520TPH CFBC BOILER REFRACTORY

Prepared By:
K.V.Sagar

Approved By:
B.RamaRao,DGM-PP.

REFRACTORY IN CFBC BOILER

Outlet Duct

Inlet duct
Screen coils

Cyclone

Ash return pipe

Combustion
chamber

Lower part

J-seal

Fluidizd bed

Burner

Refractory zones:
1) First pass.
a) Furnace
b) Furnace Bed.
c) Furnace corners.
d) Coal chutes.
e) Furnace outlet.
f) Screen coils.
2) Cyclone zone.
a) Cyclone target area.
b) Cyclone roof.
c) Cyclone bull-nose area.
d) Cyclone cone.
3) J-Seal & J-Seal return
legs.
4) Cross over duct

(COD).

5) Wind box.
6) Under bed burners.
7) 2nd Pass
a) Header seal box.
b) Manual doors & soot
blower seal box.
c) Second pass inlet area.
d) Economizer casing.

1st pass:

a) Furnace bed:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material
Equivalent
as per site material

First layer First layer : Middle weight

: 70 mm
85 mm
heat
insulated
pouring
material

Middle
Insulcast
weight heat 1100
insulated
pouring
material

Final
Layer: 80
mm

wear
resistant
plastic

Final
Layer: 65
mm

Heavy high
aluminum
castable

Phoscast 60
(or)
Phoscast 90

b) Furnace :

Thk (As
per
drawing
)
80 mm

Thk (As
per site)

Material as
per drawing

Heavy high
80 mm aluminum
castable
refractory

Material as
per site

Equivalent
material

Heavy high
aluminum
castable
refractory

Phoscast 90
XR.

c) Furnace corners:

Thk (As
per
drawing
)

Thk (As
per site)

80 mm

80 mm

Material as
per drawing

Material
Modified
as per site material

Heavy high
alumina
castable

Wear
resistant
plastic
refractory

Acco plast 80
/ Phoscast 90
XR.

d)

COAL CHUTES:

Thk (As
Thk (As
per
per site)
drawing)
60 mm

60 mm

Material as
per drawing

Material
as per site

Modified
material

Heavy high
alumina
castable

Heavy high
alumina
castable

Accoman BS2

d)

FURNANCE OUTLET:

Thk (As
Thk (As
per
per site)
drawing)
70 mm

70 mm

Material as
per drawing

Material as
per site

wear resistant wear

plastic
resistant
refractory
plastic
refractory

Modified
material
Phoscast 90XR

e) SCREEN COILS:

Thk (As
per
drawing)

Thk (As
per site)

Material as
per drawing

Material as
per site

Equivalent
material

60 mm

60 mm

wear resistant
plastic
refractory+He
avy high
alluminnium
castable
refractory

wear resistant
plastic
refractory

Phoscast 90XR

Cyclone Zone:

a) Target

Thk (As
per
drawing
)

ZONE:

Thk (As
per site)

Material as
per drawing

Material as
per site

Equivalent
material

First layer First layer : Aluminum

: 60 mm
60 mm
silicate
boards

Aluminum
silicate boards Ceramic boards

Second
Layer:
220 mm

light weight
heat insulated
pouring
material

Second
Layer: 220
mm

light weight
heat
insulated
pouring
material

Insulcast - 900

b) Cyclone Roof:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as
per site

Equivalent
material

First layer First layer : Aluminum

: 60 mm
60 mm
silicate
boards

Aluminum
silicate boards Ceramic boards

Second
Layer:
220 mm

light weight
heat insulated
pouring

Second
Layer: 220
mm

light weight
heat
insulated

Phoscast 90-

c) Cyclone bullnose area:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as
per site

Equivalent
material

First layer First layer : Aluminum

: 60 mm
60 mm
silicate
boards

Aluminum
silicate boards Ceramic boards

Second
Layer:
220 mm

light weight
heat insulated
pouring

Second
Layer: 220
mm

light weight
heat
insulated

Insulcast - 900

d) Cyclone cone

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

First layer First layer : Aluminum

: 140 mm 140 mm
silicate
boards

Material as
per site

Equivalent
material

Aluminum
silicate boards Ceramic boards

Second
Layer:
145 mm

Second
Layer: 145
mm

Light weight
bricks

Light weight
bricks

Final

Final

Wear

Wear resistant Wear resistant

Insulcast - 900

a) J-Seal:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

First layer First layer : Aluminum

: 60 mm
60 mm
silicate boards

Material as per
site

Equivalen
t material

Aluminum
silicate boards
Ceramic
boards

Second
Layer:
120 mm

Second
Layer: 100
mm

light weight
heat insulated
pouring

light weight heat

insulated pouring Insulcast material
900

b) J-Seal Return Legs:

Thk (As
per
drawing
)

Thk (As
per site)

