1. Ceramite The Wear Resistant Material
Coal Fired Power Generation
Applications

2. INTRODUCTION TO CERAMITE
Elkem Fiskaa, today
Elkem Fiskaa, 1969
Ceramite® is a technology developed by Elkem Materials during research and devlopment of Elkem Microsilica®
20 years of lab testing and coordinated industrial trials
Today: Significant applications in several industries; primarily aluminium, cement and ferrous metals

3. Ceramite® Microsilicia® & Cement The Key to High Strength Bond Phase
Microsilica - amorphous SiO2 fume, (D= micron)
Improves particle packing efficiency in castable - fills in voids between larger aggregates.
Less water needed for casting.
Dense castables with low porosity
Extreme Wear Resistance
Impervious to Gas and Chemicals

4. *A 7.1 cm cube sample is pressed with a 300 N force against a grinding wheel that is coated with a fine grade corundum sand. The sample is rotated 22 times (1 campaign) after which it is cleaned and weighed. The grinding machine is cleaned after each campaign and new media is distributed on the grinding wheel. The test requires 18 campaigns.
The Bohme Test results are expressed as the volume of material lost from the specimen in cm3 from the surface area exposed to wear.

5. Ceramite in Power Applications
Pulverizer Repair
Coal Chute Repair
Burner Vortex Repair
Off Take Boiler
Coal Chute Lining
Fan Housing
Cyclones
Baghouse Systems

6. Power Industry-Pulverizer

7. Power Industry-Pulverizer

8. Previously used beaded epoxy Customer repairs every six months
Pulverizer
Previously used beaded epoxy
Customer repairs every six months
Ongoing project

9. Coal Chute Repair

10. Coal Chute Repair

11. Customer previously repaired ceramic tile with beaded epoxy
Coal Chute Repair
Customer previously repaired ceramic tile with beaded epoxy
Would need repairs every 6 months
Ongoing project since 2006

12. Burner/ Vortexer
CERAMITE T

13. Customer uses Nitrite Bonded SiC tiles
The Problem
Customer uses Nitrite Bonded SiC tiles
Tiles routinely crack and must be repaired every six months
Ceramite Trowelable has been used as repair material for past 18 months
Based on Ceramite performance, customer decided to trial complete vortex burner

14. Worn SiC Tile with Ceramite Patch

15. Welded Wire Mesh

16. Installing Overhead

17. Finished Installation

18. Summary Four hours required to weld in mesh
Four hours to install Ceramite
Installing SiC tiles requires 36 hours
Customer intends to perform more complete installations during future outages

19. Off-Take Boiler Duct
Ceramite T
“1x1” mesh

20. Ceramite T 18 bags – 4 men - 2 hrs to INSTALL
Ceramite T 18 bags – 4 men - 2 hrs to INSTALL! Expected Service Life 6 months or more
Ceramite T

21. Coal Chute Lining

22. Coal Chute Lining

23. Customer previously used ceramic tile
Coal Chute Lining
Customer previously used ceramic tile
Tile would fail due to impact/cracking
Ceramite in service since July 2006
22,000 tons of coal per day

24. Fan Housing Repair

25. Fan Housing

26. Coal Classifier – 2 Years Later

27. Ceramite T LINED CYCLONE

28. Baghouse Duct

29. Less Surface Preparation Easily Mixed and Installed Safety
Why Ceramite?
Monolithic Lining
Less Surface Preparation
Easily Mixed and Installed
Safety
Ceramite has out performed all other wear materials