Refractories for Petrochemical plants

Refractories play a crucial role in the petrochemical industry by providing high-temperature resistance and insulation for equipements and structure used in the production of plastics, synthetic rubber, solvents, adhesives, paints and etc. These specialized refractory materials help maintain the structural integrity of industrial processes at extreme temperatures, ensuring safe and efficient operations in petrochemical plants and ensuring the quality product of industry.

At MMP, our skilled refractory engineers understand the demands and needs of the industry by offering end to-end customizable solution

1. Catalytic Cracking Units (FCC Units)

In petroleum refineries, a type of chemical process called fluid catalytic cracking (FCC) is utilized to transform heavy petroleum fractions into hydrocarbons like diesel, gasoline, and small many other compounds. FCC is a main conversion method that divides big molecules into smaller ones by using catalyst chemicals such as Zeolite, Bauxite, Silica alumina, and many more. Here in Catalytic cracking ythe carbon is rejected.

In petroleum refineries, a type of chemical process called fluid catalytic cracking (FCC) is utilized to transform heavy petroleum fractions into hydrocarbons like diesel, gasoline, and small many other compounds. FCC is a main conversion method that divides big molecules into smaller ones by using catalyst chemicals such as Zeolite, Bauxite, Silica alumina, and many more. Here in Catalytic cracking ythe carbon is rejected

2.Hydrocracking Units

Hydrocracking, is partial similar and expensive to FCC. It contains two-stage process involving hydrogenation of the hydrocarbons and catalytic cracking into small chain molecules. The process also removes the presence of impurities. Hydroracking employs high hydrogen, high process, high temperature, and catalyst chemicals same as FCC. Jet fuel, diesel, high-octane gasoline fractions, and LPG with extremely low sulfur and other substances contents are mainly the byproducts of hydrocracking. Low sulfur fuels, desulfurization, denitrogenation, and demetallization are the results of the hydrocracking process.

Refractories are essential for providing thermal insulation and defense against the severe operating conditions involved in the hydrocracking process in hydrocracking catalyst units. The catalysts and feedstock materials produce corrosive conditions, high temperatures, and pressures that these refractories are specifically made to withstand at high temperature. The Hydrocracking Catalyst Unit in the petrochemical sector may efficiently, and accurately with easy transform heavy hydrocarbons into lighter, more valuable products by lining the machinery with refractory materials like silicon carbide or alumina-silicate and many refractories.

3.Catalytic Reforming Units:

Low-octane naphtha and paraffins are transformed into high-octane reformate in a catalytic reforming unit in the petroleum refinery industry through a chemical process. Benzene, toluene, xylene, and ethylbenzene are among the aromatic compounds found in reformate, which is also used as a blending stock for high-octane gasoline. Many reactions occur simultaneously during the process, including as isomerization, polymerization, dehydrogenation, and cracking. Hydrogen is produced as a byproduct of this procedure.

Using refractory materials like silicon carbide or alumina-silicate, refractory lining the hydrocracking catalytic machinery can produce high-quality products with little to no sulfur and hazardous acid leaks.

4.Furnaces and Heaters:

In the petrochemical industry, furnaces and heaters are necessary for a variety of processes, such as hydrocarbon processing and petrochemical product manufacturing. Process heaters, and as process furnaces, in the petrochemical sector are typically powered by gas or oil. To guarantee efficient procedure products, oils must be heated to 878 °F or above. So there should be no waste of heat to the surroundings.

In furnaces and heaters, there is continuous thermal heat on parts. So to ensure the process, there should be furnace lining that is refractory materials to components.

5.Pyrolysis Furnaces:

A pyrolysis furnace is a specialized type of industrial equipment used to thermally decompose organic materials at high temperatures in the absence of oxygen. This process, known as pyrolysis, breaks down the material into simpler chemical compounds, typically producing gases, oils, solid residues, and petrochemical products. These types of furnaces are highly used in petrochemical Industry. Due to occurrence of extreme heat in oxygen absence, the components are constantly facing thermal hammering. So to avoid these refractory materials like silicon carbide or alumina-silicate are mostly used. There are also another refractories along with these.

