A chemical company operating a reactor vessel were finding that refractory performance was variable and unpredictable. Vessel life was approx. 4-6 months and most campaigns ended with a refractory failure leading to a loss of containment. Turnaround was 13 weeks including shell repairs and a complex dry-out.
Working with the company and their refractory suppliers and installers, we made significant improvements to the design including
- Installing monitoring to give a prediction of lining condition
- Changing lining configuration to reduce dry out schedule significantly
- Improving design to eliminate weak areas
- Changing material for refractories better able to withstand thermal conditions
The end result is a 150% increase in lining life, predictable life which ends to schedule without damage to the pressure vessel and a reduction in turnaround time to 7-8 weeks. This has resulted in large cost savings and increased plant availability.
Testimonials
The following testimonials have been provided by our consultancy customers
We are pleased to confirm that we have, on many occasions, worked with Sam Franklin of Eagle Refractories. We have found his depth of experience and considerable knowledge of Refractory Applications and Refractory Materials Technology, most invaluable.
Mr TS, Managing Director
I wanted to take a moment to say thank you for all your great work on this… I’m sure we will find opportunities to get your help again.
Mr KC, Lead Engineer