www.stellarcanada.com stellar canada inc. ceramite the wear resistant material coal fired power...

www.stellarcanada.comSTELLAR CANADA INC.

CeramiteCeramiteThe Wear Resistant MaterialThe Wear Resistant Material

Coal Fired Power GenerationCoal Fired Power Generation

ApplicationsApplications


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


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


*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.


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


Power Industry-PulverizerPower Industry-Pulverizer


PulverizerPulverizer

Previously used beaded epoxyPreviously used beaded epoxy

Customer repairs every six monthsCustomer repairs every six months

Ongoing projectOngoing project



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


Burner/ VortexerBurner/ Vortexer

CERAMITE T


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


Worn SiC Tile with Ceramite PatchWorn SiC Tile with Ceramite Patch


Welded Wire MeshWelded Wire Mesh


Installing OverheadInstalling Overhead


Finished InstallationFinished Installation


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


Off-Take Boiler DuctOff-Take Boiler Duct

“1x1” mesh

Ceramite T


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



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


Fan Housing RepairFan Housing Repair


Fan HousingFan Housing


Coal Classifier – 2 Years LaterCoal Classifier – 2 Years Later


Ceramite T LINED CYCLONECeramite T LINED CYCLONE


Baghouse DuctBaghouse Duct


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

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