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? 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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Capabilities Thermal Shock Resistance Engineered Particle Packing � Unique Binder System � Continuous Interconnected � Porosity Fine Pore Size 3-5 Micron � Mechanical Abrasion Resistance � Micropore Distribution of Fired Alumina Refractories Penetration resistance to � 10 molten metals AP Blasch = 20.1% AP Pressed = 22.8% AP Rammed = 21.0% 9 Non-wetting additives available � 8 Engineered 7 � Volume Fraction (%) Porosity/Permeability 6 5 Extremely High Green Strength 4 3 2 1 0 0 25 50 75 100 125 150 Pore Diameter (µm) Blasch Pressed Rammed Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
In House Testing Thermal Shock Abrasion C-704 Acid Testing Creep Resistance Cup Brick Corrosion Strength Flame resistance Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 � Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Power Plants (where we are) Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Multicyclone Dust Collectors Barron/Process/Wheelabrator Zurn/ASH/Western Precipitator/American Standard – 6”, 9” 12” 24” Exact replacement Weighs 1/3 rd 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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Multicyclone Dust Collectors Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Bubble Caps/Tuyeres/Arrowheads Ceramic replacement Weld or threaded in designs Designs to reduce plugging Strong enough to walk on Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Wear Coating – Blaschguard TM 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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 or bricks Reduction in the number of part numbers Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 1/4 th 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 � operating conditions Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Burner & Mixer Tubes Oxidation and Reducing resistant materials available Precise mounting flanges Repeatable exit bore geometries Thermal shock resistant Low mass thin walls Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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. Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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 Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Corner Fired Burner Applications Splitter Plates Coal Nozzle Tips Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Corner Fired Burner Applications Coal Nozzle Linings Anti-Roping Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Corner Fired Burner Applications Ash Control Valves Multiport Outlets Mill Discharge Valves Pulverizer, Exhauster & Crusher parts Coal Transfer linings Misc – Trona Injection Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
TiO2 Applications Micronizers Hot Tickle Piping Valves (Jamesbury & Batley) Flow Straighteners Nozzles, Venturi, Inlets, Sprayers Distributor Plates Chlorinator Sleeves Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
Mining Applications Suction Pump Liners Cones, Apexes & Spigots Valves Chutes Cyclones Proprietary and Confidential For more information please contact info@processaids.in or visit ww.processaids.in
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