Monolithic

concept

solutions for

Thermal Industry

Powerplant

Refractory Solutions for Thermal

Industry Power Plants

We have been working for years with the worldwide engineering

compa-nies, contractors and end users of the power plant industry

both for new units and maintenance.

Our worldwide presence and exper-

tise allow us to propose the most

suitable technical solutions in order

to contribute to your productivity im-

provements.

We are considered by our

customers as a major specialist. We

are deve-loping high performance

products and offer a complete range

of mono-lithic solutions specially

designed for Power Plants.

R & D experts

Technical support Design specialists Sales organisation Supervising team

Expertise in Power Plants

There is a growing need of energy

to respond to the industrialization

of many countries. This need is

covered by the erection of new

large power plants burning low

cost fuels.

For years, we have been active in the

field of power plants and when com-

bining our knowledge of refractories

with our understanding of the cons-

traints existing in power plants, we

have developed in our R&D Centre a

specific range of products which are

widely used and appreciated. With our worldwide contacts, we

have gained experience as we have

worked with all partners involved,

engineerings, contractors, installers

and end users. We offer you a full

product range adapted for effective

and efficient linings, technical sup-

port and expertise for an increased

service life and reliability. Our ex-

pertise goes from simple boilers to

circulating fluid bed boiler.

Fuel charging zone

The main common stresses are identified.

They are:

• abrasion,

• thermal shocks,

• corrosion either as a simple factor or combined with other

mechanisms dependent on lining zone.

Abrasion

Abrasion is one of the main wear factor in power plants. It is due to the

dense fuel ashes - from poor coal, lignite, petcoke - and to sand added in

fluid bed boilers.

3 FACTORS ARE INVOLVED:

1. type of particules from soft (talc) to very abrasive (coal ash),

2. particule speed,

3. impact angle, the oblique one being the worst

Abrasion is measured with a standard test where abrasive

particles are blown against pre-fired samples. The abra-

sion resistance is given by the loss of material expressed

as a volume in cm3. The abrasion resistance of monolithic

refractories is linked to the aggregate (corundum, silicon

carbide and bauxite are better than chamotte), and the

matrix. Products with high cold crushing strengh value

show excellent abrasion resistance.

The test allows a product ranking to be

established: (see table in appendix) Good abrasion resistance

• with less than 5 cm3 of loss: excellent

• from 5 cm

3 to 10 cm

3 of loss: very good

• from 10 cm

3 to 20 cm

3 of loss: good

1. types of particules Less abrasive More abrasive

TALC DUST ASHES

CLINKER COAL

2. particules speed Less abrasive More abrasive

Poor abrasion resistance

3. angle of particules flow

Less abrasive More abrasive

15 m/s

=

V

20

m/s

=

V

25

m/s

=

V

Thermal Shocks

Thermal cycling is very important as the quantity of fuel burned is regu-

lated by the quantity of steam needed.

Thermal shocks from operating temperature 850°C/900°C down to minimum

temperature 200°C/300°C can be very frequent, from once a week to 10 times

per day and can seriously damage the refractory lining with deep cracks,

spalling and loss of lining.

The products must have a good mechanical strength and modulus of rupture,

also a rupture with non brittle fracture, to support the stresses induced by

thermal shocks. The matrix system is of great importance. All severe thermal shock tests, as

well as behaviour in industrial units, have shown that linings with products

showing high mechanical strenght without a high degree of compactness have

excellent thermal shocks behaviour.

Poor thermal shock resistance Good thermal shock resistance

Corrosion

NORMALLY THERE IS NO SEVERE CORROSION EXCEPT:

• when petcoke is used as fuel, as it contains high amount of sulfur, acidic corro-

sion can occur. We have developed specific products showing excellent acidic

resistance.

• with reducing atmosphere in the lower part of the combusition chamber with

pos-sible CO formation. The CO will react with free metallic iron particles,

resulting in carbon deposition leading to growth, cracking and spalling of the

lining. CO resist-ant products are included in our range.

