Industry: Hydrocarbon Processing- Refining
Equipment and Operating Conditions: The gasifier is a large diameter vessel where fluidized coke is charged from the heater vessel and reacted with air and steam to produce fuel gas products consisting of CO, H2, CO2,and N2. The gas flows from the top of the gasifier to the bottom of the heater where it serves to fluidize the heater bed and provide heat for the reactor. The heater is a fluidized bed vessel and its primary function is to transfer heat from the gasifier to the reactor. This is an ExxonMobil licensed technology.
Problem: Refractory replacement was required from the top of the grid to an approximate height of 20’, and other random areas extending to the top section of the sidewalls. The total area replaced was around 2,400 sq ft with an 8” thick refractory lining. Use of conventional refractory would have required a specialized heat treatment company to complete a thermal dry out prior to unit start up.
Solution: Thermbond Formula 8-G was installed in the gasifier sidewall areas (over 6,000 units), and Formula 5-AG (336 units) was installed in the inverted conical wall below the grid in the heater vessel. The nozzle transition between the transfer line and the annulus of nozzles through the heater sidewalls was also repaired with Thermbrake 402 insulating material.
Product Being Replaced: ExxonMobil Type 4 Special Medium Weight Heat Insulating Refractory in the gasifier sidewalls, and Erosion Resistant Heat Insulating (Type 3) in the heater vessel conical wall.
Savings Using Thermbond: The refinery estimated a total savings of $4.5 million USD by eliminating the lengthy controlled heat cure prior to unit start up.
Products Installed: Thermbond Formula 8-G, Formula 5-AG, and Thermbrake 402
Method of Installation: Gunning and Casting
Equipment Used: Allentown N2 for gunning Formula 8-G and 5-AG
Installation Date: February 2006