Document xz2qB4bJvYRjEXnMbMK60oB0G

ISSUED BY PLIBRICO BOILER REFRACTORY SALES DIVISION May 12, 1954 scwroac mw Sine* Flibrleo (tin work today Involves getting Into May markets, it la possible that May of ua have been giving back tut to the boliar Mrkat. But tba fact la that ovaryona does a alaaabla voIum of bualaaaa la tha hollar aaskat, aad that thia aarkac atill represents our largaat voIum of bualaaaa. So It daaarvaa more actaacloo froa all .. ouraalvaa laeludad. Aad ao ua ara Introducing thia new bullatla that will com to you periodically, bringing you neve of abac1 a taking place around the country la thia phaae of our work. At thia tiM of the year you should be laying the ground work for your hollar refractory aalaa during the mmit. Salas calls on all of your cuatOMrs aad prospects now will lay the ground work so you caa secure the largest share of the rafractory repair. Ask to inspect the furnaces aad set up your dates for inspection. Offer your good services aad Plibrlco construction to do the repair work. Sell your cuatOMrs again, aad go after aad sell the prospect when you have not sold. Recently we had aa example of the importance of following up a Plibrlco material order to a customer who had not bought for a long ties. The fellow up developed the Mtarlal order into a labor contract too and nore than doubled the original order for Mtarlal a. The job finally ended up with 13,000 lba. of Plibrlco Super and a alee labor profit* follow up all orders for Mtarlala to your prospects aad customer. Their Mtarlal only orders are "door openers" you earn capitalise on. Mover taka it for grsated they won't need your installation service or additional Mtarlala. Why let someone else Install the jobt Boiler setting repair work aad new Plibrlco settings still ara being done everywhere. Look at these] Kroger Company, Marion, Indiana Santa Fe Kailroad, Argentine, Kansas Delaware Corp., Littleton, Colorado $3,383.00 (Kepalr) 1,498.14 (Kepalr) 1,783.90 (Mew Firebox boilers) BOILER SETTING BRIERS (Contd.) -2 - May 12, 1958 Pec Milk Co., Greenville, Tennessee A. C. Lawrence Leather Co., Peabody, Maas. N. Y. Central R. R., Detroit, Michigan The Borden Co., Madison, Wisconsin $6,314.41 (Repair) 7.500.00 (Repair & Convert) 2,065.40 (Repair) 3.386.00 (Repair) Continental Can Co., Haverhill, Mass. 1,946.29 (Repair) Producers Assoc, of San Antonio, San Antonio,- 2,629.63 Qtev Setting) Texas Blackstone Hotel, Omaha, Nebraska 4,852.03 (Reset Boiler) Not all these customers walked in and handed the Pllbrico salesman an order. They vers sold Pllbrico before, were kept sold between orders and than were sold again on Pllbrico. We know that knowledge is the firm foundation on which successful Pllbrico sales rest. The top-notch Pllbrico salesman knows it. No one, but no one, knows mors about his customers, his prospects, bis territory, his products than he does. Again, nothing is taken for granted. Circulate (Now) in *58 and secure the business we all want. PI W1TH PLIBRICO YOU INJOY ALL THISI AOVANTACIS --ssar??- MONOLITHIC CONSTRUCTION prsvsnn dvir ittpg; . . . tittndt isrvic* /if* Plibrico linings are one-piece. uninterrupted countless joints. There are no such trouble spots to work open, permitting dust penetration and seepage to hasten failure. Bv overcoming the bj>ic cause ot failure. a monolithic Plibrico lining JV. vures less trequent repairs, reduced down-time' POSITIVE ANCHORAGE retards bulging . . . simplifies repairs Durability that can't be equalled b> tire "riels con struction stems from the positive, permanent an chorage- which holds a Plibrico lining securelv :n place vet allows free movement under the forces of expansion and contraction. Where height war rants. Taperlok supports sectionalize the lining, transferring each section's load to the supporting structure. Walt anchors, arch hangers and sectional supports are available in types to meet any operating condition. Anchorage and sectionalizmg stmplifv repairs- too. economically localizing replacement to the gouged or damaged section only. FULL SELECTION OF PRODUCTS a provide* thg "right" ana far year job . . . tliminmtas spaeiai shape* Plibrico products include a full line of plastics and castables. These quality products cover a broad range of temperature and operating conditions. You'll find exactly what you need, tar severe or average duty, for resistance to abrasion. vibration. or thermal shock. Anil vou don't base :o or stockpile, costly, tricks-fitting special tor Pltbrtco products conform to the most ..nii'iiai contours PRACTICAL ENGINEERING ' do your planning far you . . . bluopnntt ovary dolail It sou -aant to benefit trom the mans advantages