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Transcript of Www.stellarcanada.com STELLAR CANADA INC. Ceramite The Wear Resistant Material Coal Fired Power...
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CeramiteCeramiteThe Wear Resistant MaterialThe Wear Resistant Material
Coal Fired Power GenerationCoal Fired Power Generation
ApplicationsApplications
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Elkem Fiskaa, today
Elkem Fiskaa, 1969
CeramiteCeramite®® is a technology developed by is a technology developed byElkem Materials during research and devlopment of Elkem MicrosilicaElkem Materials during research and devlopment of Elkem Microsilica®®
20 years of lab testing and coordinated industrial trials20 years of lab testing and coordinated industrial trials
Today: Significant applications in several industries; primarily aluminium, Today: Significant applications in several industries; primarily aluminium, cement and ferrous metalscement and ferrous metals
INTRODUCTION TO CERAMITEINTRODUCTION TO CERAMITE
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CeramiteCeramite®® MicrosiliciaMicrosilicia®® & Cement & Cement
The Key to High Strength Bond PhaseThe Key to High Strength Bond Phase
Microsilica - amorphous SiOMicrosilica - amorphous SiO22 fume, (D= fume, (D= 0.1 - 1 micron)0.1 - 1 micron)
Improves particle packing efficiency in Improves particle packing efficiency in castable - fills in voids between larger castable - fills in voids between larger aggregates.aggregates.
Less water needed for casting.Less water needed for casting.
Dense castables with low porosityDense castables with low porosity
Extreme Wear ResistanceExtreme Wear Resistance
Impervious to Gas and ChemicalsImpervious to Gas and Chemicals
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*A 7.1 cm cube sample is pressed with a 300 N force against a grinding wheel *A 7.1 cm cube sample is pressed with a 300 N force against a grinding wheel that is coated with a fine grade corundum sand. The sample is rotated 22 that is coated with a fine grade corundum sand. The sample is rotated 22 times (1 campaign) after which it is cleaned and weighed. The grinding times (1 campaign) after which it is cleaned and weighed. The grinding machine is cleaned after each campaign and new media is distributed on the machine is cleaned after each campaign and new media is distributed on the grinding wheel. The test requires 18 campaigns.grinding wheel. The test requires 18 campaigns.
The Bohme Test results are expressed as the volume of material lost from the The Bohme Test results are expressed as the volume of material lost from the specimen in cm3 from the surface area exposed to wear. specimen in cm3 from the surface area exposed to wear.
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Ceramite in Power ApplicationsCeramite in Power Applications
Pulverizer RepairPulverizer Repair
Coal Chute RepairCoal Chute Repair
Burner Vortex RepairBurner Vortex Repair
Off Take BoilerOff Take Boiler
Coal Chute LiningCoal Chute Lining
Fan Housing Fan Housing
CyclonesCyclones
Baghouse SystemsBaghouse Systems
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Power Industry-PulverizerPower Industry-Pulverizer
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Power Industry-PulverizerPower Industry-Pulverizer
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PulverizerPulverizer
Previously used beaded epoxyPreviously used beaded epoxy
Customer repairs every six monthsCustomer repairs every six months
Ongoing projectOngoing project
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Coal Chute RepairCoal Chute Repair
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Coal Chute RepairCoal Chute Repair
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Coal Chute RepairCoal Chute Repair
Customer previously repaired ceramic tile with Customer previously repaired ceramic tile with beaded epoxybeaded epoxy
Would need repairs every 6 monthsWould need repairs every 6 months
Ongoing project since 2006Ongoing project since 2006
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Burner/ VortexerBurner/ Vortexer
CERAMITE T
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The ProblemThe Problem
Customer uses Nitrite Bonded SiC tilesCustomer uses Nitrite Bonded SiC tiles
Tiles routinely crack and must be repaired every Tiles routinely crack and must be repaired every six monthssix months
Ceramite Trowelable has been used as repair Ceramite Trowelable has been used as repair material for past 18 monthsmaterial for past 18 months
Based on Ceramite performance, customer Based on Ceramite performance, customer decided to trial complete vortex burnerdecided to trial complete vortex burner
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Worn SiC Tile with Ceramite PatchWorn SiC Tile with Ceramite Patch
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Welded Wire MeshWelded Wire Mesh
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Installing OverheadInstalling Overhead
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Finished InstallationFinished Installation
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SummarySummary
Four hours required to weld in meshFour hours required to weld in mesh
Four hours to install CeramiteFour hours to install Ceramite
Installing SiC tiles requires 36 hoursInstalling SiC tiles requires 36 hours
Customer intends to perform more complete Customer intends to perform more complete installations during future outagesinstallations during future outages
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Off-Take Boiler DuctOff-Take Boiler Duct
“1x1” mesh
Ceramite T
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Ceramite T 18 bags – 4 men - 2 hrs to INSTALL! Expected Ceramite T 18 bags – 4 men - 2 hrs to INSTALL! Expected Service Life 6 months or moreService Life 6 months or more
Ceramite T
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Coal Chute LiningCoal Chute Lining
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Coal Chute LiningCoal Chute Lining
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Coal Chute LiningCoal Chute Lining
Customer previously used ceramic tileCustomer previously used ceramic tile
Tile would fail due to impact/crackingTile would fail due to impact/cracking
Ceramite in service since July 2006 Ceramite in service since July 2006
22,000 tons of coal per day22,000 tons of coal per day
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Fan Housing RepairFan Housing Repair
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Fan HousingFan Housing
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Coal Classifier – 2 Years LaterCoal Classifier – 2 Years Later
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Ceramite T LINED CYCLONECeramite T LINED CYCLONE
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Baghouse DuctBaghouse Duct
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Why Ceramite?Why Ceramite?
Monolithic LiningMonolithic Lining
Less Surface PreparationLess Surface Preparation
Easily Mixed and InstalledEasily Mixed and Installed
SafetySafety
Ceramite has out performed all other wear Ceramite has out performed all other wear materialsmaterials