UHPC ThermCombi lining systems

UHPC ThermCombi lining system consists of

a highly effective insulating layer and UHPC

wear protection layer

For a cement plant in Europe, we should

create a technically optimal possibility that
a complicated hot gas line is provided with

wear protection against a very abrasive

material and at the same time the gas

temperature must not drop below 700°C /

1292°F. A similar project we had years ago

for a steel plant in Asia.

In order to meet these customer requirements,

we have chosen a UHPC ThermCombi lining

system.

We reduced the temperature for the steel

structure to 80°C / 176°F. That was no problem

with the insulation material we chose. A high

temperature resistant UHPC wear protection
layer was installed on the insulation layer.

The advantage over a traditional refractory
lining is:
 - The combination lining was about 60% lighter
      in weight than a refractory lining.
 - The total layer thickness of the combination
      lining was 400% less than that of a standard
      refractory solution.
 - This meant that the steel pipe diameter was
      much smaller than with a refractory lining
      and the supports had to carry much less weight.
 - UHPC HT wear protection can withstand

      temperatures of 1200°C / 2192°F, which was

      an additional security in this project.

 - UHPC HT wear protection is several times more
      wear-resistant than refractory concrete, which
      has resulted in a significantly longer service life

      and much less maintenance.

 

Today, the new UHPC ThermCombi systems are not only used in the steel, power plant and cement industries. The construction industry has also recognised the enormous advantages for building structures and façade constructions. It is not only the insulating properties that save energy, the significantly lower material consumption and the very light precast weight - it is especially the fire and heat resistance that makes UHPC ThermCombi building constructions very safe constructions.

 

 

UHPC Wear- and corrosion protection for all pipe dimensions

UHPC linings of all kinds of pipes inside and
out was one of our first major projects more
than 25 years ago. The pipes should be
permanently protected against wear and
corrosion with UHPC under the toughest
conditions. First of all, pipes for pneumatic
material delivery lines in the cement industry
were lined. After that, pneumatic and hydraulic
pipelines for the coal-fired power plant industry
and the steel industry were lined. Later came
the offshore industry and the wastewater
industry. We lined pipes of any diameter from
40mm / 1,57inch to 8000mm / 315inch. Here,
the geometry played no major role, so
whether Y-piece, pipe bend, reducer, etc.

The huge advantage of UHPC over all liners at
that time was the seamless lining, the flexibility
in layer thicknesses, the variations in material
quality and the very high wear and corrosion
resistance for a very long service life. Even
today, pipes are in use that were lined 25 years
ago with UHPC.
Today, new pipe systems are lined with UHPC
or existing pipe systems are repaired with UHPC
material. It makes only a very small difference
whether they are concrete or steel pipes.

We use UHPC mortar, UHPC castable and
UHPC shotcrete as lining material. UHPC
Rapid material grades are used for extremely
fast repairs.

In the offshore industry, UHPC is used both
as the inner and outer lining of pipelines.
UHPC can also be used underwater. A 15mm
or 0,6inch thick UHPC coating is waterproof
and absolutely corrosion resistant. A UHPC-
lined offshore structure no longer requires
regular corrosion protection coatings. UHPC
is used today as a material for offshore
constructions and offshore foundations
worldwide.

For some years, we use high temperature resistant
UHPC material in the steel industry. Hot gas
temperatures up to more than 1000°C / 1832°F
are no problem here. We also coat hot gas pipe
system with a combination of UHPC and high
performance insulation. This makes it possible
to dispense with stainless steel as a construction
material, which in turn reduces costs enormously.


Wastewater pipelines, storm water drains, storm
water storage systems road drainage systems,
sewage systems and culverts whether made of
steel or concrete, can be easily repaired with
UHPC. It is not necessary to clean the
construction of rust before you start with the
lining. With UHPC Shotcrete, larger pipelines
can be quickly and permanently repaired. Due
to the extremely low rebound of less than 3%,
special cleaning work in the pipeline is not
necessary.

Smaller repairs can be done quickly with UHPC
mortar or UHPC Cast. As UHPC materials
exceed the compressive strength of all standard
concretes by more than once, steel and concrete
pipelines are more resilient after a complete repair.

