Power Generation and Boilers: Thermbond in Power http://www.thermbond.com/power/Wiki/Forms/AllPages.aspx RSS feed for the Thermbond in Power list. Thu, 09 Sep 2010 06:22:31 GMT Windows SharePoint Services V3 RSS Generator 60 Power Generation and Boilers: Thermbond in Power /power/_layouts/images/homepage.gif http://www.thermbond.com/power/Wiki/Forms/AllPages.aspx Coal Fired Power Boiler - Gunned Slobber Nozzled http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=37 Wiki Content:
 

Thermbond Refractories

 

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.
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

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

]]> Ashley Garcia Thu, 03 Dec 2009 20:45:39 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=37 Power Plant Coal Boiler-Ramming http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=32 Wiki Content:
 
 

Thermbond Refractories

 

APPLICATION REPORT

Power Plant Coal Boiler

Industry: Power Generation
 
Description of Equipment: Peep doors, thermocouple ports, and water cannon ports
 
Problem: Repairs needed to be made with minimal downtime
 
Solution:  Use Thermbond products that require no curing or lengthy dryout

Power Generation Coal Boiler - Water
Cannon port repaired with Formula 6P 
Repair over old refractory in either peep
sites or thermocouple openings
Repairing area over 4" thick with
Formula 15 R
Trowling Formula 6P inside a Power Coal
Boiler around a water cannon port
Product Being Replaced: Conventional Ram Refractory

Products Applied: Formula 6 P and Formula 15 R

Method of Installation: Equipment Used: Pnemautic ramming hammer and 3/4 hp drill with mixing blade.

Scope of Work: Mixed Formula 15R with hand mixer. Rammed material into place over existing refractory. Installer was pleased with the consistency. Initially Formula 6P was mixed  into a thin trowelling consistency.The trowelling cosistency worked well for thin overlays.  Additional batches were mixed so the Formula 6P could be made into a ball (like for ramming). The material was spread out on plywood to slow down the setting time. Unused material was moved and stored in an area where the temperature was 65F, as opposed to keeping the material in the boiler where temperatures were  95-100F, as they had done prior. This extended the working time for Formula 6P pleased the installers.

Installation Date: October 2007
To view this application report in a printable format, please click here
 
]]> Ashley Garcia Wed, 05 Aug 2009 15:10:29 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=32 Distiller Unit- Hand Ramming http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=33 Wiki Content:
 
 

Thermbond Refractories

 

APPLICATION REPORT

Distiller Unit

Industry: Power

 

Application: Distiller Unit

 

Product Applied: Thermbond Formula-15

 

Method of installation: Hand Ramming

 

Equipment Used: Hobart Mixer, Wood Ceiling Form, Hand Sprayer, Pneumatic Hand Rammer

 

Problem:  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.

 

Solution:  Chemically bond new refractory to existing conventional refractory using patented THERMBOND Formula-15. Distiller unit was back on-line in 24 hours.

 

 

Product replaced: 70 LCC

 

Scope of Work: Chip and remove any loose refractory. Build wood ceiling form approx 1/16 of the total surface area. Wedge form in place. Treat form with liquid activator. Mix 1/2 unit of Formula 15 at a time in Hobart. Hand pack material into cavity. Pneumatically ram material to required density. Material set in 15 minutes at ambient temperature. Release wood form, retreat with liquid activator, wedge in next position. Repeat process until entire ceiling is patched

 

Follow Up:  August 2005: Repair was originally intented to be a temporary fix, customer intended to replace burner and ceiling refractory within 3 months. In follow up call with customer, 11 months after application, the patch held up so well that they never ended up replacing the ceiling (only the burner), and distiller unit continues to operate well to this day.

