Case Study #4 - Xcell Mechanical Systems

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XCELL BOILER ROOM CASE STUDIES

Case Study #4

Project Installation: Caradco; Rantoul, Illinois

System Design: XCELL Mechanical Systems

System Installation: XCELL Mechanical Systems

Boiler Modifications: Ceramic Fireside Insulation

The Client

Caradco, is a manufacturer of windows and related products and is located in Rantoul, Illinios. This is a High-Tech woodworks manufacturing facility which requires high pressure steam for various processes throughout the plant.

The Problem

A 3-pass dry-back boiler with rear turn-around refractory which has deteriorated to a point
of non-repair
Wide, seasonal load swings, which created tremendous boiler and refractory stresses
On-off cycling which increases refractory expansion and contraction, and reduces refractory
life
Frequent refractory patching which is not a long term remedy to the crumbling and cracking

The Caradco Company's steam requirements are fulfilled by a 400 H.P. Superior scotch type boiler. This particular unit is a 3-pass, dry-back design, which features the one piece davit hinged door and a pass dividing bridge. Both of which are cast refractory as original equipment from the factory. As a result of the varying load conditions and on-off firing, the refractory tends to be exposed to a fairly harsh operating environment.

Once the refractory begins cracking as a result of the constant expansion and contraction, the effort to repair or stabilize the damage becomes futile. Eventually, the continual affects of the wearing process overcome the attempts at repair or stabilization, the result of which is to replace the entire door refractory.

XCELL BOILER ROOM SOLUTION

Ceramic Dry-back Conversion

The conventional first pass turn-around refractory was removed in its entirety. The fasteners were removed as well as the divider and door gasketing. The rear door and turnaround chamber were fitted with ceramic modules, which have a higher R-value than conventional refractory and are also far more forgiving when under the constant stress of load changes and on-off cycling.

The ceramic material, which has the quality of being a fiber based material, rather than a monolithic refractory structure, will not crack, gouge, spall or crumble. The side wall modules are fitted with an extra layer of ceramic gasket material which creates a wider sealing surface than the original conventional rope gasket. Rear door surface temperatures and the resultant heat loss are reduced as a result of the higher R-valued material.

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Xcell Mechanical Systems 30068 Route 9 Mackinaw, IL (309) 359-3084

Commercial heating and air conditioning specialist serving central Illinois