APPLICATION REPORT
Coal Fired Power Boiler - Gunned and Slobber-nozzled
Industry: Power Generation-Illinois
Description of Equipment: Coal fired burners and OFA or Overhead Fired Air Ports
Problem: New Low Nox burner technology being retrofitted into existing burners. Much of the old refractory needed to be replaced and OFA ports needed to be installed. Overhead Fired Air Ports recirculate hot air and help reduce NOx in new burner technology. Conventional refractory could not be dried out effectively in the burners or OFA without a very costly forced air dry-out company and the addition of several more days on to an already tight schedule.
Solutions Using Thermbond: Time/Cost Savings- 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.
Time Savings- Our unique binder system allows for much faster start up rates than any alternative refractory without affecting material properties and long-term performance. Thermbond will not be adversely affected by an uncontrolled start up.
Performance- The integrity of the burner flame is critical in maintaining Low Nox burner performance. Thermbond's binder system is naturally non-wetting and minimizes the buildup of slags and coking which is an important aspect of long-term efficiency and burner performance.
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Burner wall with most of the old refractory
removed. |
Gunned material around burner throat with
top hat form in place. |
Finished burner throat. |
Products Being Replaced: Conventional Refractory
Products Applied: Formula 6-AG and Formula 9-L
Method of Installation: Gunning and Slobber nozzle
Equipment Used: Reed LOVA machine,, Horizontal mixer, Stellar gunning nozzle, 2- 375 air compressors
Scope of Work: Most of the existing old refractory needed to be removed for this retrofit. Thermbond Formula 6-AG was gunned in and around the burner throats and Formula 9-L was slobber nozzled into the OFA boxes. All the work was completed on time and the boiler was back in operation without any problems. The customer was very pleased with the material selection, installation, and time/money savings on start-up..
Installation Date: 11-04-2008
Follow-up: The customer confirmed in a September 2009 phone conversation that the burners were performing well with little or no slag/coke, or “eyebrow” build-up observed.
For additional information regarding this application report, please contact Stellar’s Director, Power Industry, Brendan Gallagher Direct: (520) 906-2407, Email: brendan.gallagher@thermbond.com
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