Material selection, design, modeling, testing and manufacturing, with one engineer as your contact.
You describe what fails and where.
Blasch engineers choose the ceramic, design the part and make it.
Engineered ceramics are ceramic and refractory components designed for one application, from its dimensions, temperatures, media and loads, instead of being picked from a standard range. At Blasch, that work runs from the first description of a failure to a part that drops into your equipment: material selection from more than 15 grades, design with CFD and FEA where the application needs it, in-house testing, near net shape casting in Albany, New York, and support at installation. A drawing is not required; dimensions and operating conditions are enough to start.
A catalogue part fits many plants a little. An engineered part fits one position in one plant, and is designed around the way the old part failed.
The most expensive part of a ceramic component is not its price but the outage it causes, so the engineering goes into the reason the old part failed.
Four parts of the work, each with its own page for the details.
The Blasch process casts complex ceramic parts near net shape, with threads, tapers and changing walls cast in.
Parts from 1 oz to 2 tons, from matchstick size to sewer pipe, and assemblies of many pieces.
CFD for flow and heat transfer, FEA for stress, and lab tests for thermal shock, abrasion and creep.
Fired shapes in place of castable and brick, set without forming, curing or dry out.
One engineer stays your contact from the first call to the outage.
Where the part sits, how it fails, how often, and the dimensions and operating conditions you have.
The engineer selects the grade, designs the part and models flow, heat or stress where the application calls for it.
The part is cast, fired and checked for dimensions, strength and thermal shock behavior.
Parts arrive ready to set, often as a drop-in for the existing system, with installation guidance for your crew.
Blasch has produced more than 110 ceramic mixes. Oxides such as alumina, mullite, zirconia composites and fused silica sit next to silicon carbides with oxide, nitride, alumina or reaction bonds, aluminum titanate and silicon nitride.
The grade follows what attacks the part. Abrasive particles call for a different ceramic than a molten alloy, a thermal shock or an alkali atmosphere. Engineered ceramic materials
Many Blasch parts are designed together with the companies that license or build the process. StaBlox orifice plans are modeled with BD Energy Systems, HexWall and VectorWall for sulfuric acid service are distributed by DuPont MECS, and CeraLoop is sold through Allied Mineral Products.
Most parts are cast and fired in Albany, New York. When another forming method suits a shape better, Blasch designs it and has it made by a vetted manufacturing partner. Quality is managed under ISO 9001:2015. Quality and certifications
Three installations where the design, not just the material, made the difference.
Two US ammonia plants
All flue gas tunnels in two reformers were replaced in summer 2018 with interlocking blocks set dry by a contractor crew without masons.
Waste heat boiler retubing
Hex head ferrules that close into one surface without castable between them shortened installation compared with round ferrules in an 859 tube boiler.
CO boiler wall
A burner wall built from precast tongue and groove shapes went in within five days, where the conventional rebuild was planned for three weeks.
No. Most inquiries arrive without one. Dimensions, photos of the failed part and the operating conditions are enough for an engineer to design the part.
Ceramic components designed and made for a specific application, as opposed to standard catalogue shapes. The material, geometry and installation are all chosen for that one duty.
Yes. Blasch regularly designs to licensor and EPC specifications and works with their process models where available.
Installation is done by your crew or refractory contractor. Blasch designs parts for simple installation and provides guidance and support on request.
Send what you know: dimensions, conditions and how it fails. A Blasch engineer takes it from there.
