Abrasion Applications for Industry 580 Broadway, Albany, NY - - PowerPoint PPT Presentation

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Abrasion Applications for Industry 580 Broadway, Albany, NY - - PowerPoint PPT Presentation

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2010 Abrasion Applications for Industry 580 Broadway, Albany, NY 1-800-550-5768 - I nnovative Customized Solutions Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in Who is Blasch?

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SLIDE 1

Proprietary and Confidential

2010

Abrasion Applications for Industry

580 Broadway, Albany, NY 1-800-550-5768 - I nnovative Customized Solutions

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 2

Proprietary and Confidential

Who is Blasch?

Founded in 1979 65,000 sq ft. bldg in Albany, N.Y. ESOP = Employee owned ISO 9001 Cert Patented Process – Freeze Casting Mixes = 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 equipment Extensive in-house testing Custom Refractory Shape Makers Problem Solvers

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 3

Proprietary and Confidential

Type of ceramic - Refractory

Shapes Abrasion Resistant Thermal Shock Resistant Corrosion Resistant Can be heat conductive, but not electrically Good strength Can be insulating depending on material Lower overall cost

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 4

Proprietary and Confidential

Available Materials

Oxide and Non-Oxide Mullite Fused Silica High Alumina Oxide Bonded SiC - Oxytron Nitride Bonded SiC - Nitron OxyNitride Bonded SiC – OxyNitron Alumina Bonded SiC - Altron Reaction Bonded SiC - Invincer

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 5

Proprietary and Confidential

Capabilities

Complex, Net Shape

  • No Machining
  • Linear tol. + /- .005” (.5%)
  • Very Repeatable

Not limited by process

  • 1 oz to 2 ton
  • .06” to 6” thick wall
  • 1 part to 1,000
  • Matchstick to Sewer pipe
  • Only limited by equip

Unique shape capabilities

  • Threads – Int/Ext
  • Bends/Elbows
  • Constant walls
  • Transitional walls
  • Mating surfaces

Mortared assemblies

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 6

Proprietary and Confidential

Capabilities

Thermal Shock Resistance

  • Engineered Particle Packing
  • Unique Binder System
  • Continuous Interconnected

Porosity

Fine Pore Size

  • 3-5 Micron
  • Mechanical Abrasion Resistance
  • Penetration resistance to

molten metals

  • Non-wetting additives available
  • Engineered

Porosity/Permeability

Extremely High Green Strength

Micropore Distribution

  • f Fired Alumina Refractories

1 2 3 4 5 6 7 8 9 10 25 50 75 100 125 150 Pore Diameter (µm) Volume Fraction (%) Blasch Pressed Rammed APBlasch = 20.1% APPressed = 22.8% APRammed = 21.0%

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 7

Proprietary and Confidential

In House Testing

Thermal Shock Abrasion C-704 Acid Testing Creep Resistance Cup Brick Corrosion Strength Flame resistance

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 8

Proprietary and Confidential

Industries we serve

Powergen

  • Pulp & Paper
  • Fuel Cell
  • Gasifiers
  • Coal fired

Petrochem & Chemical Industrial Process Heating Nonferrous

  • Aluminum
  • Red Metals
  • Galvalume/Zinc

Ferrous

  • Specialty Steel
  • Steel
  • Powder
  • Iron

Other

  • Electronics
  • Semi-Con

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 9

Proprietary and Confidential

Common Abrasion Applications

Dust Collectors/Cyclones Air Heater Inserts Bubble caps/Tuyeres/Arrowheads Wear Coatings Tiles, Linings & Bricks Ferrule systems Burners & Mixer Tubes Nozzles and T/C tubes Pipe linings and elbows Corner Fired Burner Applications TiO2 Applications Mining Applications Case studies

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 10

Proprietary and Confidential

Power Plants (where we are)

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 11

Proprietary and Confidential

Multicyclone Dust Collectors

Barron/Process/Wheelabrator Zurn/ASH/Western Precipitator/American Standard – 6”, 9” 12” 24” Exact replacement Weighs 1/3rd that of steel Going on 10 years with no wear Outlets/Inlets/Spin Vanes Cheaper than NiHard Can deliver faster than cast iron Smoother than cast iron = more efficient Can be used at temps above 1,200F Can be cast more precise than steel

