ThermalWast brochure design.cdr

WA S T E TO E N E R G Y I N D U S T R Y

TOGETHER FOR MORE AT CALDERYS, OUR MISSION IS TO DELIVER VALUE TO OUR CUSTOMERS. We are a world leader in providing refractory solutions and Over 2,500 employees across services. Our value proposition to you is built on combining our 31 COUNTRIES world-class refractory product portfolio with our ability to deliver high-quality project management services - from planning and installation, to turnkey delivery and 3 R&D CENTERS commissioning. and 11 Design & Engineering Centers Across all the industries we serve – Iron, Steel, Foundry, Aluminium, Cement, Power, and Petrochem - we deliver to you 18 PLANTS our promise of superior product performance and value- in 15 Countries adding service, thanks to our global network of specialized industry experts and project management professionals. Annual Revenue of over 500 MILLION EUROS Our journey of 100 years is a testimony of our commitment to our customers. We listen to you and understand your requirements. We believe in working as one team with you and Wholly-owned Subsidiary of aiming for continuous improvement. IMERYS GROUP Together, we always reach an extra mile for our customers in our mission of delivering MORE. 2

PARTNERING YOU IN THE WASTE INCINERATION INDUSTRY FOR MORE We are a leading refractory solutions and services provider to the global waste incineration industry. Our reputation as a reference supplier in the industry is based on our in-depth expertise and extensive global experience. We undertake turnkey projects for global OEMs, Engineering Companies and Customers. For the past several decades our association with engineering companies, contractors and end users in the waste incineration industry, for both new plants and maintenance projects, has helped us maintain our leadership status as a full-service complete refractory solutions provider. Our global network of industry experts ensures that we propose the most suitable products based on your requirements and deliver you superior refractory performance and reliable services. We are able to do so by combining our innovative product range and modern installation techniques with end-to-end project management services. OUR COMPREHENSIVE PRODUCTS AND SERVICES FOR INCINERATION INDUSTRY ENCOMPASS: PRODUCT PORTFOLIO performance. management services ensure on-time and We provide a comprehensive range of INSTALLATION on-budget completion. refractory solutions to the waste Our capabilities include high-quality MAINTENANCE incineration industry. Our products cover refractory installation services using our Calderys’ maintenance services include different types of units in the Waste to own equipment. Our dedicated products permanent on-site refractory services, Energy industry including Thick and/ or Thin for shotcreting and modern gunning regular and predictive maintenance and wall grate or Roller incinerators, Static or techniques reduce stoppages/downtime, repairs, as well as trouble shooting and Circulating fluid bed incinerators, thanks to faster installation. rapid round-the-clock response to Oscillating and/or Rotary kiln incinerators emergencies. Through our reliable services, customers and Pyrolisis. We have the most modern achieve cost optimization by ways of We also conduct on-site training programs Tiles system for Waste to Energy (WTE) energy savings, reduced turnaround time, to enhance your team’s knowhow about which extends considerably the lining life. low wastage and excellent quality of finished the application, function and maintenance We have filed a patent for this new system installation for optimal performance. of the refractory solutions in use. too. PROJECT MANAGEMENT DESIGN We provide complete project management Our design offices located in Budapest services including consultation, planning, (Engineering Center Europe) and Nagpur delivery scheduling, supervision, site (Engineering Center Asia), as well as our management and also direct training for network of design engineers spread customer personnel. Be it large, small or globally, are always available to provide the turnkey projects - our end-to-end project best designs to improve your equipment 3

STRESSES Incinerators’ refractory linings suffer from stresses such as corrosion, abrasion and thermal shocks or some combination depending on the zones of the units. Poor alkali resistant castable Good alkali resistant castable ALKALI CORROSION Corrosion is the main wear factor in Product additions decrease or limit the Silicon carbide based ramming mixes and incinerators. Domestic waste, paper, corrosion. patches present a very good resistance to packaging, plastics when burned release corrosion by alkalis. • Silicon compounds are effective solutions alkali compounds in the form of chloride at operating temperature, decomposition They are penetrated but they cannot and sulphur salts. and oxidation form specific glass phases develop new expanding compounds. For These salts are in a vapor form at the blocking the porosity and forming new units operating at very high temperature combustion temperature. They penetrate phases with the alkalis without disruptive with corrosion by molten ash, we have the refractories and react with them in a growth. developed specific product mixes to line corrosive reaction with formation of new plasma torch furnace rotary kiln, and some There is lesser spalling of the hot face and compounds having a low melting hospital incinerators. alkali penetration is reduced. temperature. They are responsible for • Zirconium compounds are another ash sticking to the lining and internal effective solution. They react with alkalis at growth inducing cracking and spalling operating temperatures and form a glassy of the hot face. phase protecting the lining. Both types of structural alteration are well Certain combinations of the above systems known, the first solution is to use products give exceptional resistance for severe cases. with low open porosity permeability. 1 2 3 1- Conventional castable matrix 2 - Low Cement matrix 3- Ultra Low Cement matrix 4