ot a P'.ibrtco lining, sou needn t worry about sshich product to ase. or about the retractors design. Your ioc.il Plibrico distributor is eminently qualified to make recommendations. Behind him are the capable ser'ices and valuable experience ot our Engineering Department. Thes have dealt with virtually even ts pe ot heat enclosure as these pages show. They II -luoprint complete retractors- plans tor you. it you desire. INSTALLATION SERVICE provides (omploto service . . . undivided rospontibility It takes carerul. competent installers to bring out all the advantages or quality products and skilled engineering. That's why your Plibrico distributor maintains a trained installation crew . . ."handy and reads-, incidentally, it' ever you face an emergency.; In this way. he's ~,KL* Ynrty-.cnagfeg*.. service, service that-- beginif wrtfi^fetiai planning.- follows through to completed installation. And you enios the added advantage or dealing with a single supplier bearing tuil job responsibility. THIS LINING HAS OIIP STRENGTH' Here are rot. ."ferent views or one Allis Chuim-rs rirtng hood. one or tour sucn nooux lined a.in P'.ibrico products tor a maior cement producer Immediately apparent is the one-piece, monolithic construction that provides complete freedom :rom the joints so prevalent in ordmars tire arick con struction. Since the lining is monolithic, since there are no joints to open, the ever present dust :s pre sented from getting between the lining and the steel casing. Thus the single greatest cause ot lining tailure. and consequent maintenance expense, is completely eliminated. You'll notice, too. from the illustrations how readily ail contours have been tormed without tne use of a single special shape. Look at the tiring hood arch, the burner and inspection openings, the flared doors. Compare the simplicity and solidarity of Plibneo construction to the complexity of a lining formed with costly shapes. This monolithic lining was constructed w.th Plibneo Super Air-Bond. one of our air-setting plastics. This grade is specifically formulated tor severe combustion conditions. The air setting property offers a highly desirable advantage ... it gives the lining "deep-strength". This means that clear out to the cold face it's much stronger, pos sessing a mechanical strength that develops im mediately and uniformly right through the entire lining thickness. As with all Plibrico linings, it's securely anchored, with our patented Rexo-Anchors firmly embedded in the lining to act as "shock-absorbers'', relieving the stresses and strains of expansion and contraction, and overcoming the problems caused by vibration. At Ml yM in rti I tK* wirt* ih diAfctr rtu*t <*! !* Nr tkvMty Hi* iMggiN <** # rtt* cvrvft M tufa 4 From Inquiry to Instoilation . .. JUST FIVE DAYS! service .* more (han a word to vour Plibrieo -titer much more. Here' .1 tvpical c.i-c to .:u'tr..:e `fie point. On .1 Tuc'duv our Pubrtco .t.-tri.-uter .n 4 midwcstcrn town received word trom .1 cement pl.mt m .mother town th.it thev reemreu 1 complete lining tor .. tiring hood. In rapid orcer followed ,n inspection. lavouts. .rnj estimates. Materials .md ei^uipment were moved to the plant, r.-.uned installers went to wont on Thursdav and the roilowine Saturday atternoon the kiln was on the line. V' slapdash 10b either as you ean see trom the accompanvmg photo taken just as installation w.i-, eompleted in aeeordanee with the sketch below. Plibrieo Jointless Firebrick as installed in the hood above is pounded solidly into place. As installation progresses. anchors attached to hooks fastened to the easing are embedded in the re fractory. The surrace is trimmed smooth and con trolling expansion joints are cut into the surface. Note otfset in lining to protect kiln nose castings. INSULATION CUTS HE"aT LOSS~48fc " ..provides cooler, safer working conditions Notice in the print ot the hood at right that insulation is provided between the refractory lining and the easing. That insulation reduces the heat passing through the hood by 48^. making the cold race just twice as cool. Men working on the burner door are cooler, safer. and can work more efficiently. The chart below illustrates the cold face temperature difference between a tire brick lining, a Plibrieo lin ing that is insulated and one that is not flUINCX 2AQ0*P HOT FAC! PLASTIC 3400* P HOT FACS BLOCK INSULATIOM feASTIC 380* P COLO FACS 4S0*P COUJ FAC* 7# - * 3400* F '* * *( HOT FACt * '** . , era Hth iy*ea 4 4 ilM MM * fee hat feu Mm F* fe* aatd feu immm utfea m fea*w fe f* fel 4 fe M4u uea> lafc- aafe4 ha S4 4h* F. Whh 4 V* a# I 1 k aaafer, hafea aafe 4H fee. F. 4 r 4 FWa afe t* at Ufe