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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