6. Hydrodesulfurization Units

Hydrodesulfurization (HDS) unit is a catalytic process used in petroleum refining to remove sulfur and nitrogen compounds from natural gas and refined petroleum products. The HDS process takes place in a fixed-bed reactor at elevated temperatures (300–400 °C) and pressures (30–130 atmospheres) in the presence of a catalyst like an alumina.

Refractories are required to survive the high heat and harsh conditions that the desulfurization process entails. These refractories shield the sulfur compounds and other harsh components from heat and offer thermal insulation. The Hydrodesulfurization Unit can efficiently remove sulfur from petroleum products, like gasoline and diesel, by lining the equipment with specialized refractory materials like silicon carbide or aluminasilicate.

7.Gasification Units

Gasification is a thermochemical process that converts carbonaceous materials, such as coal, biomass, or petroleum coke, into syngas (synthetic gas), primarily composed of hydrogen, carbon monoxide, and carbon dioxide. High temperatures (typically between 800°C to 1800°C) in the presence of a controlled amount of oxygen or steam is required.

In gasification units, refractories serve a important function because of harsh surroundings inside the gasifier. High temperatures, chemical degradation, thermal shocks, and mechanical wear are all things that these materials have to resist. The safety, protection, lifespan, and effectiveness of the gasification process are all directly impacted by the use of refractory materials.

8. Thermal Oxidizers:

A thermal oxidizer, also known as a thermal incinerator, is a type of combustion device that converts toxic gases, volatile organic compounds (VOCs), and hazardous air pollutants (HAPs) into carbon dioxide (CO2) and water by the use of heat. The atmosphere is thereafter exposed to the ensuing emissions. In chemical factories and other establishments that emit pollutants or smells, thermal oxidizers are frequently utilized. Temperatures of at least 1400°F are usually required to operate thermal oxidizers. Refractory materials like silicon carbide or alumina-silicate are therefore necessary to shield the system from high heat temperatures.

9. Sulfur Recovery Units (Claus Process):

The oil and gas industry depends extensively on Sulfur Recovery Units (SRUs) to extract sulfur compounds from process gases generated during natural gas processing and refining. The hydrogen sulfide (H2S) in these units is converted into elemental sulfur through a sequence of chemical processes that can be sold or processed further as a valuable byproduct. Through the reduction of sulfur emissions that contribute to acid rain and air pollution, Sulfur Recovery Units are essential for environmental protection. For the petrochemical industry to produce cleaner fuels and maintain compliance with strict regulations, they are essential.

Refractory linings play a crucial role in Sulfur Recovery Units (SRUs), which transform refined oil's sulfur waste into elemental sulfur in oil and gas refineries.

10. Incinerators:

Incinerators are made to burn garbage at high temperatures and produce heat, gas, and ash. trash of all kinds, including medical, hazardous, and municipal solid trash, can be safely disposed of at these facilities. By burning waste, incinerators lessen the amount of toxic compounds released into the atmosphere and produce electricity. In order to reduce emissions and guarantee adherence to environmental standards, contemporary incinerators are outfitted with cutting-edge equipment for controlling air pollution

Refractory materials like silicon carbide or alumina-silicate are therefore necessary to shield the system from high heat temperatures.

Refractory linings play a crucial role in Sulfur Recovery Units (SRUs), which transform refined oil's sulfur waste into elemental sulfur in oil and gas refineries.

11. Burner Blocks and Tiles:

High-temperature resistant materials called burner blocks and tiles are utilized in industrial furnaces, kilns, and incinerators. Because of their ability to tolerate high temperatures, they act as insulation and shield buildings from thermal harm. These thermal shock-resistant, long-lasting blocks and tiles can be tailored to meet certain industrial requirements. Ensuring safe and effective operation in high-temperature situations is their main duty.

