Transcript Whetstone Technology, LLC

Ceramite
The Wear Resistant Material
Coal Fired Power Generation
Applications
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INTRODUCTION TO CERAMITE
Ceramite® is a technology developed by
Elkem Materials during research and devlopment of Elkem Microsilica®
20 years of lab testing and coordinated industrial trials
Today: Significant applications in several industries; primarily aluminium,
cement and ferrous metals
Elkem Fiskaa, today
Elkem Fiskaa, 1969
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Ceramite®
Microsilicia® & Cement
The Key to High Strength Bond Phase
Microsilica - amorphous SiO2 fume,
(D= 0.1 - 1 micron)
Improves particle packing efficiency in
castable - fills in voids between larger
aggregates.
Less water needed for casting.
Dense castables with low porosity
Extreme Wear Resistance
Impervious 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
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
machine is cleaned after each campaign and new media is distributed on the
grinding wheel. The test requires 18 campaigns.
The Bohme Test results are expressed as the volume of material lost from the
specimen in cm3 from the surface area exposed to wear.
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Ceramite in Power Applications
Pulverizer Repair
Coal Chute Repair
Burner Vortex Repair
Off Take Boiler
Coal Chute Lining
Fan Housing
Cyclones
Baghouse Systems
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Power Industry-Pulverizer
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Power Industry-Pulverizer
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Pulverizer
Previously used beaded epoxy
Customer repairs every six months
Ongoing project
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Coal Chute Repair
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Coal Chute Repair
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Coal Chute Repair
Customer previously repaired ceramic tile with
beaded epoxy
Would need repairs every 6 months
Ongoing project since 2006
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Burner/ Vortexer
CERAMITE T
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The Problem
Customer uses Nitrite Bonded SiC tiles
Tiles routinely crack and must be repaired every
six months
Ceramite Trowelable has been used as repair
material for past 18 months
Based on Ceramite performance, customer
decided to trial complete vortex burner
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Worn SiC Tile with Ceramite Patch
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Welded Wire Mesh
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Installing Overhead
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Finished Installation
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Summary
Four hours required to weld in mesh
Four hours to install Ceramite
Installing SiC tiles requires 36 hours
Customer intends to perform more complete
installations during future outages
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Off-Take Boiler Duct
Ceramite T
“1x1”
mesh
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Ceramite T 18 bags – 4 men - 2 hrs to INSTALL! Expected
Service Life 6 months or more
Ceramite T
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Coal Chute Lining
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Coal Chute Lining
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Coal Chute Lining
Customer previously used ceramic tile
Tile would fail due to impact/cracking
Ceramite in service since July 2006
22,000 tons of coal per day
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Fan Housing Repair
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Fan Housing
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Coal Classifier – 2 Years Later
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Ceramite T LINED CYCLONE
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Baghouse Duct
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Why Ceramite?
Monolithic Lining
Less Surface Preparation
Easily Mixed and Installed
Safety
Ceramite has out performed all other wear
materials
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