2010 abrasion applications for industry - processaids ceramics company presentation.pdf · 2010...
TRANSCRIPT
Proprietary and Confidential
2010
Abrasion Applications for Industry
580 Broadway, Albany, NY 1-800-550-5768 - Innovative Customized Solutions For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Who is Blasch?
Founded in 197965,000 sq ft. bldg in Albany, N.Y.ESOP = Employee ownedISO 9001 CertPatented Process – Freeze CastingMixes = 110 Prod. & 85 Dev.75 combined years Ceramic design experience (we are all engineers)AutoCAD, Solidworks, Cosmos & Flowworks (FEA/CFD)Engineer our own molds and equipmentExtensive in-house testingCustom Refractory Shape Makers Problem Solvers
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Type of ceramic - Refractory
ShapesAbrasion ResistantThermal Shock ResistantCorrosion ResistantCan be heat conductive, but not electricallyGood strengthCan be insulating depending on materialLower overall cost
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Available Materials
Oxide and Non-OxideMulliteFused SilicaHigh AluminaOxide Bonded SiC - OxytronNitride Bonded SiC - NitronOxyNitride Bonded SiC – OxyNitronAlumina Bonded SiC - AltronReaction Bonded SiC - Invincer
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
CapabilitiesComplex, Net Shape
No MachiningLinear tol. +/- .005” (.5%) Very Repeatable
Not limited by process1 oz to 2 ton.06” to 6” thick wall1 part to 1,000Matchstick to Sewer pipeOnly limited by equip
Unique shape capabilitiesThreads – Int/ExtBends/ElbowsConstant wallsTransitional wallsMating surfaces
Mortared assemblies For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Capabilities
Thermal Shock ResistanceEngineered Particle PackingUnique Binder SystemContinuous Interconnected Porosity
Fine Pore Size3-5 MicronMechanical Abrasion ResistancePenetration resistance to molten metalsNon-wetting additives availableEngineered Porosity/Permeability
Extremely High Green Strength
Micropore Distributionof Fired Alumina Refractories
0
1
2
3
4
5
6
7
8
9
10
0 25 50 75 100 125 150
Pore Diameter (µm)
Volu
me
Frac
tion
(%)
Blasch Pressed Rammed
APBlasch = 20.1% APPressed = 22.8% APRammed = 21.0%
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
In House Testing
Thermal ShockAbrasion C-704Acid TestingCreep Resistance Cup Brick Corrosion StrengthFlame resistance
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Industries we serve
PowergenPulp & PaperFuel CellGasifiersCoal fired
Petrochem & ChemicalIndustrial Process HeatingNonferrous
AluminumRed MetalsGalvalume/Zinc
FerrousSpecialty SteelSteelPowderIron
OtherElectronicsSemi-Con
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Common Abrasion Applications
Dust Collectors/CyclonesAir Heater InsertsBubble caps/Tuyeres/ArrowheadsWear CoatingsTiles, Linings & BricksFerrule systemsBurners & Mixer TubesNozzles and T/C tubesPipe linings and elbowsCorner Fired Burner ApplicationsTiO2 ApplicationsMining ApplicationsCase studies
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Power Plants (where we are)
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Multicyclone Dust Collectors
Barron/Process/Wheelabrator Zurn/ASH/Western Precipitator/American Standard – 6”, 9” 12” 24”Exact replacementWeighs 1/3rd that of steelGoing on 10 years with no wearOutlets/Inlets/Spin VanesCheaper than NiHardCan deliver faster than cast ironSmoother than cast iron = more efficientCan be used at temps above 1,200FCan be cast more precise than steel
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Multicyclone Dust Collectors
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Air Heater/Ash Cooler Inserts
Tooled for all nominal boiler tube sizesUp to 3 foot lengthsCan cast 1/16” wallWalk-on featureReplaceable or permanentSiC or AluminaCheaper than replacing boiler tubesCan seal up leaksProtects welds and tubesheet
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Bubble Caps/Tuyeres/Arrowheads
Ceramic replacementWeld or threaded in designsDesigns to reduce pluggingStrong enough to walk on
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Wear Coating – BlaschguardTM
1 part system – no mixingCures in 8 hoursSprayableGood to 600F tempsStays “rubbery”Designed for impactApplications:
Baghouse wallsExhaust DuctworkChutesPulverizersAir PreheatersDust CollectorsTubesheets
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Tiles, Linings, Bricks, Misc.
