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FEATURE HAZARDOUS AREAS


REPLACING HIGH TEMPERATURE GRADE RCF LININGS IN THE PETROCHEMICAL INDUSTRY


When it comes to lining fired heaters in the petrochemical industry, refractory ceramic fibre (RCF) has been the go-to material, but it has its drawbacks. Steve Chernack, global engineering manager at Morgan Advanced Materials’ Thermal Ceramics business, looks at how these can be mitigated, and a new option for petrochemical operators


I


n the petrochemical world, RCF has long ruled as the material for lining fired heaters. The


material possesses several attributes that ensure it performs well in harsh environments. This includes having a low thermal conductivity and heat capacity, thermal shock resistance and the ability to withstand extreme temperatures. On the operation side, it is renowned for its handleability and longevity in service, while it has a good resistance to pollutants. These characteristics mean RCF can extend the


life of fired heaters, increase their energy efficiency and ultimately the furnace’s reliability. However, RCF does come with its drawbacks.


Notably, the material produces crystalline silica as a by-product when fired, which can have an adverse effect on health. EU regulations are now in place to address the health concerns of RCF and crystalline silica, requiring materials manufacturers to search for innovative solutions to protect workers and introduce furnace linings fit for the future. Under the EU Carcinogen Directive, businesses are


required to use substitutes to RCF where it is technically and economically feasible to do so. However, until recently, no material has been able to match the superior insulating performance and high melting point of RCF.


THE ECONOMICAL VS. ETHICAL VS. REGULATION ARGUMENT For many oil refinery operators, replacing RCF with other alternatives will negatively affect furnace uptime. A typical large furnace can generate product revenues of £100,000 or more per day. Clearly, many operators are having to weigh up the pros and cons between putting furnaces into extended periods of downtime that affects their bottom line and complying with EU regulations designed to further protect worker’s safety. On the opposite face of the coin, operators do


value their ethical approach. In a number of cases, RCF linings have been maintained beyond their expected lifespan, rather than replacing them. This is both for monetary reasons and in the hope that a viable alternative will be made available. Additionally, from 2020 onwards, producers


and users of RCF in Europe will have to keep the amount of fibres in the workplace <0.3 fibres/ml. Such controls make using RCF difficult and expensive. Disposal of RCF is also costly, requiring special landfill sites. All of this is compounded by the increasing


commitment of major industrial companies to improve ‘green’ standards.


10 AUTUMN 2019 | INDUSTRIAL COMPLIANCE


A SILVER LINING Clearly, replacing RCF is easier said than done, however, switching out RCF does have benefits that can be easily overlooked. Due to the crystalline silica in RCF, before any


work in or around a fired heater with an RCF lining can happen, workers must ensure that they wear a full set of appropriate personal protective equipment. This is to meet guidelines on occupational exposure limits, but also to protect against other hazards. Finally, if any emergency repairs are needed, then


operators need to call in specialists and order materials to repair the lining. Quite quickly, what looked like one day for planned downtime can spiral into days or weeks of extended downtime.


THE ISSUE OF HAZARDOUS WASTE When decommissioned, RCF linings require specialist disposal that adds extra costs. For example, in the EU, wastes containing more


than 0.1wt% of RCF are classified hazardous under Directive 91/689/EC. RCF wastes from manufacture and use are required to be handled and disposed of by a licensed waste contractor in an appropriately licensed hazardous waste landfill.


A UNIQUE ALTERNATIVE TO RCF So, there is plenty of reason to switch from RCF linings to a low biopersistence alternative. However, existing low biopersistence fibre compositions do not perform as well from a thermal perspective, nor do they resist pollutants as well. To solve this challenge, Morgan Advanced


Materials has been using its Fibre Centre of Excellence to conduct research into RCF alternatives. Instead of attempting to make marginal gains in low biopersistence performance, Morgan has taken a different approach and revisited RCF itself. The result of this research is Superwool XTRA, a fibre that uniquely does not form crystalline silica. Crucially, in terms of its effect on environmental, health and safety risks, Morgan’s breakthrough material is exonerated from any carcinogenic classification under Nota Q of Directive 97/69EC. For petrochemical operators, they can be rest


assured that Superwool XTRA meets the American Petroleum Institute’s (API) standards, which guides the industry. The API’s classification temperature which is to be used for insulation outlines an obligatory 150°C overtemperature capability on the fibre within furnaces. Critical furnaces within the oil refinery and petrochemicals industry run between 1,200°C and


1,250°C and therefore require materials with a 1,400°C minimum classification rating. Superwool XTRA offers a performance equal, and in many cases superior to RCF.


MAKING THE SWITCH For operators looking to switch away from RCF, it is important that due consideration is given. Identifying the need for a new furnace lining is


not an easy task as testing and trialling new materials can be costly per trial, not to mention furnace downtime. Furnace linings which may have developed


breeches over time are prone to increased thermal loss; some of which may not be visible from the outside. To minimise costs, it is recommended that testing coincides with the scheduled downtime, so fabricators can swap-out and install the new lining. One technique for identifying thermal losses lies


in the use of infrared (IR) thermography scans. By using these IR scans, engineers can keep the furnace in operation while conducting an analysis.


DESIGN CAREFULLY To achieve maximum efficiency and longevity for the materials specified during the furnace relining process, it is critical to ensure the engineering design is appropriate. Not only must the materials have enough studs to


hold them in place, they also require sufficient joints for expansion or shrinkage. If a brick lining is installed without adequate expansion joints, the brick can grow so large that it pushes the entire lining off the furnace wall. Over long periods of time at temperature, fibre


modules degrade resulting in shrinkage gaps between the modules. These normally need filling with more fibre during scheduled maintenance shut-down periods. With Morgan’s Superwool XTRA, the fibre expands when heated to high temperatures, which has several benefits. First, potential shrinkage gaps possibly visible at


cool-down will close-up during operation. Second, expansion properties allow Superwool XTRA to be used in critical applications when mating dissimilar lining materials.


A BRIGHTER FUTURE The industry’s search for an RCF alternative is now over. Superwool XTRA has proven itself through considerable testing and real-world applications to be a viable alternative to RCF.


Morgan Advanced Materials www.morganadvancedmaterials.com


/ INDUSTRIALCOMPLIANCE


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