Instructions for Storing, Keeping and Using the Refractory Material of 480T/H CFB Boiler of Hangzhou Boiler Group

Indian Project

1. Requirements of Storing and Keeping the Field Wearproof and

Refractory Material
The amorphous refractory material for CFB boiler is classified into the hydraulic and heat hardening type. The material has a rigorous request for the storage conditions. The moisture absorption and rain drenching have a big affect to the material performance. In order to allow various materials to fully exert their performance and prevent the failure in storage and keeping, the regulation is formulated hereby: 1. When the material is being delivered to the worksite, it should be placed in a dry environment and the drench is prohibited. When raining, it is required to have a good damp-proof action for loading and discharging various refractory material. 2. When the castable is loaded or unloaded, it is prohibited to throw it from the vehicle in order to prevent the packing inner bag from damage and the material failing due to moistening. 3. When the castable is unloaded, the custodian shall supervise the process, separately store the refractory material which is damaged and drenched and duly reject it. The performance indexes of these material cannot reach the original design request. 4. The case-hardened products shall be handled with care, the spoilage of edge, angle and arris shall be prevented during the discharge and handle, in order to avoid the affect to masonry construction and directly causing the fall of total performance of masonry surface. 5. All the refractory materials are required to be stored in the warehouse where is well-ventilated and has the good protective measures for moisture. The suitable storage temperature is 25. The material shall be neatly stacked, and respectively identified as per the specs, types. The label shall be legible so that the check and physical count are easy. 6. If only the outdoor storage is allowed, you should make sure that ground is flat, the measures for rain prevention are good and the storage position is relatively high. Its prohibited to place them in a low position. The standard forklift shall be applied in the

conveyance. Since the outdoor storage condition is poor, the warranty period of refractory material will be severely affected. 7. The usage of material shall have a serious and definite plan. It is necessary to minimize the times of conveyance, and special people shall be appointed to be responsible for the cautious handling during conveyance. 8. For the material to be delivered to worksite, it should be strictly prevented from rain drenching and should be distinctly labelled for fear the misuse. 9. The shelf life of all amorphous refractory materials under the good storage condition after arrived in the worksite is 5 months, the shelf life of liquid binder and additive is 5 months, the shelf life of case-hardened refractory material is 1 year(it should be separately specified when the material has the special storage requirements). 10. When stored, the material shall be separated from the ground with the board, dampproof cloth etc.

2. Instructions of Using the Refractory and Insulating Material

I.Use Instruction for Wearproof & Refractory Plastic 1.Package of Material and Precautions 1.1 The wearproof plastic uses a phosphate combining with the corundum, alumina clinker and superfine powders etc. The phosphate binder, coagulant and additives are added in the field per the demand. 1.2 Package of Wearproof Plastic 1.2.1 The wearproof plastic powders use the woven bag where the coagulants in small packets are placed. The binder for wearproof plastic is packaged in barrel. The weight of each barrel is 30Kg. The curing agent for wearproof plastic is placed in the wearproof plastic powders bag in small packets. 1.2.2 Usage: A bag of plastic powders puts up a packet of curing agent. 1.3 The construction quality of material shall be controlled by the construction company. Our factory provides the use demands and relevant precautions for material. 1.4 Never moisten and drench the material during the transportation and storage.

Especially, the coagulants and curing agent shall be in a good custody. 1.5 The proportion of the material and binder: dry powder: binder=100:15 approx. The fill of binder is depended on the air temperature and humidity of worksite in some extent. Generally, the fill of binder shall be more when the air temperature is high. 2. Precautions before Material Construction 2.1 The material shall be mixed by the coercive agitator. 2.2 The relevant preparatory work must be finished before the material construction, and the necessary construction machines and tools shall be equipped according to the different construction method. 2.3 Arrange the relevant people to perform the all-round quality check and acceptance to the concealed projects prior to construction, the construction cannot begin until they are confirmed OK. 2.4 Clean up the worksite and prevent the mix-up of foreign matters in material prior to construction. 2.5 The construction company and user shall systematically perform the quality check for the heat-insulating nails(dowels), the construction will begin upon the approval of both parties. 2.6 Before the material construction, a layer of l.0mm-thick bitumen shall be daubed on the heat-insulating nails(dowels). 2.7 Before the material construction, the builders shall accept the training, and the simulation test can be done when necessary. The construction cannot begin until they are familiar with the construction performance of material. 3. Mixing of Material in Construction 3.1 Pour the aggregate and curing agent into the agitator per the ratio and mix them up till an even color. Then add the measured binder and continue the mixing(first add 2/3 of measured binder and add the remaining binder relied on the particular construction demand. They can be put into use after evenly mixed up(the mixing time is usually 5-6 min.). 3.2 The fill of binder can be adjusted according to the weather change and temperature in the field.