S o l u t i o n s fo r

Grate Fired Combustion Chamber

4 6

4 1

3

2

5

1 FUEL CHUTE

DENSCAST 50

PLICAST HyMOR 2800 4 ROOF

PLIGUN GX A-60 S7

2 WEAR ZONE / GRATE

AH 405 SR

TRANSITION

DENSCAST 50

DENSCAST 50 A

PLICAST HyMOR 2800 R

PLICAST LX 58

3 WALLS

DENSCAST 50

PLICAST LX 58

PLIBRICO Standard AB

PLIBRICO Superal-X AB

PLIBRICO Redd ram

PLIGUN GX A-60 S7

AH 405 SR

PLICAST LX 58

5 SLAG HOPPERS

PHLOX 1400

PLICAST HyMOR 2800

6 GAS THROAT

PLIGUN GX A-60 S7

AH 405 SR

PLIBRICO Standard AB

PLIBRICO Superal-X AB

S o l u t i o n s fo r

Power Plant Fluidized Bed

1 FUEL CHUTE

GIBRAM

DENSCAST 80

2 SLAG OUTLET

GIBRAM

PHLOCAST M 32

3

1

ASH HOPPER

PHLOX 1400

PLICAST HyMOR 2800

5

4 WALLS AIR BOX

8

7

6

4

2 3

PLIGUN Strong-Lite

KERLITE 130 MP

5 NOZZLE BOTTOM PLILINE B-85 MP

GIBRAM

MONROX B

6 LOWER BOILER

WALLS UP TO FREE BOARD LEVEL

PLICAST HyMOR 2800 R

DENSCAST 80

DENSCAST 50 A

PHLOCAST M 28 HF

PLIBRICO Redd-ram

7 BOILER WALLS ABOVE FREE BOARD (EBK)

PHLOCAST M 28 HR

PLIFLOW SiC

DENSCAST Sicto

PLIBRICO Redd-ram

SiC-V-85-E

PLIPATCH SiC 70

8 UPPER PART FURNACE, BOILER WALLS

AH 404 SR

AH 405 SR

SPRAYCAST F 60 R

PLIGUN MM 55 S5

S o l u t i o n s fo r

Power Plant Circulating Fluidized Bed

12 13

9

9 10

1 FUEL CHUTE 15

GIBRAM 11

DENSCAST 80

2 SLAG OUTLET 11

GIBRAM

PHLOCAST M 32 8 11

3 ASH HOPPER 11

PHLOX 1400 1

PLICAST HyMOR 2800

7 14

4 CLASSIFIER

PHLOX 1400

4

PLICAST HyMOR 2800 5

6

GIBRAM

PLILINE B-85 MP 2

5 WALLS IN AIR BOX

PLIGUN Strong-Lite

KERLITE 130 MP

6 NOZZLE BOTTOM

PLILINE B-85 MP

GIBRAM

MONROX B

7 LOWER BOILER WALLS UP TO FREE BOARD LEVEL

PLICAST HyMOR 2800 R

DENSCAST 80

DENSCAST 50 A

PHLOCAST M 28 HF

PLIBRICO Redd-ram

8 BOILER WALLS ABOVE FREE BOARD (EBK)

PHLOCAST M 28 HR

PLIFLOW SiC

DENSCAST Sicto

PLIBRICO Redd-ram

SiC-V-85-E

PLIPATCH SiC 60-90

9 INLET TO CYCLONE

(INCL. DUCT)

PHLOCAST M 28 HR

DENSCAST 50 A

MONROX SiC 30

DENSCAST Sicto

AH 404

AH 405

SPRAYCAST F 60 R

PLIBRICO Redd-ram

10 UPPER CYCLONE WALLS, EROSION AREA

DENSCAST 50 A

PHLOCAST M 28 HR

PLICAST HyMOR 2800

PLIBRICO Redd-ram

PLILINE B-85 MP

11 CYCLONE WALLS, OTHERS

DENSCAST 50 A

PHLOCAST M 28 HR

PLICAST HyMOR 2800

AH 404

AH 405

SPRAYCAST F 60 R

12 CYCLONE ROOFS, INCL. INLET AREA

AH 405

SH 420

PLIGUN 816

PLILINE B-85 MP

PLIBRICO Redd-ram

MONROX B

13 GAS DUCT

PLIPATCH SiC 60-90

SiC-V-50-E

SiC-V-85-E

PLIGUN Hydro-Mix

H 90 CA GUN

14 LOOP SEAL / INTRIX (COMPACT BOILER)

PLICAST HyMOR 2800

MONROX B

GIBRAM

DENSCAST 50 A

PLIBRICO Redd-ram

14 LOOP SEAL ROOF

AH 405

SPRAYCAST F 60 R

15 TARGET AREA

CYCLON

MONROX B

GIBRAM

PLILINE B-85 MP

S o l u t i o n s fo r

Power Plant Coal Dust Fired Boiler

3 4

5 2

1

1 WATER FLUSHED SLAG HOPPER

Victor Spinell with steel fibres

DENSCAST Sicto

2 HOPPER BETWEEN BOILER AND

SLAG CONVEYER

SiC-V-85-E

PLIPATCH SiC 70

3 UN-COOLED BURNING ZONE

PLIBRICO Redd-ram

PLIBRICO Superal-X AB

4 BURNING ZONE SiC-V-85-E

PLIPATCH SiC 70

5 SLAG ZONE

OF ASH HOOPER

SiC-V-85-E

PLIPATCH SiC 70

S o l u t i o n s fo r

Power Plant Water Cooled Grate Fired Boiler

(bio-mass)

