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Hydrocarbon Industries

Hydrocarbon

Refractories for Crude & Vacuum Distillation Units (CDU/VDU)

CDU & VDU heaters are used for heating up crude oil for the refining process.

Typical temperatures inside the heaters range from 800°C to 1000°C. The unit are equipped with Burners in the floor and /or side-walls.The process feed oil is transported through tubing inside the heater The main function of the refractories lining is to have good insulating properties in order to minimize heat loss.

FLOOR

MAXLYTE 11 MAXLYTE 7/9 HDFB(Mahakoshal 38/ 40

BURNER BLOCKS

PCPF MAXMON 60Li/70Li PCPF MAXMON 60A

RADIANT SECTION / ARCH

MAXLYTE 11 C/G MAXLYTE- 9 / 7 C/G

CONVECTION SECTION

MAXLYTE 11/9 C/G

Refractories for Catalytic Reformer Furnace (Platformer)

Catalytic Reformer is used to obtain better distillation efficiency. The product is transported through tubes inside the furnace at an operating temperatures of about 1000°C.

FLOOR

(HDFB) Mahakoshal 40/42 MAXLYTE-11 C/G MAXLYTE -7/9 C/G

BURNER BLOCKS

PCPF MAXMON 60Li/70Li PCPF MAXMON 60A

RADIANT SECTION / ROOF

MAXLYTE 11 C/G MAXLYTE- 9 / 7 C/G

FLUEGAS DUCTS

MAXLYTE 7/9

INTERMEDIATE WALLS

HDFB ( Mahakoshal 40/42)

Refractory Solution for :

Fired HeatersFired heaters in circular or rectangular shapes with modular designs are generally used to increase the temperature  of the products in the processing line. Temperature inside these heaters may vary in the range of 600°C to 1000°C.

FLOOR

HDFB (Mahakoshal 38/40/42) MAXLYTE-11 c MAXLYTE -9/7C

BURNER BLOCKS

PCPF MAXMON 60Li/70Li PCPF MAXMON 60A

RADIANT SECTION / ROOF

MAXLYTE 11 C/G MAXLYTE- 7/9 C/G

FLUEGAS DUCTS

MAXLYTE 7/9 C/G

Refractories Fluid Catalytic Cracking Unit (FCCU)

FCCU cracks the long chain hydrocarbon and heavy residue into light weight and high grade products such as propane,butane, gasoline and high octane petrol.

FCC unit requires advanced refractory materials as the come in direct contact with the processing inputs refractory, along with the catalyst. This results in severe erosion of the refractory lining apart from presence of reducing atmosphere inside.Mahakoshal Refractories are cost effectively formulated to ensure excellent service life and performance with reduced maintenance requirements. 

REACTOR / REGENERATOR

(WALL, HEAD & BOTTOM)MAXLYTE 3Li - 23 C/G MAXLYTE 5Li - C/G

REACTOR / REGENERATOR PLENUM

MAXPHOS - 85 P MAXPHOS - T90

DISTRIBUTOR  REACTOR INNER RISER

MAXPHOS - 85 P MAXPHOS - T90

REACTOR OUTER RISER

MAXMON - 55 Li

REACTOR / REGENERATION PRIMARY- & SECONDARY CYCLONES

MAXPHOS - 85P MAXPHOS T90

SPENT CATALYST STANDPIPE

MAXGUN - 55 G MAXMON - 55 C

Refractories for Sulphur Recovery Unit (SRU)

All Refineries are equipped with sulphur recovery units where the acid gas is burned off in a furnace. After burning, the resultant flue gas contains Hydrogen Sulphide (H2S), carbon dioxide, light hydrocarbons, Nitrogen, etc.

Mahakoshal Refractories can supply appropriate Lining materials -both prefabricated shapes and monolithics for all the equipment parts/ zones in this process - such as burners, main chambers, mixing chambers, matrix blocks , incinerator chambers, waste heat boilers and sulphur condensers, tail gas treatment unit etc. 