Advantage of UHPC 
Absolutely waterproof
Absolutely moisture resistant
Extremely corrosion resistant
Very high life expectancy
Very good resistance to a variety of chemicals
Very high strength


www.hhbc-consulting.de
info@hhbc-consulting.de 



 

UHPC in alternative and regenerative energy production

UHPC materials are used in all processes of alternative and active native energy production used as the material for foundations, as a lining-material for protection against corrosion, wear and as a construction material. Due to the diverse application possibilities and the superior properties compared to standard concrete qualities, UHPC are increasingly used in the mentioned areas. UHPC has the advantage that it can be processed just like standard concretes.

Hydroelectric power plants or storage power plants
Due to the extreme corrosion resistance of UHPC concrete constructions with a much higher reinforcement density per volume can be used. This can significantly increase the strength of the construction or the wall thicknesses or layer thicknesses can be reduced while maintaining strength.
In the right combination UHPC is very resistant to wear and cavitation.
Since UHPC already reaches 70% of its maximum nominal strength in the standard quality after 48 hours and in the special quality after only 12 hours.
UHPC is available as mortar, casting material and shotcrete material.

Tidal power plants
Some tidal power plant systems are already being used in Europe and Asia. There are now a lot of technical variations of tidal power plants for the coasts but also for directly in the sea. One thing all needs a stable seawater resistant and durable foundation.
Based on the experience gained with the foundation systems of the offshore wind power plants, high quality UHPC materials are ideally suited for this purpose. In particular, the enormous adhesive power of UHPC in anchoring and bolt system is required here. What is once shed in a UHPC foundation can no longer be removed from the foundation, even with enormous forces. Not only in this regard, UHPC is many times superior to normal standard concrete.

Biogas power plant

Biogas has been produced in many small plants in the past. There are already very large production facilities in Europe. The plants have corrosion and wear problems due to the production process. Especially wherever standard concrete was used. Here, a UHPC protective layer of a few millimeters can be used to achieve permanent corrosion protection. To achieve a very long service life, UHPC concrete should be used for the new construction.

UHPC the future competitor of steel in many applications

We know many people think UHPC is just
a concrete, possibly a special concrete and
with this concrete you do what you just do
with concrete, nothing more. People which
think in this way, should not continue to
deal with UHPC in the future and continue
to mix their old beautiful concrete.

The philosophy of hhbc-consulting is not
the simple replacement of concrete with
UHPC. That would be like replacing gravel
with diamonds.

We use UHPC in the construction industry
where it makes sense, in very specific areas
but our real competitor market in the future
is the steel market. There are a huge number
of applications where UHPC is better, more
durable, cheaper, easier and faster to
manufacture than steel.
UHPC is corrosion and wear resistant and in a HT Version also high temperature resistant (up
to more than 1000°C).


One example of many from the past years, Rolling bearing systems
A steel mill suffered damage to several rolling bearings in the area of ​​the rolling line (the area where the hot slabs are rolled at high speed and high speed to thinner plates). These rolling bearings are manufactured from a very special casting. The problem was that not enough bearing systems were available. These bearing systems are extremely expensive and have a very long delivery time.
In this case the steel plant would have had to wait more than 4 months. What would mean 4 months, the rolling mill could only be used to 30% of the capacity, a million loss.

By chance, we had heard of this problem in a
meeting for a machine floor renovation. We
looked at the drawings and specifications out
of pure interest. After a short internal
discussion, we made the following proposal
to the plant management:
We can copy the bearing completely made of UHPC. We could mix the UHPC material with graphite balls of a certain quality and size. We could achieve a high compressive strength of the material. We could process it to have similar surface roughness as the original bearing and what was extremely important we were sure to provide such a bearing to the factory in just four weeks.
We have provided the factory with the bearing systems within four weeks at one sixth of the original price. The bearings were in operation for 5 months, by 80% of the production capacity until they could be replaced with the newly made cast bearings. We have saved a lot of money for the plant with our UHPC solution.
´

UHPC - Alternative engery power plant

UHPC Ultra High Performance Concrete products used as wear and corrosion protection for all kind of alternative energy production plants.
All of our UHPC special concrete products have a minimum compressive strength of 120 MPa / 17400 psi. UHPC concrete can install on concrete and steel structures, for new constructions as well as for repairs. UHPC concrete for wear and corrosion protection can be processed as mortar, grout or shotcrete.

