Industry: Petrochemical
Description of Equipment: Rotary Kiln Coke Calciner
Problem: Refractory life not meeting customer's expectations. Customer wanted to extend refractory service life to up to two years. Conventional refractory was failing shortly after one year in service requiring unscheduled shutdowns for refractory repair until major outages could be scheduled.
Solution: Stellar recommended Thermbond Formula 6-L for its durability, its ability to withstand coke penetration and its ability to withstand extreme thermal shock.
Product Being Replaced: Conventional water-based quick-fire castable
Savings Using Thermbond: Extended refractory life to nearly three years and increased production by eliminating unscheduled outages for refractory repair.
Products Applied: Thermbond Formula 6-L
Method of Installation: Slip-Casting
Equipment Used: Refractory paddle mixer
Scope of Work: Contractor removed existing refractory. Thermbond was cast in a checkerboard fashion. Panel sizes were 1 square yard. One section of the kiln was cast in this configuration and then the kiln was rotated to cast the next section. Because of Thermbond's rapid setting characteristics the subsequent pours were finished in half the time of conventional materials.
Installation Date: October 2004
Follow Up: In October 2005 the installation was inspected. Thermbond was in very good condition with only minor cracking, a result of mechanical issues with the rotary kiln. No refractory repairs were required. In February 2007 the kiln was again inspected and no repairs were required; 29 months of service!