1 3

3

2

1 FUEL STOKER

DENSCAST 50 A

2 ASH HOPPER 3 BOILER WALLS

PHLOX 1400 DENSCAST 50 A

PLICAST HyMOR 2800 DENSGUN 50 A

S o l u t i o n s fo r

Power Plant Melting Chamber Boiler

(grinded-coal)

2

3

1

1 MELTING SLAG OUTLET

SiC-F-85-LC

KOR-Z F 52 LC

2 BURNER 3 MELTING CHAMBER

(TUBE WITH STUDDING) (TUBE WITH STUDDING)

SiC-V-85-E SiC-V-85-E

SiC-V-90-E SiC-V-90-E

S o l u t i o n s fo r S o l u t i o n s fo r

Power Plant Lignite Fired

Lignite Firing Boilers

1

3

1

2

4

1 RECYCLING DUCT 5

PLICAST HyMOR 2800 R

PLIGUN 814

KERGUN SiC 30

PLICAST HyMOR 2800

PHLOCAST M 32

4 WATER-COOLED

BOILER HOPPER

2 LIGNITE BURNERS

PLIGUN MM 55 S5

PLICAST HyMOR 2800

DENSCAST Sicto

MONROX AX

5 UN-COOLED

3 START BURNER

AFTER FIRING CHAMBER

PLIBRICO Superal-X AB PLICAST HyMOR 2800

P ro d u c t s

Technical Information

Formula design Chemical analysis (%) Water

Material required for

Permanent

Product name

CCS

required mixing on

linear

Max grain

Binding

(N/mm2)

Main comp Al2O3 SiO2 Fe2O3 SiC (t/m

3) site (litres/ change (%)

size (mm) system 100kg)*

Added at

-0.3

60

AH 404 SR 5 Chamotte Hydraulic 48 1.7

2.20

the nozzle

(110°C) (110°C)

AH 405 SR 5 Bauxite Hydraulic 82.9 1.5

2.65 Added at -0.3 70

the nozzle

(110°C) (110°C)

AH 406 SR 5 Andalusite Hydraulic 69.3 0.9

2.60 Added at 95

the nozzle

(110°C)

DENSCAST 50 5 Bauxite Hydraulic 82.9 1.5

2.65 5.6 - 6.4 -0.3 70

(110°C)

(110°C)

DENSCAST 50 A 5 Chamotte Hydraulic 53 0.6

2.40 5.6 - 6.4 -0.1 75

(110°C)

(110°C)

DENSCAST 80 5 Alumina Hydraulic 78 0.5

2.70 5.2 - 6.0 -0.2 80

(110°C)

(110°C)

DENSCAST Sicto 5 Silicon Carbide Hydraulic 18 0.5 56 2.50 6.0 - 6.8 60

(110°C)

GIBRAM 5 Bauxite Hydraulic 82.5 1.5

2.90 5.0 - 6.0 125

(110°C)

H 90 CA Gun 5 Chamotte Hydraulic 24 1.6

KERGUN SiC 30 3 Silicon Carbide, Hydraulic 34.8 0.6 33.8 2.10 Added at 80

Chamotte the nozzle (110°C)

KERLITE 130 MP 5 Insulation Hydraulic 36.5

6 1.30 Added at 12

chamotte the nozzle

(110°C)

KOR-Z F 52 LC 3 Alumina Hydraulic 52 14.9 0.15 3.0 2-3 -0.3 70

(110°C)

(110°C)

MONROX AX 5 Andalusite Hydraulic 52.1 0.5 9.5 2.80 5.5 - 6.5 110

(110°C)

MONROX B 5 Bauxite Hydraulic 84.5 1

2.80 6.0 - 7.0 60

(110°C)

MONROX SiC 30 3 Silicon Carbide Hydraulic 33.2 0.7 34.6 2.40 7.0 - 7.5 80

(110°C)

PHLOCAST M 28 HF 5 Chamotte Hydraulic 47.3 0.6

2.33 5.7 - 7.6 115

(110°C)

PHLOCAST M 28 HR 5 Chamotte Hydraulic 45.5 1.3

2.20 6.0 - 7.5 100

(110°C)

PHLOCAST M 32 5 Bauxite Hydraulic 77.7 1

2.65 6.5 - 8.5 130

(110°C)

PHLOCAST M 23 5 Chamotte Hydraulic 37.5 3.2

2.10 7.0 - 8.5 85

(110°C)

PHLOX 1400 5 Chamotte Hydraulic 39 2.3

2.28 7.5 - 9.5 70

(110°C)

* exl. rebound by gunning

NOTES: CALDERYS does not warrant the accuracy, fi tness for purpose or update of any information disclosed herein. The recipient shall refer to instructions

and advice provided under any technical documentation. This document and the information contained herein are the exclusive property of CALDERYS.