Waterwall tiles – U-shaped, Pour Behind, Bolt on and Epoxied on configurations.Mating tongue & groove, shiplap or male/female joint designs availableInterlocking bricksNo limit to sizeGeometric tolerances held very tight to ensure onsite fit upEngineered Shapes to replace tiles or bricksReduction in the number of part numbers
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Ferrule Systems
WHB - Firetube, Condensers, Heat ExchangersRound Head Ferrules
Traditional designSolid headsVarious flange designs and locationsOld technologyRequires refractory to hold in place
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Ferrule Systems
One Piece HexEliminates the need for monolithic refractory tube sheet face.Many useful features possible due to the Blasch precision casting process.Allows for quick inspections and maintenance.Installs in 1/4th the time over conventional round installationsQuicker refractory cure-outNo anchors required = no hot spotsEngineered pre-cracked system – will allow for temp. swingsMore thermal insulation can be usedEngineered for the boiler based on operating conditions
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Burner & Mixer Tubes
Oxidation and Reducing resistant materials availablePrecise mounting flangesRepeatable exit bore geometriesThermal shock resistantLow mass thin walls
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Nozzles and T/C Protection Tubes
NozzlesInternal/External threads available.No shape limitationsCorrosion/Abrasion resistance over high alloy steels.Cheaper than exotic steelsSpecialize in FGD Nozzles
T/C Protection tubes (T-wells)
Good to 3,000FWon’t oxidizeThermal shock resistant.
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Pipe Linings and Elbows
Flanged pipe liningsShip lapped endsLong radius elbowsPipe LiningsAbrasion/Corrosion resistant1/16” – 4” wall available½” to 4ft ID’s availableSeamless designs availableSmooth bores to prevent wear from startingEase of assembly
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Corner Fired Burner Applications
Splitter PlatesCoal Nozzle Tips
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Corner Fired Burner Applications
Coal Nozzle LiningsAnti-Roping
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Corner Fired Burner Applications
Ash Control ValvesMultiport OutletsMill Discharge ValvesPulverizer, Exhauster & Crusher partsCoal Transfer liningsMisc – Trona Injection
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
TiO2 Applications
MicronizersHot Tickle PipingValves (Jamesbury & Batley)
Flow StraightenersNozzles, Venturi, Inlets, SprayersDistributor PlatesChlorinator Sleeves
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Mining Applications
Suction Pump LinersCones, Apexes & SpigotsValvesChutesCyclones
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Ceramic Butterfly Valve – case study
Coal fired CFB Powerplant in PA sent us ten 12” Brass Butterfly assemblies. Blasch reverse engineered, designed and built 10 all-ceramic replacement inserts and shipped within 2 months. The brass ones would last only 6 months in an ash laden piping system. The Blasch Ceramic versions were inspected after 2 year of use and show little signs of wear.
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Tongue & Groove Lining – case study
Mating T & G jointsAllows for expansion and contractingEngineered pre-cracked system – reduces spallingRequires no mortarReduces # of parts
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
HexWall Checkerwall – case study
Standard Brick Checkerwalls take several days to install, but fall down constantly due to the mortar crumbling and the bricks shifting/sagging. Blasch designed and patented an interlocking hex shape with T&G joints. Requires no mortar, can grow and contract, is self supporting, installs in 1/4th
the time, can be taken down for repairs and cost 2/3rd that of high alumina brick.
For more information please contact [email protected] or visit ww.processaids.in
Proprietary and Confidential
Abrasion Applications for Industry
2009
Questions?
580 Broadway, Albany, NY 1-800-550-5768 - Innovative Customized Solutions For more information please contact [email protected] or visit ww.processaids.in