 

 

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

]]> Ashley Garcia Wed, 05 Aug 2009 15:30:16 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=33 Coal Fired Power Boiler- Gunned, Rammed, Cast http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=31 Wiki Content:
 
 

Thermbond Refractories

 

APPLICATION REPORT

Industry: Minerals Processing Industry- Plant Power Boiler
 
Description of Equipment: Coal Fired Power Boiler- Western US

Problem: Minimize downtime during plant outage. Refractory cure-out and dry-out are the bottleneck 

Solution: Gun, ram, and cast appropriate Thermbond product in wet bottom ash hopper, wind box, and burner throats.

 

One wall of wet bottom ash hopper
gunned with Formula 6 AG

Wind box to be cast with Formula 8B

an insulating Thermbond product

Placing Formula 15R by hand before

Ramming into place with bench rammer
Burner throats near completion
 
Product Being Replaced: Conventional castable refractories
 
Savings Using Thermbond: Approximately 3 days of downtime eliminated and over $60,000 in gas costs for longer, more controlled, firing in required for conventional refractories. 
 
Products Applied: Formula 6AG was gunned 9 inches thick in the entire bottom ash hopper. Formula 8B was installed in the burner wind boxes, and Formula 15R was rammed into the burner throats.

 
Method of Installation: Gunning, ramming, and casting.

Scope of Work: The minerals processing customer who owns the power plant previously used Thermbond for time saving and performance benefits on a much smaller scale and specified it for this outage.  Nearly 30 pallets of Thermbond were installed during this outage.  A large, well known, refractory contractor from California performed the tear-out, anchor placement, and refractory installation.  Their knowledge of Thermbond products was instrumental in meeting the deadline set by the customer.  The ash hopper was completely relined with 9” of Formula 6AG. Rebound rates averaged between 10-15% depending on the crew and location in the ash hopper being gunned.  Formula 8B, an insulating castable, was chosen to line the wind boxes attached to the burners.  The wind box mixes preheated air before it is fed into the burners. Finally Formula 15R was rammed into 8- 4’ diameter burner throats.

 

The work was completed on time and the customer put the boiler back into operation without any problems.  It was a very successful Thermbond installation and the customer intends to use Thermbond on future outages.


Installation Date: July 2008
 
If you would like additional information regarding this application report, please contact Brendan Gallagher @:  Mobile: (520)906-2407, Email: brendan.gallagher@thermbond.com
 
To view this application report in a pritable format, please click here
 
]]> Ashley Garcia Wed, 05 Aug 2009 15:07:34 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=31 Burner Throats-1300 MW Power Station- Rammed, Hand Packed http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=30 Wiki Content:
 
 
 

Thermbond Refractories

 

APPLICATION REPORT

Burner Throats- 1300 MW Power Station

Industry: Power Generation
 
Description of Equipment: 650 MW Coal Fired Generating Unit
 
Problem: 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 deteriorated to such an extent that they required full thickness replacement.
 
Solution:  Find a refractory product that provides longer service life and minimizes downtime for installation and heat-up. 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.
 
Burner throat ready for Thermbond
installation
Side view of Burner Throat prepared and
ready for installation
Partial installation of burner throat
Completed burner throat installation
 
Product Being Replaced: Conventional Plastic Refractory
 
Products Applied: Thermbond Formula 15-R
 
Method of Installation: Hand-packing and ramming
 
Equipment Used: Pneumatic ramming hammers, 250 lb paddle mixer
 
Scope of Work:  Thermbond was rammed and hand-packed to replace the plastic refractory in the burner throat areas. No form-work was required. Thermbond chemically etches to the metal surfaces, creating a chemical bond. All 68 burner throats were installed at full thickness.
 
Installation Date:  April 2007
 
Follow Up: In April 2008, upon inspection a light coating of ash was found on the refractory, but this is not a criteria for replacement. In this difficult environment, conventional products sometime only last for a few weeks before the product falls off. The most critical area for refractory is in the burner throat, because it affects the efficiency of the flame. All of the Thermbond that was rammed in the throat looked excellent in the burners and had not fallen out, and that is extremely important.
 
