Petrochemical industry
Incinerators in the petrochemical industry are batch-operated kilns whose inner walls are primarily constructed using refractory materials such as high-alumina bricks, refractory castables, and refractory plastic materials. These incinerators operate in harsh environments, and their inner-wall refractory materials are subjected to erosion by various chemicals, physical abrasion, and mechanical stresses, making them highly susceptible to damage.
Compared to conventional industrial kilns, incinerators used in the petrochemical industry have even higher requirements for refractory materials—these materials must not only withstand high temperatures but also exhibit excellent resistance to corrosion and outstanding thermal stability at elevated temperatures. In the petrochemical refining sector, vertical incinerators for waste liquids are commonly employed. Their core function is to oxidize and burn the waste liquids generated during petrochemical production—liquids that are toxic and harmful—thereby converting these hazardous substances into less harmful compounds before they are released into the atmosphere.
If the tail-liquid nozzle of the incinerator can atomize properly, the refractory materials on the furnace inner wall will experience relatively less thermal shock. However, in actual operation, the tail-liquid nozzle often fails to atomize correctly, and the unatomized tail liquid is directly sprayed onto the furnace lining, causing direct erosion of the refractory materials. At the same time, the temperature in the locally impacted areas drops sharply, creating a temperature difference between these areas and the surrounding furnace lining, which in turn generates internal stresses. Once these internal stresses exceed the strength of the refractory material itself, cracks begin to form. These cracks gradually expand, eventually leading to the fracture of the refractory material. Coupled with the continuous erosion caused by the tail liquid, the furnace lining’s refractory materials keep shedding and deteriorating.
In the past, the inner walls of incinerators in the petrochemical industry were mostly lined with high-alumina bricks. Under these conditions, the service life of the furnace lining was no more than one year, necessitating frequent shutdowns for maintenance and inspections, which severely impacted the company’s production efficiency and economic benefits. Later, companies switched to refractory castables as furnace lining materials, replacing the original high-alumina bricks. After being cast and formed, these refractory castables exhibit excellent structural integrity and tight sealing properties. They also demonstrate outstanding resistance to thermal shock and erosion, allowing them to be used continuously for up to 12 months before requiring replacement of the lining. During periodic shutdowns for inspection, only localized areas with severe damage need to be repaired by applying a small amount of refractory coating, thereby further extending the service life of the furnace lining.
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