Coal Gasification Power Plant

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Case Study: Dual Component Casting

From 2012 through 2014, JT Thorpe International performed significant refractory work on a grassroots 582 MW Integrated Combined Cycle Coal Gasification plant. A majority of the work was performed in the shop via form and pour. Over 2 million pounds were poured over the course of two years. This enormous dual component casting job required very tight Quality Control and complex engineered steel forms and anchor designs.

The branch connection forms required computer modelling to meet dimensional tolerances for the refractory lining thicknesses, ranging from 5” to 12” thick in each of the dual layers. Some of the pieces that were poured were 10 feet diameter and over 75 feet tall. There were dozens of individual pieces of equipment to refractory line. Some individual pieces weighed over 400 tons after refractory installation.