’s quite an achievement for us to have booked a record sales year considering the current world economy.  But the bigger picture is even more gratifying:  Over the past twenty years, we changed the way a large portion of the world looks at refractory solutions.  Utilizing our technology, customers everywhere are able to reduce downtime, increase uptime, and improve their bottom line to a degree previously unachievable.  I credit not only our products but equally our dedicated and creative staff and our unique approach to sales and customer service. I’m proud of the fine work we do at Stellar Materials.“

Testimonial from a Customer in the Aluminum industry in Norway:

 

"We have successfully used Thermbond products for different applications for the last 7 years. Thermbond has been used in aluminium smelters as well as in different parts in ammonia plants worldwide. The reason for choosing Thermbond is normally the benefits of fast heat up after installation."

 

New Director of Technical Service, Jeff Pchola

 

Director of Technical Services, Jeff Pchola

 

Effectively immediately, Jeff Pchola is Stellar Materials’ new Director of Technical Services, reporting directly to Vice President of Engineering, Jens Decker. This change allows Stellar to continue to expand our engineering department to support and empower our growth, and further strengthen our position as a market technology leader.

 

Jeff’s educational background in mathematics, physics and project management, along with his prior professional experience in the chemical and molten metal industries combine with his three years of experience with Stellar Materials to make him an ideal fit for this position.

 

Jeff will be moving with his wife, Dianne to the Ann Arbor area over the next few months, and will be working closely with Jens at the plant in Whitmore Lake.

 

Jeff will continue in his role of Aluminum Industry Specialist.  While his primary focus will be on aluminum industry issues, he will also be working on product development and managing the installation services of Stellar Materials across all industries

 

Testimonial from a Production Manager in the Aluminum Industry: 

"On the service side of things, they have proven themselves to be extremely reliable. With their Thermbond products the time necessary for curing the installation is minimal and this allows for quick turnaround of the furnace."

 

*Clarification to Thermbond Tip: Durasorb Wrap (published in Vol. 3, Issue 12)

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 recommends the use of Durasorb Wraps, a hydrophobic absorbent pad with outer tarpaulin backing to minimize the safety and housekeeping issues in the event a 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. Peter can be reached at peter.billi@thermbond.com

 

 

 

 

 

 

 

 

 

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