Tail Gas Reactor BOTTOM / HEADS

MAXHEAT-C C/G MAXLYTE-13 C/G

Main Burner / Main Combustion Chamber

MAIN BURNER

MAHAKOSHAL 90/92 SHAPES MAXMON 90 SUPER MAXMON-ULC 95

MAIN COMBUSTION CHAMBER

MAHAKOSHAL 90/92 SHAPES MAXMON ULC 953 MAXLYTE 15Li/13Li

BAFFLE WALLS/ MATRIX BLOCK

PCPF MAXMON 90 SUPER PCPF MAXMON ULC T95

Refractory Solution for Petro Chemicals Processing Unit : Ethylene furnace

The most important material in Petro-chemical process industry is Etylene . Starting from Ethylene many different products such as Polyethene, PVC, Ethylene Glycol, Styrene and many other products are produced .

FLOOR

HDFB(Mahakoshal 40/42) /MAXLYTE-13Li, MAXLYTE-9 Li

RADIANT SECTION

MAXLYTE- 13Li C/G, MAXLYTE-9Li  C/G, MAXLYTE-11 Li C/G

ROOF / ARCH

MAXLYTE- 13Li C /G, MAXLYTE-9Li  C/G

CONVECTION ZONE

MAXLYTE 13 C/G, MAXLYTE 9 C/G

PEEPHOLES

MAXLYTE 13C, MAXLYTE 9C

BURNER BLOCK

PCPF MAXMON 60Li/ 70Li, PCPF MAXMON 60 A

Refractory Solution for :

Petroleum Coke Calcining :

Green Petroleum-coke (GPC), the final residue by-product of the Refinery processing Plant is turned into usable carbon for industrial uses through Calcination. This calcined Coke is mainly used for production of Anodes for the primary Aluminum industry and for production of Graphite electrodes.

There are mainly types of coke calcining plants using Rotary kiln and vertical shaft calciner for large capacity plants. Refractories used for the Rotary Kiln calciner is described here.During the process in the Rotary kiln, calcination takes place in stages as the green coke moves slowly through the length of the kiln at progressively increasing temperature zones from 150 QC up to 1450 QC. In the initial section of the kiln the GPC loses its moisture at about 200 QC. De-volatilization occurs in the next section, at temperatures ranging from 600 QC-1000 QC. De-hydrogenation, some de- sulphurization and densification of the coke takes place at temperatures between 1000 QC - 1350 QC in the last section. There is a direct contact between the product under processing and the kiln refractory lining.Mahakoshal can provide a cost effective solution with Refractory Bricks and Monolithic products required for trouble free operation withstanding high temperature, abrasion, high thermal shock and chemical attack inside the Kiln.

Mahakoshal Refractory for Pet-Coke Calciner and Incinerator

INLET ZONE / FEED CHARGE CHU

MAXMON 80 / 70L

Kiln- Drying/Preheat Zone

Mahakoshal 42S /42D Bricks Mahakoshal 50S/60S Bricks

Kiln - De- volatilization/ Densification

Mahakoshal 70S/70Li Bricks

DISCHARGE END / CHUTE

MAXMON 80/90

COOLER

MAXMON 70/80

INCINERATOR

Mahakoshal 60A/ 70Li Anchor/ Bricks MAX MON 60/70Li, MAXPHOS 60/ 70Li

Solutions for Carbon black reactor

Carbon black is produced mainly from Heavy oil feedstock in a horizontal tubular Furnace with partial combustion/oxidation in presence of insufficient air . Two types of Carbon Black -hard and soft varieties are produced for end Uses in Tire industry, News printing and in many other applications.

The processing feed stock is injected in the Tubular Furnace and process gas in this reformer come in direct contact with the refractory lining. Due to the presence of high percentage of 1-12 and CO in the process gas, high purity refractories with low silica and low iron are required for the lining. High temperature- up to 1800°C and a high velocity of the process gasses result in a very harsh environment for the refractory lining.

REACTOR HEADER/ VENTURI

MAXMON ULC-90/ 90CR MAXMON ULC-95 SUPER MAXLYTE-13 Li / 90Li(Bubble Alumina)

BREACHING/QUENCHING/COOLING

MAXMON ULC-90 SUPER MAXLYTE -11Li/ 13 Li MAXMON-45/50 (Cooling zone)

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