UHPC HT High Temperature wear and corrosion resistant material can also applied in a combination with a thin high effective insulation
material. This combination can reduce the amount
of refactory material by approx. 50%

Benefit of UHPC lining systems

 - Smooth surfaces
 - Jointless surfaces
 - Resistant to rapid temperature fluctuations
 - Temperature resistance up to 1.000°C/1832°F
 - High compressive strength
 - High wear resistant
 - Good thermal insulation
 - Flexible layer thicknesses
 - Good chemical resistant
 - Very good corrosion resistant
 - Good resistance to mechanical loads

Incineration power plant

Incineration plants have beside wear problems
also corrosion problems. Waste burning creates
a aggressive atmosphere.

Standard application:

• Ash system
• Dedusting system
• Rubbish bunker
• Pneumatic pipeline system
• Burner feeding system
• Roadway redevelopment 

Biomass power plant

Here mostly it is all kind of wood and bio waste which is used as firing material. In the complete material handling process you will find wear and corrosion.

 

 

 Biogas power plant

We offer for corrosion and wear problems in the gas production process UHPC linings for:

• Bunker
• Shredder
• Dewaster
• Material transport system
• Mixtank
• Fermentation tank
• Storage tank

www.hhbc-consulting.de
info@hhbc-consulting.de

UHPC - Wear and corrosion protection in incineration plants

In modern incineration plants today large quantities of household rubbish and industrial waste are burned for the purpose of extraction process steam and energy.

The burning of waste considerable demands on the process equipment and their construction material by the discontinuous garbage quality a very high material quality.

For some years, UHPC material has been used as wear protection with and without thermal insulation in waste incineration plants. The advantage of UHPC is the unique combination of temperature resistance, 
very good wear protection and very easy 
processing. UHPC is equally suitable for 
new constructions as well as for repair work. 
UHPC HT wear protection material can also 
be used on refractory linings in a fast-curing 
version for short-term repairs.

Benefits of UHPC lining material

• Easy installation method
• No special tools are necessary
  
• Flexible layer thickness
• Overhead installation possible
• Jointless installation
• Extreme compressive strength
• Very high wear resistant
• Very good corrosion resistant
• Very good thermal shock resistant
• Adapts each of surface geometry
• Fast curing at ambient temperature
• High temperature resistant

Lining areas

• Routes of waste collection vehicles to discharge area in the waste bunker
• Waste bunker ramps and walls
• Waste feed hopper
• Waste conveyor duct to the burner grate
• Ash handling systems
• Dedusting systems

UHPC Supervisor projects worldwide

Today we completed our 100th Supervisor project

Since the first customer request more than 20 years ago, we have meanwhile completed projects with UHPC materials in more than 35 countries around the world. We looked after offshore, corrosion, wear protection, concrete rehabilitation, architecture, hydraulic engineering, road construction, etc.
On behalf of our customers, we have carried out assembly projects, trained fitters on site, carried out complete assemblies independently, assessed damage, worked out repair solutions, etc.
Our current project was the rehabilitation of 10 km of lanes at Europe's largest flower auctioneer.

Here some impressions of our worldwide jobs

www.hhbc-consulting.de
info@hhbc-consulting.de

The future of offshore wind energy with UHPC

Monopile wind turbine designs are still the most widely used standard foundation design in many coastal areas.
Jackets, Gravity base, Tripods and Tri-piles systems are also used depending on requirements and needs.
UHPC is used in all foundation techniques.

Monopiles

UHPC grouting material is used for the connection between monopile and transition pieces.
Monopiles have been deployed with even larger turbines in even deeper waters, currently up to 41 meters. 9 diameter monopiles are now in production. We estimate that more than 2000 monopiles worldwide have been installed with UHPC grouting and transitions pieces.

Benefits

• Extremely high strength
• Very good fatigue properties
• Minimal shrinkage
• Extreme bond between UHPC grouting material and steel
• Fast setting development
• Very high inner cohesion
• No mixing with sea water
• Absolutly seawater resistant
• Very low hydration heat
• No corrosion

Jackets
Jackets are generally considered to be better than monopiles for seabeds where the substrate is poor or deeper water. So here UHPC can be used in the "transition piece" and in the lower foundation.