hiiiltn. fea a4 fen Mae fc- aa4r IN 4a*. F. Man Iw h ai h> 4T- 5 HSftS'S VISUAL PROOF . . . anchored Plibrico linings simplify repairs You can ->ee ror yourself the effectiveness of Plibrico's anchored construction by taking a close look at the lining in the firing hood at the right. Notice the much whiter portion along the sidewalls and on up the near edge ot the arch. That part has seen service --was. in fact, put in as a repair to a tormer lining. Naturally it was anchored to resist bulging and offset vibration. Then when it became necessary to repair the rest of the lining. Plibrico was chosen on its record. Because of the positive anchorage, it was easy to lease the older sectiotv of'Plibrico in place, even when the "key" was removed. And it was equally easy to follow the irregular lines of that old portion when installing the new Plibrico Super since this plastic refractory can be formed to any contour. Speaking ot contours, see how the arch is stream lined. curving trom back to front to provide a smootfl rtow for hot air recovered from the cooler. The off set hood, smaller photo, further typifies Plibrico workmanship at this same plant. EVERY HOOD A PLIBRICO HOOO . . . this ona, plus six othars It all began early in 1956 with the installation of anchored, dust-tight monolithic Plibrico linings in three ot the plant s seven firing hoods. As replacement linings became necessary, three more firing hoods were convened to monolithic Plibnco construction. Management's faith in this type of construction proved sound when tive years atter the original installation, inspection revealed that two of the hood linings were still m evcellent condition and the third was in good condition. Because or this service record, the seventh hood was also Plibrico lined, (t pays. l*#M tank cm qvickiy can-- Jtata* fcikrt, start rtw pr* jwiicn, bctaf m cscHy <*{* repair* TROURLB "SHOOTING" RISTORKS HOODS PAST ~ . . . adds months more equipment service life When hood brick work loose, when had -paiU ,s;. cur. when sections are eroded, therev a quick ,.nj simple was to restore sour lining and prevent a comiv maior repair, an untimely production thutdow n. You simply^shoot-" right over the existing lining with one or oufpneumatically applied servicing miw' The accompanvtng illustrations show sou how attc.-mei> this tirst aid treatment works. Utilizing P!isu\? Gun Mis ag. this plant s mainte nance superintendent round that he was able to 'o.-k in loose brick, to tighten up the entire lining and con tinue operating. And he did not have to shut the equipmcnt down for long since Plisui can be applied to hot linings as well as cold. Plistis Gun Mis ag shoots well with either wet or dry gun equipment, has excellent bonding character istics and is highlv resistant to abrasion. Badlv spailed or eroded areas can be restored to (heir original lining thickness. You can stock this unusually serviceable retractors indefinitely, have it on hand tor any emergenev Or. use it tor a continuing program of preventative main tenance as the plant pictured now does. After l't aMMita *44*4 www wait i*M 'riellirtif ef Owt Mia at. Hi h**4 wt vi*4 at amt. Gaa Mia * caa M elia4 W Mt taU liaana. 7 . . . and what a difference! Why is Plibrico construction superior ;o oro.n..-. tire brick.' See tor yourself. These photoer-pns :.-;i ;he story more pouertully. more con'incm-clv man mere words could ever do. E'en a casual dunce ihosvs the vast difference, the clear vupenontv ot monolithic Plibrico construction. At the far lett is a view ot a clinker cooler >.oewall taken at the cool end just anove me erases See how the wall is bulged, how gaps have opened, and individual brick are working loose. Oust rus eaviv gotten behind this lining to exert pressure and hasten tailure. Vibration has added its effect. All because ot those troublesome joints and the lack ot effective anchorage. But see this same area in another cooler. The service pertod is comparable and there the compari son ends. Lined with Plicast. this one has no gaping joints, no fat bulges. That's the beautv -- and the economy -- of Plibrico s monolithic anchored construction. THIS ROOF IS INDEPENDENT . . . needs no sidewall support How can practical engineering be valuable? Here's a perfect example -- one that demonstrates the economies which thoughtful engineering can achieve. The slanted roof in the cooler pictured requires no support from the refractory sidewalls; it's totally independent. You can see this quite clearly in the lower view. Notice the slight gap at the right where the sidewall and roof meet, a gap which, incidentally, closes when the unit's m servtce. What's the purpose? Suppose