Material as per
site

Equivalen
t material

First layer First layer : Aluminum

: 20 mm
20 mm
silicate boards

Aluminum
silicate boards

Ceramic
boards

Second
Layer:
170 mm

Insulcast 900

Insulcast 900

Second
Layer: 200
mm

Material as
per drawing

light weight
heat insulated
pouring
material

COD:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as
per site

Equivalent
material

First layer First layer : Aluminum

: 60 mm
60 mm
silicate
boards

Aluminum
silicate boards Ceramic boards

Second
Layer:
220 mm

light weight
heat insulated
pouring
material

Second
Layer: 220
mm

light weight
heat
insulated
pouring
material

Insulcast 900

WIND BOX:

Thk (As
Thk (As
per
per site)
drawing)
100 mm

100 mm

Material as
per drawing

Material as
per site

Modified
material

Middle weight
shaped
material

Middle
weight
shaped
material

Walls:
Phoscast 60 &
Roof: Phoscast
90 -XR

Under bed burners:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as per
site

Equivalen
t material

First layer First layer : Aluminum

: 50 mm
50 mm
silicate boards

Ceramic blanket

Ceramic
blanket

Second
Layer:
140 mm

Second
Layer: 160
mm

Light weight
heat insulated
pouring
material

Aluminum bubble Insulcast ball

900

Final

Final

High strength

Hyper cast -80

Phoscast

Second Pass:
Economizer Casing:

Thk (As
per
drawing
)

Thk (As
per site)

Material as per
site

Equivalen
t material

First layer First layer : Aluminum

: 160 mm 160 mm
silicate boards

Aluminum
silicate boards

Aluminum
silicate
boards

Second
Layer:
123 mm

Dolomite bricks

Dolomite
bricks

Second
Layer: 123
mm

Material as
per drawing

Dolomite
bricks

Second Pass:
Second pass in let:
Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as per
site

Equivalen
t material

60 mm

60 mm

wear resistant
plastic
refractory

wear resistant
plastic refractory

Phoscast
60

Header Seal boxes:

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as per
site

Equivalen
t material

150 mm

150 mm

High strength
castable
refractory

Aluminum bubble LC-45 /

ball
White Heat
-K

Manual door & Soot blower seal boxes:

Thk (As
per
drawing
)

Thk (As
per site)

100 mm

100 mm

Manual door

Material as
per drawing

Light weight
heat insulated
pouring
bricks:
material

Material as per
site

Equivalen
t material

Aluminum bubble LC-45 /

ball
White Heat
-K

Thk (As
per
drawing
)

Thk (As
per site)

Material as
per drawing

Material as per
site

Equivalen
t material

100 mm

100 mm

Heavy high
alumina
castable

Hyper cast - 80

LC-80

fractory material mixing procedure:

Sl.N
O

Material
Description

Light Weight Heat

Insulating Pouring
Material (50Kg Bag)

High Strength Wear

Resisting Material
(50Kg Bag)

Light Weight
Brick(Insulation
Brick)

Additive

Water Qty
Remarks

CA-50-G6
(17.5
kg/Bag)

20 -22
Liters

CA-70
( 3.5kgs/Ba
g)

3.5 Liters

Equal
Slurry
amount of
(50kg/Bag)
water

Wear Resistant Brick Wear

Resistant
Mortor
(50kg/Bag)

Heavy High Alumina

Equal
amount of
Binder(Wear
Resistant
Binder)

shutter to be
removed after 12
hours of application
Soak 12 Hrs Before
Use

Sl.N
O
6

1
2
3

Material
Description
Middle Weight
Shaped Material
Wear Resisting
castable Refractory

Middle Weight Heat

Insulated pouring
material

Additiv Water Qty

e
CA-50-G6
( 8.75 kgs
)
CA70(1kg)

Remarks

5-7 Liters

Wear Resistant
Binder(2.5 kgs
premix time
and 2.5 kgs at
the time of
mixing)

Soak 12 Hrs
Before Use by
mixing 2.5 liters
of binder

CA-50-G6
( 8.75 5-7 Liters
kgs )

INDIAN REFRACTORY PRODUCTS

5.375 kgs
Phoscast-60
1.75- 2
Binder(10.75%)
liters(3.5-4%)
(or)
3350 ml
Hypercast-80(LC-80)
2.87
Liters(5.75%)
Insulcast-900

Sl.N
O

Material
Description

Accomen BS-2

Accoplast - 80

Additive
0.1% - 0.2%
Nil

Water
Qty
5%
Nil

Shutter to be
removed 12 Hrs.
Pneumatic hammer
required

Plastic Crete 90D

Remarks

Insulcast - 1100

25 Liter

PRECAUTIONS

Expiry period.
Proper storage.
Proper equipment for mixing and application/cleanliness of mixtures.
Measuring/batching tools/equipment.
Mixing procedure.
Good quality of water.
Adding additives as per OEM recommendation.
Fixing anchors as per drawing and quality of welding.
Bituminous paint on anchors or PVC caps.
Cleanly ness of area where the lining to be applied.
Proper shuttering.
Expansion gaps with suitable materials.
Proper application method i.e. vibration during pouring or casting, shuttering
supports, dismantling procedure.
Proper dry out as per OEM recommendation.