Gravity foundations
Are well suited for rocky sea beds. The complete foundation system can be manufactured on land and then pulled into position with a ship and then sunk. Depending on the design, the entire foundation piece can be made from UHPC

The future - with floating foundation design

This includes

• Spar
• Semi-submersible
• Barge
• Tension-leg platform

Spars
First systems are already being tested. In the near future, a wind farm with spar systems is to be built off Scotland.
These systems can reach total lengths of over 90 meters, with about 75 m of them underwater. The entire underwater area can be made of UHPC.

Semi-submersible
Similar to the Spars, the whole underwater construction can be made of UHPC.

Barge
Barge systems are actually classic pontoon systems. There are now UHPC concrete available which in addition to their high strength also swim without the large cavities inside the barge must be generated.

 

www.hhbc-consulting.de
info@hhbc-consulting.de

UHPC - Wear protection system for coal fired power plants

Large quantities of materials like hard coal,
lignite and ash are handled in a coal fired
power plant. To ensure a constant production,
most of the conveying (hydraulic or pneumatic),
storing and production equipment must lined
with wear protection products.

Based on the long experience in wear
protection system engineering for the most
of the OEMs of grinding and mill systems
like impact mills, vertical roller mills,
hammer mills etc., together with our
partner WPE DK we can offer standard and
custom made UHPC wear protection lining
systems.

We supply custom made solutions and
engineered systems like pipe components
with electrical wear control or pipe
components with a combination lining of
wear and heat reduction linings.

For circulation fluidised bed steam power
plant we engineer and install dedusting and
ash transport systems with a high quality
wear protection linings or combination
linings of wear and insulating material.

We deliver and install special custom
made wear linings for different burner systems.

We engineer and produce 
lining systems for mill suppliers like: 

Loesche            LM Verical Mill
Gebr. Pfeiffer   MPS Vertical Mill
ALSTOM         SM Mill, Raymond Roller Mill
HITACHI         Vertical Roller Mill
FLSmidth         ATOX Vertical Roller Mill

UHPC Installation areas

Cyclones                                                                        Cellular wheel sluice
NID-Systems for flue gas cleaning                                Chutes  
GSA-Systems for flue gas cleaning                               Pumps
Pneumatic transports systems                                       Ventilator housing and blades
Hydraulic transport systems                                          Coal mill
Trough chain conveyors                                                Burner systems
Submerges chain conveyors                                         Ash silo
Apron conveyors                                                           Coal bunker

 

WPE DK International

Phone: 0049 176 601 73146
E-mail: info@wpe-dk.dk
Homepage: www.wpe-dk.com

Wear Protection with UHPC wear protection concrete

UHPC is a high wear resistant ultra dense ceramic concrete (Ultra High Performance Concrete). It is a material mix of cement binder, microsilica, superplastiziser and ceramic aggregates (Quarz, Bauxite, Corundum, Silicon carbide).

The combination of high compressive strength, high dense particle packing and extrem hard aggregate, create a flexible and simple to install wear resistant material.

UHPC material can install in any thickness it is needed. It is a jointless lining and over-head-installation is not a problem.

It is produced in a mortar and in a castable material version.
No special underground treatment is required. Steel or concrete surface should be free of loose particles and free of oils and fats. For the installation of such wear protection system it is necessary to install a anchor system. As a standard we recommend follow anchor/reinforcement system:

a) Rhombic wire mesh

b) Honey- or Hexagon mesh

Two UHPC binder versions are produced, one for process 

temperature of max. 450°C/840°F (normal material quality) and 

one for high process temperature of max. 1.200°C/2190°F (high temperature quality)

Advantages

• High wear resistant
• Good impact resistant
• Extreme high compressive strength
• Good corrosion resistant
• Flexible in layer thickness
• Overhead installation is possible
• Thermo shock resistant
• Jointless lining
• Very short curing time

UHPC as a wear protection system has been used worldwide for more than 25 years in cement plants, steel plants, coal fired power plant and mines.

WPE DK International

Phone: 0049 176 601 73146
E-mail: info@wpe-dk.dk
Homepage: www.wpe-dk.com