that it were necessary to replace a sidewall. If the roof were supported by that wail, down it. too. would come. Up would go repair costs as well as the production time lost. To eliminate this needless waste. Plibrico construc tion calls for the Plicast Tuff-Mix roof to be sup ported throughout its length and width by arch hangers suspended from permanent steelwork above. This, in turn, is supported at the sides by simple exterior steel. s . . . biend varying grades of Plieasi Here i .1 hne example to illustrate the effectiveness *.ii ...n -e u-hievcd b\ combining varying grades ,w i*!.e..'t e..'t.i'le retractorv. This Fuller cooler. and ..iioiner .ike t at the Some plant, cmplovs both Plic..st Turf-Mix and Pltcast 15. Tuif-Miv .1 used tor the entire root and tor the ..ide-v.ills .n the hotter rone. It combines two val,i.ipie properties which nuke it ideal tor this service. F-r-t. esccilent abrasion resistance and second, e\.crtionailv hi-an strength, uniform through a wide 'cmperaiure range. The Turf-Mix root is suspended trom stainless allov hangers emoedded in the retractorv'. In the close-up ot this root, lower right, notice the onepiece construction, the treedom trom trouble pro ducing :oints. There are no gaps through which air can infiltrate and reduce efficiency. Similarlv. in the close-up or the bullnose. see the smooth contour so easilv tormed with Plicast ... no costly special shapes here. In tact, counting the few inexpensive structural steel pieces, the anchors and the one-piece BLEND EFFICIENCY WITH ECONOMY 1 ! lining, there construction. For economy, with no reduction in efficiency. Plicast 15 lines the sidewalls in the cool end. No need tor a more expensive grade capable of stand ing temperatures never reached. Instead Plicast 15. designed tor intermediate duty, provides all the pro tection required with consequent savings. It. too. ;s positivelv anchored, impervious to dust penetration. 9 ttm It vlw (MUitf * mthf kilnMia W. Sm w*ar rmd*d Matt, rM, Mm ImIIiwm Iwm4 -x :r?:i'i r V , > - < . . . jam* efficiency at lowtr cost In this clinker cooler, total wall thickness has been reduced one-third ... the usual 13>: inches have been cut to 9 inches which in cludes 2 inches ot block insulation. That means using 6' c inches less ot retractors-, resulting, as sou can well appreciate, m a supstantui reduction in overall cast. Yet equally important is the tact that this reduction is achieved without reducing <tf|. ciency in the least. Greater efficiency is main tained through using the block insulation. Your men benetit from cooler working conditions, too. You can see how easily this wall thickness was achieved in the accompanying photos. No changes were required m the unit's basic con struction: it was only necessary to set the wall back, providing a euro above the grates as shown. The inset view gives a clear picture ofthe reduced thickness and shows, too. how nor mal thickness is resumed behind the impact plates. PUBRICO EXTERIORS BETTER, TOO Putting a durable lining in a cooler is one thing . . . but Plibrico pays equal attention to the extetior. Here's a case in point. While in stalling the lining at the left, see how Plibrico constructs the exterior. To the basic steel work of this Allis-Chalmers cooler a steel cas ing has been added, together with intermediate channels. Permanent, and re-usable, the entire structure is more durable, gives sounder back ing to the lining. Insulation, placed between the refractory and the steel whtrt it btlonfj. gives necessary protecuon. keeps extenor tem peratures well in bounds. 10 SCCTIOM . . overcome* installation problems Here s .1 picture showing part of the chain section in .1 n steal kiln. A >ou iee. the chains here are secured to lues Perhaps vou niav he more tanuliar vwith chains .ocurevJ bv retainer rings. Whatever the tvpe ot chain .upport. retractors installation can pose a problem unless sou pour the lining with Plicast. Installing a sound, tight lining in the chain section with brick demands time-consuming, painstaking cutting and luting that is expensive and unnecessary. Pouring Plicast. however, eliminates this installation Jitncultv. tor Plicast readily contorms to any contour, tornung a smooth, tight monolithic lining. For this serv ice. where the retractors- must withstand the mechanical abuse or the chains. Plicast is available in a choice of grades especially tormulated tor resistance to abrasion. And. remember, a Plicast lining offers sou positive an chorage too. . . . with Plicast construction Pictured here is a tvpical dust chamber as constructed with Plicast castable refractory. Unlike an ordinary tire brick lining, there