To view this application report in a printable format, please click here
 
]]> Ashley Garcia Wed, 05 Aug 2009 15:02:11 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=30 Burner Throat Repair-Ramming http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=29 Wiki Content:
 
 
 
Thermbond Refractories
 
APPLICATION REPORT
 
 

Industry: Coal Fired Power Plant

 

Description of Equipment: Coal fired power plant burner face

Problem: The maintenance manager and mechanical supervisor at the power plant needed to repair the refractory in burner throats to improve burner performance. Their 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.

 

Solution:  Install 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. 

 

Product Being Replaced: Conventional 85% alumina plastic refractory

 

Benefit Using Thermbond: Thermbond ramming materials bond to existing refractories and require little or no dry-out. These two features address the customer’s initial concerns plus, because dry-out is minimized, down time is also reduced.

 

The maintenance manager and mechanical supervisor were so impressed with the ease of installation for Thermbond, they expanded the scope of work. The additional scope of work was done within the original shutdown schedule.

 

Products Applied: Thermbond Formula 15-R, a 60% alumina ramming material.

 

Scope of Work: Thermbond Formula 15-R was mixed in a Holbart mixer and then rammed around the outside of 42 burner throats, feathered out to five inches thick.

Equipment Used: A 30-quart Hobart mixer and Ingersol-Rand pneumatic bench rammers

 

Installation Date: February 2009

 

Follow Up: Inspection scheduled during outage in November

 
For additional information regarding this application report, please contact Stellar's Sales Manager, Jamie Cambetta: Direct: (561) 558-5815, Email: jamie.cambetta@thermbond.com
 
To view this application report in a printable format, please click here.
 
 
]]> Ashley Garcia Wed, 05 Aug 2009 14:56:42 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=29 Boiler Repair in Australia http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=28 Wiki Content:
 
 

Thermbond Refractories

 

APPLICATION REPORT

Boiler Repair in Australia

 

Industry: Power

 

Company: Major Power Station

 

Application: Unit 2 Boiler, Penthouse Refractory Repair

 

Product Applied: Thermbond Formula Castable

 

Method of installation: Vibration

 

Equipment Used: Paddle mixer, vibrator, concrete finishing tools

 

Problem: The refractory in the 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.

 

Solution: Used mullite based Thermbond Formula Castable to provide a solution to the current damaged conventional refractory that surrounded 137 tubes, 48mm in diameter. Contractor applied Thermbond to areas of existing damaged conventional refractory, creating a permanent repair that rapidly cured and dried within hours so unit could go back into service.

 

Product replaced: Conventional refractory

 

Safety Advantage: The permanent Thermbond repair to existing fired refractory will reduce the potential for burns to cleaning operators. The dust can flow through cracked conventional refractory and burn personnel as the plant has experienced in the past.

 

Scope of Work: An industrial vacuum cleaned out fly ash and any loose existing refractory material. A 2mm thermal insulating paper was glued around the steel tube penetrations to allow for some expansion and contraction during temperature fluctuations. The repair averaged 60mm in depth and some exposed anchors were evident. Whenever possible insulation blanket was laid down and the Thermbond refractory cast and vibrated into place.

 

Plant Engineer’s comment after the installation: “The Thermbond repair work is complete, the refractory went in quite well and there were no problems at all. All the damaged refractory was removed down to the super wool layer. The super wool was replaced and ceramic paper was wrapped around the tubes. The contractor was very professional in their work. If the product performs well in these conditions, I will look at doing the rest of the penetration repairs with Thermbond.”

 

Special thanks to John Pulbrook, Sales Manager, Refractech Pty. Ltd. for this application report. John and Refractech have been a successful Stellar Materials International Strategic Partner for over ten years.

 

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

 

]]> Ashley Garcia Wed, 05 Aug 2009 14:41:35 GMT http://www.thermbond.com/power/Wiki/Forms/DispForm.aspx?ID=28