ACID CORROSION It can be met in some units such as gas cleaning towers. To avoid this corrosion, specific acid resistant products tested to international standards have been developed for installation by casting or gunning. Good acid resistant castable Poor acid resistant castable ABRASION Abrasion in domestic waste incinerators is The test allows a product ranking to be Corrosion resistance ranking a main wear factor which concerns the established: (see table) charging and the sides of the combustion 3 1. types of particules • With less than 5 cm of loss: excellent zones. less abrasive more abrasive 3 3 • From 5 cm to 10 cm of loss: very good Abrasion is measured with a standard test 3 3 where abrasive particles are blown against • From 10 cm to 20 cm of loss: good pre-fired-samples. The abrasion resistance Our range offers products with excellent is given by the loss of material expressed as abrasion resistance, and also products 3 a volume in cm . The abrasion resistance of answering to combined stresses such as talc clinker dust coal ashes monolithic refractories is linked to abrasion with corrosion. aggregate (corundum, silicon carbide and 2. particules speed bauxite are better than chamotte) and the less abrasive more abrasive matrix. Products with high cold crushing strength value show excellent abrasion resistance. v = 15 m/s v = 20 m/s v = 25 m/s 3. angle of particules flow less abrasive more abrasive 5

IMPORTANT FACTORS FOR INCINERATION WITH CO-GENERATION HEAT TRANSFER For incineration with co-generation, the heat transfer is an important characteristic. SiC additions modify the heat transfer which is very important to optimise the heat recovery. Our range offers products with SiC additions from 10% to 90% to answer the choice of heat transfer. Where high temperature is needed to over burn NOX into NO2, low SiC are preferred. SiC percentage varies according the zone to line. Low cement castables with alkali resistant matrix are also good alternatives for a low heat transfer when burning domestic wastes and biomass. THERMAL SHOCKS They are not frequent as incinerators generally operate continuously. In the same way as for abrasion resistance, products with specific corrosion resistance have also sufficient thermal shock resistance. INSTALLATION TECHNIQUES Our different specialities give you the possibility to chose the way of installation: • Casting vibrating rodding behind formwork, • Self flowing for thin linings, • Gunning and low porosity gunning for thick linings, • Low porosity paint gunning for thin linings on tubes, • Spraycasting, • Ramming 6

WASTE INCINERATORS WITH GRATE FIRED BOILER Roof Above First Pass ACCMON GUN 60 Hot Front Roof ACCMOM 60/ACCMONGUN 60 S5/ ACCMON GUN 85SC INSULYTE 8 S WDS BOARD CF -PAPER (1260Gr) Chute Side Walls ACCMOM 60/AC 60 AP POROSINT 500 INSULYTE 10S /POROSINT 500 WDS BORD /CP (1260Gr) Wear Zone Grate Transition ACCMON CAR INSUL YTE 11LIZ CERAMIC BOARD Hot boile walls 70% Sic NITRIDE BRICK/AC 60 AP ACCMON CAR INSULYTE 11LIZ / POROSINT CERAMIC BOARD / POROSINT 500 7

Upper Combustor First Pass ACCMON 60/ACCMON 80SC 70% SiC NITRIDE BONDED TILES FLOWMON 60 SC-BACKUP FILLING Fiy Ash Hopper FLOWMON 60 SF End Wall ACCMON 50/ AC 50 S /ACCMON 60 INSULYTE 10 S/POROSINT 500 WDS BOARD /CF BOARD Side Walls ACCMON 50/AC 50 S / ACCMON CAR POROSINT 500 INSULYTE 10 S /POROSINT 500 WDS BOARD /CF BOARD 8

