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Thermbond in Power

Application Reports
Boiler Repair in Australia	The refractory in B2 Penthouse around the tube penetrations was in poor condition and needed repair to minimize the ingress of fly ash and hence reduce the clean out time for the Penthouse in future outages.Used mullite based Thermbond Formula Castable to provide a solution to the current damaged conventional refractory that surrounded 137 tubes, 48mm in diameter.
Burner Throat Repair-Ramming	The maintenance manager and mechanical supervisor at the power plant needed to repair the refractory in burner throats to improve burner performance. The desire was to repair the existing refractory rather than take the time to tear out and replace it in its entirety. Conventional refractory could not be dried out effectively and there was concern about conventional refractory bonding to the existing refractory. Installed Thermbond Formula 15 R, which requires no curing or lengthy dry out. This formula eliminates the thermal dry out restrictions for the start up of the furnace.
Burner Throats-1300 MW Power Station- Rammed, Hand Packed	Clinker and ash buildup on the top sections of the burner quarls created an eyebrow, resulting in localized hot spots and inconsistent flame patterns. Conventional plastic refractory installed in the 68 burner quarls deterioriated to such an extent that they required full thickness replacement. Thermbond was chosen because it has little or no cure time and can withstand rapid and uncontrolled ramp-up to operating temperature without damage. Thermbond also resists thermal cycling and has proven to resist surface penetration of clinker, ash, and coke buildup.
Coal Fired Power Boiler- Gunned, Rammed, Cast	Minimize downtime during plant outage. Refractory cure-out and dry-out are the bottleneck. Gunned, rammmed, and cast appropriate Thermbond product in wet bottom ash hopper, wind box, and burner throats.
Distiller Unit- Hand Ramming	Refractory in ceiling of distiller unit was cracked and damaged after less than two years of normal operation. Replacement of conventional refractory involves extensive labor and time for removal of existing material, plus 3-5 days for dry-out prior to running. Chemically bond new refractory to existing conventional refractory using patented THERMBOND® Formula 15. Distiller unit was back on-line in 24 hours.
Power Plant Coal Boiler-Ramming	Repairs needed to be made with minimal down time. Used Thermbond products that require no curing or lengthy dry out, Formula 6-P and Formula 15-R.
Coal Fired Power Boiler - Gunned & Slobber Nozzled	New Low Nox burner technology being retrofitted into existing burners. Much of the old refractory needed to be replaced and OFA’s boxes needed to be installed. Conventional refractory could not be dried out effectively without a very costly forced air dry-out company and the addition of several more days on to an already tight schedule. Gunning and slobber nozzleing the Thermbond products provided an extremely fast and easy installation. Because Thermbond chemically bonds to existing refractory and requires no curing or lengthy dry out the plant was able to bring the boiler back up saving gas consumption and extra outage days.