3.3 The amount of used material during construction could be adjusted according to the quantity of builders and construction progress. 3.4 The mixed-up material must be used up within 30min. Its prohibited to mix it again by secondly filling the binder. The material after the initial setting must not be used. 3.5The filled amount of binder is 13-15% by weight. 4. The Material Construction 4.1 The optimal ambient temperature for the material construction is 10-30. When the ambient temperature is lower than 10 in winter, you should have the suitable heat insulation measure. When the ambient temperature is higher than 30 in summer, you should have a cooling measure. When constructing in the rainy season, you should have the moisture prevention measure. 4.2 Construction by the Manual Pounding 4.2.1 When manually pounding the material, two persons are in a group. One person twists the mixed wearproof plastic into a chunk and lays on the equipment. The other person uses a wooden or rubber hammer to pound it. When pounding, the strikes shall be regular and one-by-one, the no-pounding and scattered pounding are not allowed. Make sure that the pounding will cause the material to be flattened and firm. 4.2.2 When the material surface is flattened, the construction by spraying the water on surface is not allowed. 4.2.3 During the material construction, two persons are in a group. The unitary working face is preferably 1000-1500mm in width. Use the plywood of 0.5mm to make the templates for side. If the equipment under construction is on the hot face, the side templates must be laid on the fin of water-cooling wall, cannot be just opposite to the water-cooling wall. When the construction of a unit is finished, the upper plastic shall be cut flush with a trowel or fork knife. Then remove the side templates. When erecting the templates of next unit, repeat the above steps. 4.2.4 If the construction of wearproof plastic needs to stop halfway, it can be stopped after the construction of a unit is finished. 5. Maintenance of Wearproof Plastic

When the construction of wearproof plastic is finished, the roasting or baking can be carried out after 7-10 days of natural maintenance. Take care to avoid the rain drenching during the construction and maintenance of wearproof plastic. Therefore, the reliable moisture prevention measures for equipment shall be provided for the construction of wearproof plastic. 6. The Quality Inspection and Repairing Method of Plastic 6.1 The Quality Inspection of Plastic 6.1.1 After the plastic is dried by baking, use the half-pound hammer to gently hit the liner. The liner should emit a clear echo without the occurring of loosening and ruggedness. 6.1.2 After the liner is dried by baking, the surface shall be flat without the roughness and obvious cracks. 6.2 The Repairing Method of Plastic 6.2.1 When any faulty position of liner is repaired, the liner shall be holed into a shape which is small outside and large inside. The minimum scope of repairing shall at least include 5 heat-insulating nails(dowels) (at least 300300mm) 6.2.2 All the repairing work shall be performed by using the same method as original construction method. II. Instructions for Construction of Wearproof and Refractory Castable(Including Steel Fiber Wearproof and Refractory Castable, Hyper-aluminum Refractory Castable): 1.Package of Material and Precautions 1.1 The wearproof and refractory castable uses a low cement combining with the corundum, alumina clinker and superfine powders etc. The cement binder and additives are added in the field per the demand. 1.2 Package of Castable The castable uses the woven bag where the binders and additives in small packets are placed. The weight of castable aggregate is 50Kg per bag. 1.3 The construction quality of material shall be controlled by the construction company. Our factory provides the use demands and relevant precautions for material.

1.4 Never moisten and drench the material during the transportation and storage. Especially, the coagulants and curing agent shall be in a good custody. 1.5 The warranty period of cement for binding material is 5 months. If exceeding 5 months but less than 6 months, the cement performance test shall be done subsequently and it can be put into use after tested OK. 2. Precautions before Material Construction 2.1 The material shall be mixed by the coercive agitator. 2.2 The relevant preparatory work must be finished before the material construction, and the necessary construction machines and tools shall be equipped according to the different construction method. 2.3 Arrange the relevant people to perform the all-round quality check and acceptance to the concealed projects prior to construction, the construction cannot begin until they are confirmed OK. 2.4 Clean up the worksite and prevent the mix-up of foreign matters in material prior to construction. 2.5 The construction company and user shall systematically perform the quality check for the heat-insulating nails(dowels), the construction will begin upon the approval of both parties. 2.6 Before the material construction, a layer of l.0mm-thick bitumen shall be daubed on the heat-insulating nails(dowels). 2.7 Before the material construction, the builders shall accept the training, and the simulation test can be done when necessary. The construction cannot begin until they are familiar with the construction performance of material. 3. Mixing of Material in Construction 3.1 Pour the aggregate, cement binder and additives into the agitator per the ratio and mix them up till an even color. 3.2 The evenly mixed dry material can be churned by filling the water. The total amount of filled water shall be measured per the demand of each mixing when filling the water. First fill 2/3 of total amount, then fill the remaining water according to the