are no joints here. The monolithic, gap-tree surrace prevents dust from penetrating and collecting behind the lining, thus prevents it from caus ing lining failure and or cracking the outer wall. For .m eveeilent comparison, see the inset view at right... the Plicast wail is straight while the brick wall is obviouslv bulced. Another aovantage ot using Plicast is that grades can be varied and combined to meet individual conditions. For example. Totr-Mi\ used on the wall opposite the Min end resists the abrasion encountered. For the indtpendentlx .uxpended root. Tutt-Lite keeps weight down, keeps the steelwork cool, and is amply abrasion resistant. The balance will Jepend upon service temperatures or .irr.ision seventy In j Florida citrus plant, rive Indiana dryer turnacev designed by Williams Bros, & Miller were turnisrted to deliver ample heat to each evaporate utu-i lbs. ot water per hour from an .nput ot 13.000 lbs. of citrus pulp con taining moisture . . . delivering 39:0 lbs. ot product with S'-; moisture. Complete monolithic Plibrico linings were installed in all rive furnaces, identical to the one illustrated at the rtaht. See the unusual tiring head with the numer ous tempering air inlets. Consider how many special shapes would be required to substitute for. but not duplicate, this lining. It couldn't be duplicated, for Plibrico provides an anchored monolithic lining tree from the joints so ad versely affected by vibration. See how Pli brico conforms easily and smoothly to the many contours involved. Plibrieo Super Air-Bond was used in the tiring head and the hotter end. Formulatedfoc resistance to thermal shock. Plibrico Super effectively combats spalling, provides line service under severe conditions. The balance ot the lining is Plibrico Standard Air-Bond, ideal for average conditions. Both materials have air-setting properties. After four seasons of service--7 months per season--all 5 furnaces were inspected. The total bill for repairs, including material and labor, came to S79.23 ... an average of only 57c per month per furnace. That's what we mean by durability and low maintenance. ... typical of your Plibrico distributor Here's another cylindrical drier furnace ot the same type as installed :or another jr.in-zc Iuice concentrate plant. Shown utter a tull vear of service, it's a line example ot the .alihra or work you can expect when >our retactorv worv, :s handled by your local Plibrico distributor and his expert installation crew. You'll agree, won't you. that here is a challenging job' How well that challenge has been met! How much more difficult and so much more expensive would have been the installation ot special shapes to form all those tempering air inlets. And the result would have been a maze of joints subject to the effects of vibration, instead, the Plibrico lining so skillfully in stalled by expert craftsmen is unmterupted bv such joints. Round, oval, or oblong ... ail openinp are easily tormed with Plibrico. plastic and readily workable. While fine materials and capable installation play their part, the lasting qualities of a Plibrico lining can be attributed tn no small measure to the intelligent use and placement of anchors and seats. How many anchors to use? How many seats? Where to place them.' Success or failure rests upon the correct answers . . . and Plibrico has them. Anchors are spaced at proper intervals to provide maxi mum holding power throughout the lining. Seat locations are carefully calculated to trans fer part of the refractory load to the outer shell. With the entire lining securely held, repain can be made to any one section without disturbing the rest. IfcOC* Mll/tAllOM super Ain ae uiaico ita*o**o Aia ao*-- . * V *. PLIBRICO LINING ARRANGEMENT as applied to dryer him* aces shewn en this and tha preceding page. 13 Two oil-fired Allis Chalmers dryer furnace* produce two million tons of dry rock annually for this phosphate processor. The local Plibrico distribu tor began maintaining one furnace in 1949. Plibrico products proved so effective that when the second furnace was added later, it was provided with a complete monolithic Plibrico lining. Measuring 13' inside diameter by 37' long, the second furnace, shown above, combines Plibrico Super Air-Bond and Plibrico Standard Air-Bond. Super Air-Bond is used in the hot end to effectively withstand the severe temperatures encountered. Standard Air-Bond easily meets the conditions in the cooler end. In both materials, the Air-Bond feature makes them air setting, develops much greater strength clear through the entire lining thickness. Due to the fine service of the linings in the dryers, Plibrico products