Alkaline Hydrolysis Resistant and Durable Refractory Linings for Fired Process Heaters

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Title Alkaline Hydrolysis Resistant and Durable Refractory Linings for Fired Process Heaters
Creator Moody, K.J.
Date 2017-12-12
Description Paper from the AFRC 2017 conference titled Alkaline Hydrolysis Resistant and Durable Refractory Linings for Fired Process Heaters
Abstract Since the late 1960's there have been problems associated with rapid lining deterioration of insulating castables used in Fired Process Heaters. New ceramic compositions, using patented hydrophobic insulating aggregates, eliminate alkaline hydrolysis reactions in the refractory linings of Fired Process Heaters. This hydrophobic technology also enables these new compositions to be fired in without holds and without dryout and at rates of 200oF to 400oF in new installations and in turnarounds. ; Fired Process Heater modules often wait in storage from 12 to 18 months before erection and completion of an operable refinery - an invitation to Alkaline Hydrolysis deterioration of the insulating castable lining. Expensive dryout procedures have been the common method to partially mitigate these deteriorations. To this end, API 560 Section 11.5.1 prescribes and requires drying out the lining within 45 days of installation at temperatures of 500oF (260oC). Dryout procedures only delay the Alkaline Hydrolysis Reaction, they do not eliminate the potential reactions nestled in the matrix of the insulating castables. ; However, experience proves that too often the risk and costs of alkaline hydrolysis and related downtime is significant to Owners even with dryout. The solution is to "prevent the disease" not to "cure it". Serious gaps exist in the support provided by supplying vendors and manufacturers to avoid these problems. Until now, Owners are left without a dependable alternative or a reasonable level of accountability and have typically paid for the consequences of the problems from Alkaline Hydrolysis of shutdown and delay.; These new technologies, using patented hydrophobic insulating aggregates and high purity raw materials, are engineered to prevent the Alkaline Hydrolysis Reaction and eliminate deterioration of the lining compositions. This paper describes the new ceramic compositions using hydrophobic aggregates, the chemistry of the reactions, and rapid test methods that demonstrate how these new technologies do "prevent the disease" of alkaline hydrolysis and enable fast firing of the installed linings.
Type Event
Format application/pdf
Rights No copyright issues exist
OCR Text Show
Metadata Cataloger Catrina Wilson
ARK ark:/87278/s6pk4s4d
Setname uu_afrc
Date Created 2018-12-10
Date Modified 2021-05-06
ID 1388793
Reference URL