Reproduction, alteration, copy, release, publication or distribution, in whole or in part, is not allowed. References, trademarks and specifi cations of the products may change according to the geographical area to be supplied. Please check the availability of the

products with the sales area manager.

Water

Formula design

Chemical analysis (%)

Material required for Permanent

Product name

CCS

required mixing on

linear

Max grain

Binding

(N/mm2)

Main comp

Al2O3 SiO2 Fe2O3 SiC (t/m

3) site (litres/ change (%)

size (mm) system 100kg)*

High alumina

Inorganic-

-0.8

75

PLIBRICO Red-Ramm 6 69 23 0.8

2.7

raw materials chemical

(110°C) (800°C)

PLIBRICO 6 Chamotte

Ceramic 31 62 1.7 1.9 1.2 32

Standard AB (110°C) (800°C)

PLIBRICO Superal-X 6 Bauxite

Ceramic 73 22 1.35 2.62 -1.2 35

AB (110°C) (800°C)

PLICAST HyMOR 2800 6 Chamotte Hydraulic 50 43 0.75

2.33 6.4 - 7.6 -0.05 120

(110°C) (110°C)

PLICAST HyMOR 6 Chamotte

Hydraulic 51 42 0.7 2.38 6.4 - 7.6 -0.05 120

2800 R (110°C) (110°C)

PLICAST LX 58 6 Chamotte Hydraulic 57 38 1.1

2.53 5.6 - 6 -0.04 95

(110°C) (110°C)

PLIGUN 814 6 Chamotte Hydraulic 48 36 3

2.35 -0.05 75

(110°C) (110°C)

PLIGUN 816 6 Bauxite Hydraulic 84 4.5 1.1

2.7 -0.05 90

(110°C) (110°C)

PLIGUN GX A-60 S7 6 Andalusite Hydraulic 51 37 0.9 7 2.35 0 28

(110°C) (110°C)

PLIGUN Hydro-Mix 6 Chamotte Hydraulic 36.5 48 2.4

2.14 -0.1 40

(110°C) (110°C)

PLIGUN MM 55 S5 6 High alumina Hydraulic 57 30 0.8 5 2.6 -0.05 90

raw materials (110°C) (110°C)

PLIGUN Strong-Lite 4 Light-weight Hydraulic 39 41 5.5

1.68 -0.05 20

chamotte (110°C) (110°C)

PLILINE B-85 MP 4 Bauxite Hydraulic 84 8 0.8

3.15 4.4 - 5.2 -0.1 140

(110°C) (110°C)

PLIPATCH SiC 70 4 Silicon Carbide Chemical 16 5 0.2 70 2.75 -0.1 40

(110°C) (110°C)

PLIPATCH SiC 60 3 Silicon Carbide Inorganic- 25 5 0.2 63 2.75 -0.5 50

chemical (110°C) (110°C)

PLIPATCH SiC 90 4 Silicon Carbide Inorganic- 1.6 7 0.3 87 2.65 -0.2 30

chemical (110°C) (110°C)

PHLOX 1400 5 Chamotte Hydraulic 39

2.3 2.28 7.5 - 9.5 70

(110°C)

SH 420 3 Silicon Carbide Hydraulic

1.1 30.6 2.3 Added at 63

the nozzle

(110°C)

SiC-V-50-E 3 Silicon Carbide Chemical 36.6 6.6 0.15 51 2.55 -0.1 90

(110°C) (800°C)

SiC-V-85-E 3 Silicon Carbide Chemical 6.3 4.2 0.09 85 2.58 0 95

(110°C) (800°C)

SiC-V-90-E 3 Silicon Carbide Chemical 1.6 6 0.09 89 2.48 0 90

(110°C) (800°C)

SiC-F-85-LC 3 Silicon Carbide Chemical 8.8 4 0.03 85 2.42 6.2 -0.3 75 - 85

(110°C) (800°C)

SPRAYCAST F 60 R 6 High alumina Hydraulic 60 34 0.95

2.45 5.6 - 6.4 -0.05 50

raw materials (110°C) (110°C)

Victor Spinell with 5 Spinel

Hydraulic 70 2 2.60 9.2 - 10.0 100

steel fi bres

(110°C)

* exl. rebound by gunning