were chosen when this firm built the electric phosphorus furnace seen in the photo at right. To form the lining, Plicast Tuff-Mix was selected for its uniformly high strength and it* ability to resist abrasion. That it proved effective is attested by the fact that when constructing a second similar furnace. Tuff-Mix was again the choice. Try Plibnco products, and you'll chooee them again, too. tltcnc *** fwmtt nfM it tf hwt ll4 wit* 4*rcfel. *tlM 'ttiitwn fflcau TwS-MIc. ** it, wtt*. ft* rt Snitfcirtf t* mi, pttct ctvt* fhrtvy* w*i<* tltortStt trtm f* fwrntt,. Skttch thtwt Sttadt. GAS FIRED DRIER HEART OF GRANULATING PROCESS ... and it's PUbrico lined munrated above are three views of a pa Sackett dryer furnace which ptayt a. ley ndr.'ia^..;,:, producing granulated' rerallner^PolStaot ; \",. enter the rotary dryer lacaeoenffifecc a*d; -- " " is removed at the ate of^XD-jjSk If*J proersa. pellets. tt*`u '" ~ dec- The eyitodrie^AnacK ] loaf and "Hf ,S dtafeeter^"'' ^ ~ ` * * the pbotoe-above- asd'thef entire ftirnece-lhaB^ja. if; even around tSk temperi&gj; a 9* thkknwetod grade that withauadt stf'entge setting feartse provides throughout the liaised-'.ii If* anchored to localize future, re too. by seats, which tratkfe^. furnace ibeQ. thereby the refractory. The is lined ae per the Bond, and here, too* v;w O' lft `99k* *rt wll wftilo noof to it ,* *** t tNroOf trefroiKo to rho front*"** chomtor on* torory dry*# >*# no**io<# lmn* comrrvction tht liMindM on* tittni lHooot. All ctAiivn on* tttniMfi or* ootily formo* wtfc Plikriro. Al r.fltt or* tntonor o* iwl of tnttlitr FSockorf Otytf in onothor or, tkowtny thof thillo* workmongni# ig ytwn *moro*or row oro, for thoro t O Plifengo dig* tfib tolohono. PLIBRICO LINING IN ALPALPA DRYER 3e!ow are wo ..-ers located at the Canadian alralta dehydrating c.-mt ot an internationally known pioneer in the teed and cereal business. The dryer turnace at the right features a monolithic Plibrico lining which has required no service work since its initial installation ... a continuous span of close to three years. One year after this dryer was built, an identical furnace was installed on the dryer at the far left, replacing an older furnace. The new furnace was also lined with Plibrico and it. too. has been in constant service ever since without need of repair. Notice how the near end of the furnace is larger in diameter thaa that section extending to the rotary dryer. The near end slips over the far end like a sleeve, covering it for a distance of 7*. with a clearance all around of 6" to form the air intake. Both sections are lined with Plibrico Stand* ard. the grade for long service . . . obviously . . . under ail average combustion conditions. Overall length of these gas fired furnaces is 19'S*. and temperatures run to 1600 deg. In any process, needless shutdowns are expensive: repair costs are the insult added to the costly injury of lost production. But refractory repairs are far less trequent when you use Plibrico products, as is evidenced by the performance of Plibrico linings at this plant. 16 "EXCELLENT RECORD... SPEAKS WEU FOR DESIGN AND CONSTRUCTION..." Such were the comments trom the wee prcvwicnt ot one ot.the world'v largest brtclc plants. writing after the Ur%er furnace designed and constructed ?!i. brteo had given a1: vears of constant lerwee *.:> onlv a minimum ot maintenance. When huilt. this furnace was the largest hot ^ir turnace in the world outside ot the heat treating riciu. capable ot drying 600.000 brick per JuV The upper photo gives you an idea of us mze. Shown is 'he primary combustion chamber ... the burner cone . . . and a part ot the >econdarv- .vmruwvn chamber designed to develop 2000 deg. F. The primary combustion chamber -.s the onlv area that needed repairs as the lower photo ciearlv shows. Plibrico Super is used here to meet t.ne severe conditions. A large battle wall tactng tne burners, but not shown, is faced with P'.tbrco Standard. Plicast 17. a first quality castable tor service temperatures up to 2500 deg., forms the lining m the secondary combustion chamber. The roof .s of suspended construction, and the side walls are air cooled to lengthen service life. Economical and serviceable Plicast 15 forms the remainder of the lining in the mixing and tempering chamber. This installation demonstrates several advantages of dealing with Plibrteo . . . namely our abiluv to engineer, to design, to install, and to provide ,,nd coordinate the use of various types and grades of refractory for maximum effectiveness and economy. To sum it up with another quote. . . satisfactory in every respect." Features a UNIQUE MUFFLE ARCH The picture at the