Petrochemical industry
Introduction:
Core equipment in the petrochemical industry, such as ethylene cracking furnaces, hydrogen reformers, process heaters, and waste liquid incinerators, operates under extremely harsh conditions including high temperatures (1100–1350°C), strong reducing atmospheres, high-temperature carburization, chemical corrosion, and frequent thermal cycling. Refractory materials must offer excellent high-temperature stability, anti-carburization, corrosion resistance, thermal shock resistance, and thermal insulation properties. Zhengzhou Jinshan Refractory Materials provides professional and reliable refractory solutions tailored to different petrochemical units, helping customers extend equipment service life, reduce unplanned shutdowns, improve energy efficiency, and lower overall maintenance costs.
1. Ethylene Cracking Furnace
Working Conditions:
The ethylene cracking furnace is the heart of ethylene production. The radiant section tube wall temperatures can reach 1100–1200°C in a strong reducing atmosphere rich in hydrocarbons. Severe high-temperature carburization, oxidation, and sulfidation corrosion occur, combined with frequent start-stop cycles that cause strong thermal shock. The refractory lining in the radiant and convection sections faces long-term high-temperature scouring and thermal stress, making it prone to spalling and cracking.
Recommended Refractory Materials and Advantages:
- Lightweight high-alumina bricks + ceramic fiber composite lining: Lightweight high-alumina bricks provide good high-temperature structural strength and slag resistance. Combined with ceramic fiber felts/modules, they significantly reduce heat loss (energy savings of 15–25%) while resisting carburization and thermal shock — ideal for radiant section walls and arches.
- High-alumina castables and plastics: Fast installation with excellent integrity, thermal shock resistance, and anti-carburization properties. Suitable for complex areas and local repairs, greatly extending lining life.
- Aluminosilicate fiber modules or blankets: Extremely low thermal conductivity (≤0.15 W/m·K), used in convection sections and insulation layers to minimize shell heat loss and improve thermal efficiency.
2. Hydrogen Reformer / Steam Reformer
Working Conditions:
Hydrogen reformers (SMR) operate at 1200–1350°C under high-pressure steam reforming conditions in a strongly reducing atmosphere, leading to severe carburization and metal dusting corrosion. The radiant section walls and burner areas endure extreme thermal loads, requiring strict heat loss control for energy efficiency.
Recommended Refractory Materials and Advantages:
- High-alumina or corundum-based castables: High Al₂O₃ content, excellent refractoriness and anti-carburization performance. Ideal for radiant section walls and target walls, capable of withstanding intense thermal radiation and reducing atmospheres.
- Lightweight insulating castables + ceramic fiber composite: Used in insulation and convection sections to lower shell temperature and reduce energy consumption while maintaining good thermal shock stability.
- Precast blocks: Factory-prefabricated and high-temperature fired, used around burners and high-wear areas for fast installation, precise dimensions, and long service life.
3. Process Heaters / Fired Heaters
Working Conditions:
Process heaters are widely used in crude distillation and hydrocracking, with temperatures ranging from 800–1100°C. Different zones experience oxidizing-reducing atmosphere changes, flue gas corrosion, and material scouring. Hot spots and local overheating frequently occur at the furnace bottom, radiant section, and flue.
Recommended Refractory Materials and Advantages:
- High-alumina bricks and phosphate-bonded high-alumina bricks: Good abrasion and thermal shock resistance, used in radiant section walls and bottoms to withstand flue gas scouring and temperature fluctuations.
- Abrasion-resistant high-alumina or silicon carbide castables: Outstanding scouring and wear resistance, suitable for furnace bottoms and flues. Easy to install with excellent sealing properties.
- Ceramic fiber modules: Lightweight, fast installation, and superior insulation for convection sections and roofs, enabling quick maintenance during shutdowns.
4. Waste Liquid / Hazardous Waste Incinerator
Working Conditions:
Petrochemical waste liquid incinerators operate intermittently with large temperature fluctuations (800–1300°C). Poor atomization from the tail liquid nozzle causes direct scouring of the lining, resulting in severe thermal shock and complex chemical corrosion from various acidic and alkaline substances. Traditional high-alumina brick linings often last less than one year.
Recommended Refractory Materials and Advantages:
- High-alumina or corundum castables: High density, excellent thermal shock and chemical corrosion resistance. Monolithic casting provides superior integrity and effectively resists direct tail liquid scouring, with service life up to 12+ months.
- Acid/alkali-resistant high-alumina bricks: Selected according to waste composition for high-wear zones, significantly reducing spalling and cracking.
- Refractory plastics and patching materials: Ideal for quick local repairs during scheduled shutdowns, shortening downtime and improving equipment availability.
5. Other Units
For Fluid Catalytic Cracking (FCC) regenerators, Sulfur Recovery Units (SRU), and other petrochemical equipment, we provide fully customized refractory solutions and technical support based on specific operating conditions (e.g., catalyst abrasion, high-temperature oxidation).
Why Choose Jinshan Refractories?
- Rich experience and technical expertise in petrochemical projects
- Strict quality control system and advanced testing equipment ensuring stable performance in high-temperature reducing atmospheres
- Customized formulations and technical solutions based on specific units, process media, and operating conditions
- Professional technical support, installation guidance, and comprehensive after-sales service
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whatsapp:+8615936268068
Phone:+86-15936268068
Email:zzjsrefractory@gmail.com
Address: Chengguan Industrial Zone, Xinmi City, Henan Province
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