CFBC HOT CYCLONE Cyclone Roof ACCMON 80 / CALDE SUPERGUN B/ CALDE SUPERGUN SC INSULYTE 8 S / ACCGUN INS 8 Cross Over Dust ACCMON 45 / CALDE SUPERGUN C INSULYTE 10 S / ACCGUN INS 8 Cyclone Non Target Area ACCMON 60 Cyclone Target Area ACCPLAST 55 ACCMON / ACCPLAST80 / ACCPLAST 60 ACEPLAST RAM BS 1 / INSULYTE 8 S / INSULYTE 10 S ACE PLAST RAM BS 2 INSULYTE 8 S / INSULYTE 10 S Cyclone Cone ACCMON 60 / ACCMON BS 1 INSULYTE 8 S / INSULYTE 10 S Down Corner Combustor All Walls ACCMON 60 / ACCMON BS 1 ACCPLAST 80 / ACCMON BS 2 / INSULYTE 8 S / INSULYTE 10 S ACCMON 60 INSULYTE 8 S / INSULYTE 10 S Seal Pot Roof ACCMON 59 LX / ACCMON AZS INSULYTE 8 S / INSULYTE 10 S Seal Pot ACCMON 60 / ACCMON BS 1 INSULYTE 8 S / INSULYTE 10 S Sliding Piece Start Up Burner ACCMON 60 / ACCMON BS 2 ACCPLAST 80 / ACCPLAST 70 SC/ INSULYTE 8 S / INSULYTE 10 S ACCMON BS 3 / ACCMON AZS INSULYTE 8 S / INSULYTE 10 S Return Leg ACCMON 60 / ACCMON BS 2 INSULYTE 8 S / INSULYTE 10 S Return Leg Bottom ACCPLAST 80 / ACCMON BS 2 INSULYTE 8 S / INSULYTE 10 S 9

CFBC COLD CYCLONE Cyclone roofs, Gas duct including inlet area ACCSMON 45 ACCMON GUN 60 ACCSHOT 60CC ACC SHOT 15 SC ACC SHOT 62CC ACE PLASTRAMC ACE PLAST RAM BC PATCH (CBB) FLOWMON 60L CALDE SUPER GUNB ACE PLASTRAM BC PATCH (CBB) Inlet to cyclone Target area cyclon including duct ACCPLAST 70SC ACE PLAST RAMBC ACCMON BS2 ACC PLAST 70SC ACCSHOT 15SC ACC PLAST 80 ACCSHOT 70SC ACCMON Bs2 (Shortcrete) ACCSHOT 15 SC ACCSHOT 70 SC Cyclone walls others ACCMON 45 ACCSHOT 60CC ACCPLAST 80 Fuel Chute ACCPLAST 55 ACCMON CAR (PCPF) ACCMON 80 Lower boiler walls up to free board level ACCMON 80S ACC PLAST 80 ACCMON CRC ACC PLAST 70SC (Burned) Loop seal / intrix ( compact boiler Loop seal roof) ACCMON Bs1 ACC PLAST RAM BC Walls air box Ash hopper Nozzle bottom ACE PLAST RAM BC ACCMON 45 Whyheat C ACCMON 80s ACCMON 60 Whytheat C ACCMON 60 ACCMON 60 ACCMON 80S ACCMON 45 Slag outlet FLOWMON 60 ACCMON BS2 ACCMON BS2 ACCMON CAR ACCMON BS2 10

COMPOSITE TILES – DESIGNED ESPECIALLY FOR INCINERATORS Connecting the best materials of today to produce the solution of the future Its advantages: l High heat transfer coefficient l Superior infiltration resistance to slag l Very low wettability l The mechanical fixation of these two materials eliminates pressure/stress points in both tiles while allowing slight expansion when exposed to process temperatures. l The vertical and horizontal step joint prevent diffusion of the pollutant gases towards the boiler tube wall l In order to compensate the thermal expansion, the tile has been fitted with a 3 mm thick soluble fiber felt l The advantage of this dry fitted system is that it offers the possibility of equalizing the boiler wall differences and irregularities 11

COMPOSITE TILES – DESIGNED SPECIALLY FOR INCINERATORS Calderys HYXOS Anchoring System: The HYXOS anchoring system is developed to provide the best tile anchoring solution available. The anchor installation flexibility is realised by giving the installer the possibility to hand weld or stud weld the anchor to the boiler wall. The ‘wheel’ can be adjusted on the stud to ensure a perfect fit of the tile on the boiler tube wall. HYXOS stud and wheel HYXOS wheel on stud The tile slides down to lock itself in place on the HYXOS anchor 12

REFRACTORIES SOLUTION WTE General Arrangement WTE Burner Wall Brick Option WTE Side Wall WTE SiC Tiles Installation 13

TECHNICAL DATA NOTES: CALDERYS does not warrant the accuracy, fitness 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 specifications 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. 14

TECHNICAL DATA * Rebound excluded 15

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