left is an interior view of the furnace oa -the opposite page. That doghouse or muffle arch, that lining within a lining, is trulv unique and certainly- could not be duplicated by ordinary Are brick 'construction. From the exterior view you can see bow air is brought into the furnace through the large damper. Then in the interior view, see another port at the upper left. Notice, too. the three openings in the muffle arch which would indeed complicate the construction were this not one-piece Plibrico con struction. Since it is Plibrico construction, this lining requires no special shapes, and as you see, it has oo trouble causing joints. Plibrico Super is used for the muffle arch where the concentrated beat makes conditions severe, while Plibrico Standard forms the remainder of the lining. For any unusual construction, consider Plibrico first. TIN YKAftS OP SKRVICK . . . and no repairs neadad One decade after installation the Plibrico setting tor the coal-tired alfalfa dryer illustrated here was still m good condition. And what's mors not a single repair had been made in that span of years. The entire firebox is lined with Plibrico as detailed in the print at the right. In the photo above you see the front wall while to the right you're looking back across the bridgewall at the inclined arch and sidewall. Openings along the arch admit air. Notice in the pnnt the wall anchorage and arch suspension, keys to Plibnco's long service. Beyond the firebox, in the drying tunnel. Plicast is used. The stack, too. has a Plicast lining, atr-cooled to retard thermal shock. HUMUS DRYER FEATURES PLIBRICO LINING Her* is aa indirect fired dryer used in processing humus, the organic matter of the soil and a component of some fertilizers. This dryer, built by Perkins Dryer Company, handles 6000 lbs. of humus per hour. 24 hours a day. Input material contains 50 to SO% moisture, and output is rigidly controlled to 12% moisture. Hot gases generated in the combustion chamber. lower left of print, temper as they enter the dryer chamber, upper right, through which the dryer passes (see photo). The gases circle and enter the dryer. Plibrico Standard, the original plastic, forms the anchored lining in the combustion chamber, while various grades of Plicast are used in the dryer enclosure as the pnnt shows. ia uamco uaaico su*t* am ono -3P THIS FURNACE IS DIFFERENT . . still th lining's Plibrieo Dryer furnaces may differ in design, hut monolithic Plibnco linings are applicable to all types. Here, for instance, is a dryer de signed by E. Renneburg & Sons Co. as used by a major producer in the held of chemicals. The distinctive feature of this furnace is the method by which tempering air is introduced. In the print at the left, notice the two bridgewalls in the lower left corner. Volumes ot tempering air are brought in behind each of these,by natural daft. In the caster photo 'above you can see how easilyahese. waits havebeen constructed with Plibnco. The grade used for the chamber behind the first wail ;s Standard Air-Bond while Super Air-Bond is used in the pnmary combustion area tor the walls and the arch. Notice in the upper right photo the air pons just beneath the arch. These were introduced by Plibnco to provide a protective air bath for the arch, thereby increasing the service life. This serves as one more illustration of the practical engineenng that goes into every Plibrieo insullauon ... for the customers benefit. AM drama wiwdlw *Wtt Pflbrics nWnMl and daiftmad |M) at ffiM la *yat Aiabir . . . IW.U Wt.l|M imatadnQ |wii far dm daar . . . maam 17 far dm Invar dda Wit . . . HTwil Vari*n and fat and Wit. . . lamaal ntaart IS fat dm #>< and mail by M iw--lm*--. Mata ham MWrtw* tatii ata tamdtnad and aaad fm |nnr t*Maarr and lew im anatadaa. 1* CUT INSTALLATION COSTS 27.3%... CUT DOWNTIM1 BY IS DAYS Repairs to your lightweight aggregate kiln lining can be made economically. Ami these repairs can be made quickly too. getting your kiln back in production without neediest delay by using Plicast casubie refractories. The company that operates the kiln pictured here definitely cut their insxallatton time and costs. Their initial experience with our castables involved a test section lined with Plicast K-L MuC At the same time, kiln block were placed on both sides of the K-L Mix. After four months, the kiln block to the cool side of the K-L Mix required replacement, (n just three more months, the kiln block to the hot side of the K-L Mix were also badly worn and had to be replaced while the original K-L Mix had worn less than one-sixth of its initial thickness, clear proof of its excellent resistance to abrasion. 