construction demand. Under the prerequisite of meeting the construction, the less water fill, the better. 3.3 After the mixing is finished, the castable shall be immediately taken out. It's prohibited to mix the material in agitator for a long time. The material after the water fill shall be used up within the specified time which is generally less than 30min. The material after the initial setting shall be discarded. It's prohibited to replace it into the agitator to mix for use. 3.4 Fill of Steel Fiber 3.4.1 When the castable powders, cement binder and additives are mixed in the agitator, slowly fill the measured steel fiber into the mixed dry material to avoid the conglomeration of fiber. 3.4.2 The filled amount of steel fiber is usually 1.5-2.0% (refer to the design demand for the particular spec and filled amount). 3.5 The filled amount of wearproof and refractory castable is 6-8% by weight. The filled amount of hyper-alumina refractory castable is 10-14% by weight. When filling the water for mixing, never exceed the filled amount of water offered by our factory. At the same time, the water quality shall reach the drinking water standard. 4. Construction of Material 4.1 Before the construction of material, you must finish the reparatory work relating to the construction, equip the necessary construction tools according to the different construction method and measure the water quality etc. 4.2 The construction of material uses the pattern erection and vibration. 4.2.1 Prefabricate the template as per the drawing demand. The height of prefab template shall be determined according to the thickness of cast boiler wall. For the boiler wall with the casting thickness below 80mm, the casting height each time shall be less than 400mm. In case of the casting thickness above 80mm, the casting height each time shall be less than 800mm. After completing the templates, you should try to assemble them in advance. When the pre-assembly is OK, you can start to erect the templates in the field. 4.2.2 The erection of templates shall be secure and tight, without the leakage of slurry.

4.2.3 When constructing the castable, use the vibration rod for construction. Vibrate the material while pouring it. Make sure sequentially construct, slowly insert and slowly pull out during vibration. Avoid the contact with the dowels if possible when inserting the rod. Never vibrate the material by placing the rod in a same position, because the excessive vibration will cause the eccentric deflection of castable and destroy the whole structure of castable. 5. Maintenance of Castable After the completion of construction, you can begin the natural maintenance when the surface has a certain strength, you can cover it with the wet hemp sack or straw mat. The boiler baking can be performed after maintenance for 7-10 days. 6. The Quality Inspection and Repairing Method of Castable 6.1 The Quality Inspection of Castable 6.1.1 After the castable is dried by baking, use the half-pound hammer to gently hit the liner. The liner should emit a clear echo without the occurring of loosening and ruggedness. 6.1.2 After the liner is dried by baking, the surface shall be flat without the roughness and obvious cracks. 6.2 Repairing Method of Castable 6.2.1 When any faulty position of liner is repaired, the liner shall be holed into a shape which is small outside and large inside. The minimum scope of repairing shall at least include 5 heat-insulating nails(dowels) (at least 300300mm). Moisten the around with water. 6.2.2 All the repairing work shall be performed by using the same method as original construction method. III. Instructions for Construction of Heat-insulating Castable 1. Material 1.1 The light heat-insulating castable is mainly composed of the light aggregate and powders. It is delivered in the bulky composite form. The binder and additives are added as per the proportioning demand at worksite. 1.2 The material construction uses the manual daubing method and pattern erection

vibration method. 1.3 The material construction refers to the use points and relevant precautions for material. 1.4 The cement binder for the material uses the hyper-alumina cement. 2. Construction of Material 2.1 Manual Daubing 2.1.1 Pour the aggregate, hyper-alumina cement and additives into the agitator per the demand, dry mix them till an even color(it is usually 3min). 2.1.2 The evenly mixed dry material can be churned by filling the water. First fill 2/3 of measured total amount, then fill the remaining water according to the construction demand (note: the amount of filled water is 25-30%). 2.1.3 The mixed material with water fill shall be used up within the specified time(usually 35-40min). 2.1.4 When constructing the material, twist it into a chunk and firmly pile it from downside to upside. Gently hit the liner with a wooden hammer and make it evenly distribute. Do not break the aggregate in castable when pounding. Duly check the thickness of castable for the specified demand. The surface shall be flattened without cracks. 2.1.5 The construction clearance of material shall be processed into the steps. The construction on its lower part can begin only after moistening. 2.2 The pattern erection and vibration construction shall dispose of the interface and remove the residues. 3. Maintenance of Material 3.1 After the completion of construction, you can begin the fog and wetting maintenance when the surface has a certain strength. 3.2 Maintenance method: use the atomizer to manually spray. Determine the times of spray depended on the wetting situation of material surface. Keep a wet surface. 3.3 The maintenance time shall be at least 24h. In principle, spray the water every 30min approx. But you can suitably increase or decrease the times of spray according to the weather condition.

3.4 For the liner which the maintenance is finished, you can begin the construction of wearproof and refractory castable in the outer layer. 4. Repairing of Material When any faulty position of liner is repaired, the liner shall be holed into a shape which is small outside and large inside. The minimum scope of repairing shall at least include 3 heat-insulating nails. Thoroughly moisten the position to be repaired with water. All the repairing work shall be performed by using the same method as original construction method.

Yixing Zhonghuan Refractory Material Co., Ltd. Engineering Technology Dept. May, 2011