12. Flue Gas Lines and Flue Stacks:

Flue Gas Lines and Stacks are essential components in industrial facilities for the safe and efficient removal of exhaust gases produced during combustion processes.

• Flue Gas Lines: These are pipelines that transport exhaust gases from combustion equipment like boilers, furnaces, or incinerators to the flue stack. They are designed to handle high temperatures and corrosive gases.
• Flue Stacks: Also known as chimneys, these vertical structures release flue gases into the atmosphere at a safe height, ensuring the dispersion of pollutants and minimizing environmental impact.

Refractory materials like silicon carbide or alumina-silicate are therefore necessary to shield the stacks(chimneys) and flue gas traveling pipe.

13. Reactors:

High-temperature resistant materials called burner blocks and tiles are utilized in industrial furnaces, kilns, and incinerators. Because of their ability to tolerate high temperatures, they act as insulation and shield buildings from thermal harm. These thermal shock-resistant, long-lasting blocks and tiles can be tailored to meet certain industrial requirements. Ensuring safe and effective operation in high-temperature situations is their main duty.

14. Continuous Catalytic Regeneration:

The method of continuously renewing catalysts used in the hydrocarbon cracking process is known as continuous catalytic regeneration, or CCR, and it is employed in petrochemical refineries' fluid catalytic cracking units. The catalyst in CCR systems is pumped back and forth between the reactor and regenerator units, where it is renewed to continue to fuel the cracking reaction.

In order to maintain the effectiveness and performance of the catalysts, refractories play a critical role in CCR units by offering thermal insulation and protection against the high temperatures and severe conditions involved in the regeneration process.

15. Cracking Coils:

Cracking coils, also referred to as radiant cracking tubes, are an essential part of petrochemical facilities that generate the plastics, propylene and the chemical ethylene. Heats as high as 2,000°F (1,100°C) in a furnace are applied to the feed and steam inside the cracking coil during the cracking process, cracking the material into different forms.

Refractories used in cracking coils, particularly in petrochemical plants, are critical for maintaining the integrity and performance of the furnaces involved in cracking processes like steam cracking of hydrocarbons. These refractories must withstand high temperatures, thermal shock, and corrosive environments. By using refractory materials such as alumina-silicate or silicon carbide, cracking coils can efficiently convert heavy hydrocarbons into lighter products like gasoline and olefins

16. Coke Drums:

When heavy oils are converted into lighter products like gasoline and diesel through an extended coking process, coke drums are a necessary component. Due to their ability to insulate against heat cycling and severe temperatures encountered during the coking process, refractories are an essential component of coke drums. Coke drum service life is increased by these specific refractory linings, which also reduce thermal stress and stop heat loss. Coke barrels frequently contain high-alumina, silica, and fireclay refractories.

These materials are chosen for their thermal characteristics as well as their resistance to chemical and abrasive attack. Coke drum refractories must be properly built and maintained in order for the petroleum refining industry to operate safely and effectively.

17. Heat Exchangers:

Heat exchangers are essential parts of many industrial processes, especially those in the petrochemical, and power generation industries. Heat exchangers are devices that transfer heat without mixing two or more fluids, usually one hot and one cold. The materials used to build heat exchangers, mainly the refractory linings, are essential for long-term durability and effective performance in high-temperature applications. Majorly used refractories are Fireclay Refractories, High Alumina, Ceramic Fiber and high aluminia. To ensure the heat exchanger's effectiveness, durability, and safe operation in hot and corrosive settings, the refractory material decision is essential.

Refractory materials are integral to the efficient and safe operation of petrochemical plants. Selecting the right type of refractory for each above areas ensures the longevity and performance of the equipment, reduces downtime, and enhances overall productivity. By understanding the specific requirements of each area within a petrochemical plant, our expertise can optimize their refractory usage, leading to more sustainable and cost effective operations. MMP Refratech provide various kind of refractory materials and installation in petrochemical industry with customize specifications to all above systems.