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Overview
All process heaters operate at high temperatures and are constructed with process tubes inside a refractory-lined enclosure, which is heated by radiant heat from gas-firing or, less commonly, oil-firing.
Refractory linings are insulating and minimize heat loss, making them essential to retaining the high-temperature environment. However, when subjected to high temperatures, refractory can deteriorate and potentially lead to failure if remedial work is not carried out.
Types of refractory lining include refractory ceramic fiber, brick, and castable or concrete. If refractory failure results in an unplanned shutdown, it can cost plants more than $1m/day in lost production.
In this white paper, Johannes Poth, Fired Heater Efficiency Subject Matter Expert at Integrated Global Services (IGS) discusses the most common causes of refractory failure, how to inspect fired heaters or furnaces for damage, and the methods of repairing refractories online without the need to disrupt normal operation.
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