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 12

Proprietary and Confidential

Multicyclone Dust Collectors

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 13

Proprietary and Confidential

Air Heater/Ash Cooler Inserts

Tooled for all nominal boiler tube sizes Up to 3 foot lengths Can cast 1/16” wall Walk-on feature Replaceable or permanent SiC or Alumina Cheaper than replacing boiler tubes Can seal up leaks Protects welds and tubesheet

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 14

Proprietary and Confidential

Bubble Caps/Tuyeres/Arrowheads

Ceramic replacement Weld or threaded in designs Designs to reduce plugging Strong enough to walk on

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 15

Proprietary and Confidential

Wear Coating – BlaschguardTM

1 part system – no mixing Cures in 8 hours Sprayable Good to 600F temps Stays “rubbery” Designed for impact Applications:

Baghouse walls Exhaust Ductwork Chutes Pulverizers Air Preheaters Dust Collectors Tubesheets

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 16

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 available Interlocking bricks No limit to size Geometric tolerances held very tight to ensure onsite fit up Engineered Shapes to replace tiles

  • r bricks

Reduction in the number of part numbers

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 17

Proprietary and Confidential

Ferrule Systems

WHB - Firetube, Condensers, Heat Exchangers Round Head Ferrules

Traditional design Solid heads Various flange designs

and locations

Old technology Requires refractory to

hold in place

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 18

Proprietary and Confidential

Ferrule Systems

One Piece Hex

  • Eliminates 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 installations

  • Quicker refractory cure-out
  • No anchors required = no hot spots
  • Engineered pre-cracked system – will

allow for temp. swings

  • More thermal insulation can be used
  • Engineered for the boiler based on
  • perating conditions

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 19

Proprietary and Confidential

Burner & Mixer Tubes

Oxidation and Reducing resistant materials available Precise mounting flanges Repeatable exit bore geometries Thermal shock resistant Low mass thin walls

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 20

Proprietary and Confidential

Nozzles and T/C Protection Tubes

Nozzles

Internal/External threads available. No shape limitations Corrosion/Abrasion resistance over

high alloy steels.

Cheaper than exotic steels Specialize in FGD Nozzles

T/C Protection tubes (T- wells)

Good to 3,000F Won’t oxidize Thermal shock resistant.

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 21

Proprietary and Confidential

Pipe Linings and Elbows

Flanged pipe linings Ship lapped ends Long radius elbows Pipe Linings Abrasion/Corrosion resistant 1/16” – 4” wall available ½ ” to 4ft ID’s available Seamless designs available Smooth bores to prevent wear from starting Ease of assembly

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 22

Proprietary and Confidential

Corner Fired Burner Applications

Splitter Plates Coal Nozzle Tips

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 23

Proprietary and Confidential

Corner Fired Burner Applications

Coal Nozzle Linings Anti-Roping

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 24

Proprietary and Confidential

Corner Fired Burner Applications

Ash Control Valves Multiport Outlets Mill Discharge Valves Pulverizer, Exhauster & Crusher parts Coal Transfer linings Misc – Trona Injection

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 25

Proprietary and Confidential

TiO2 Applications

Micronizers Hot Tickle Piping Valves (Jamesbury & Batley) Flow Straighteners Nozzles, Venturi, Inlets, Sprayers Distributor Plates Chlorinator Sleeves

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 26

Proprietary and Confidential

Mining Applications Suction Pump Liners Cones, Apexes & Spigots Valves Chutes Cyclones

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 27

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

  • nly 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 info@processaids.in or visit ww.processaids.in

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Proprietary and Confidential

Tongue & Groove Lining – case study

Mating T & G joints Allows for expansion and contracting Engineered pre-cracked system – reduces spalling Requires no mortar Reduces # of parts

For more information please contact info@processaids.in or visit ww.processaids.in

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SLIDE 29

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 info@processaids.in or visit ww.processaids.in

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Proprietary and Confidential

Abrasion Applications for Industry

2009

Questions?

580 Broadway, Albany, NY 1-800-550-5768 - I nnovative Customized Solutions

For more information please contact info@processaids.in or visit ww.processaids.in