20 Naturally, when the luln was later reiined completely, our Plicast K-L Mix was again selected, but for an expanded area. Beside it. where abrasion was not quite as severe, was added another grade of castable. Plicast Tuff-Mix. This blend of grades achieved an initial economy while providing the proper degree of abrasion resistance each zone required. Both Plicast materials were poured in place, flowing readily to conform to the contour of the steel shell even where (he kiln was out of round. And the monolithic lining these castables formed is positively anchored in place. In completely relining this kiln, the company was able to accurately evaluate both time and cost (actors of the Plicast installation. Here is what their comparisons revealed. Consider first the speed. The enure Plicast installation, including anchorage, forming, placement and curing took WitfiMi Hi* fw (v* t**f ktim wifkmM i<i#*ft ftmi p#i*r f* **fMf iH* w****tttHig Pfkatt Iwiwif. Two grades of Plicast castable refractory form monolithic lining in calcining zone. just eight Jays. That represent*#* saving o( fifteen days as compared to the time that would have been needed for bricking the same length. Now consider the economy. The complete, in-place cost for the Plicast installation turned out to be 27.3 less than would have been spent to brick the two zones. t-'se Plicast castables in your kilns for fast, economical, and durable installations. SUSPIND YOUR OVPSUMtjKBTTL . . . benefit from the many advantages a Pfibriee monolithic sotting offers A full Plibrico kettle seniat promotes economy ia several ways . . . through simpler installation, more efficient operation, increased service life, and less costly repairs ... all explained more fully in a moment. First, it should be understood that a full setting can be applied only to a suspended kettle. Consider, though, that the cost of suspending a kettle is relatively inexpensive, and is mom than offset by the savinp to be gained. Suspension itself is a step toward economy for the kettle load ia taken off the refractory and put where it belongs, thereby reducing the possibility of failure. What about those economics? To begin with, there's the economy of a lining installed without using premium priced special shapes. Shapes aren't needed because Plibrico Joint* less Firebrick, being plastic, can readily be formed to any contour as the illustrations show. As far more efficient operation. Plibrico recom mends a two component lining as shown in the print, consisting of the proper grade of Plibrico Air-Bond backed by a layer of block This lining is thinner the three ***** available, yet provides the same efficiency while also providing mom cinwbinrino space. Service life of thn setting is increased became a Plibrico lining ia monolithic and anchored u veil as being sectionsBy supported. As tbs illustradoa on the next page show, a Plibrico lining is a angle continuous piece; unbrokcpjty the multitude of joints which am the weak spots of an ordinary K"gIn an ordinary lining; joints open and individual brick work loose, causing bulging and eventual collapse. But them am no joints in a Plibrico K'"g And for positive protection, anchors embedded in the refractory bold the lining securely in pises. The combination of Plibrico Super Air-Bond, formulated specifically for severe duty, and positive anchorage saeTOM u *ri TLS hi. _fVQC* '.WUTIW,. inwea vrmg ia sons iteea iMMjttna effectively reams the thermal shock that results from cyclic operation. Finally, when repairs am needed. they're lem cost ly since they're localized; only the damaged area need be replaced. Irregular as that area may be, plastic Plibrico conforms to its contour. The rat of the lining is bald rigidly in place by the anchors and seats. The half plan section at ths left details Plibriee construction through Um air dsaoibctioe pons of a typical orpsum kettle. You am tee hew ths eam Ay pitted iastaHatioa looks in the how up phots tt tbsr' ` * V right The sgaiieani (beams, of course; Jr fi* j- settee of special thepre, Instead you tee thrown,.. -lA continuous lining ehkh Pfibbco makes yriMe Here is truly ruharmriaF and durable cossroctSaot ' " a one-piece lining that is wcartly anchored hi ptWft ' The print it the left shoes Pttrioo'l dedga for a gypsum keuto with a ree-compoeeat Hnsnf In this particuiar part of the kettle's of 9 inches of PSfarioo Sbpcr 5 inches of block imnisrtqft in lama efficiency sad as bustioa area. The phoee at' furnace section i Slctw*4 > Hm W* n aiWiim rrs* W ***, ItM iWt rypa esm. Man** pmnntmt*r Ms rsfeMsry fs Ik* kot nS fts. !(* jsfj wk MfcsM t-i Mis sat wanty urinsl hmr dsrsSiiiiy. T\i* m is mHm mm jmmt *4 23