FCC Unit · Regenerator
The regenerator of an FCC unit regenerates catalyst. Its lining long-term bears high temperature (650–750℃), high-velocity catalyst fluidization scouring and flue-gas corrosion. Catalyst wear is the main failure mode; severe wear exposes anchors, threatening safe operation.
Catalyst scouring: catalyst circulates at high velocity in the regenerator, continuously abrading the wall lining. Anchor exposure: once wear passes the lining thickness, anchors are exposed, further destroying lining structure and accelerating wear. Thermal shock: start/stop and regeneration temperature swings shock the lining. Corrosion: sulfur/nitrogen oxides and catalyst dust impose combined chemical and abrasive attack.
After lining wear and anchor exposure, vessel walls thin and overheat locally, with cracking and leakage risk; catalyst wear debris enters the system, hurting fluidization and product quality; forced shutdown shortens the unit's long-term operating cycle.
Design the regenerator with a two-layer lining:
Layered placement: cast insulation first, then wear layer, with cleaned interfaces for bonding. Wear-layer work: strictly control water and vibrate fully for density. Anchors: weld fully and inspect weld quality. Bake-out: follow the curve to prevent wear-layer spalling.
Monitor regenerator wall temperature and lining condition; investigate on anomalies. At maintenance, measure wear-layer residual thickness and patch or replace zones beyond limits; record wear data to optimize thickness and grade.
SiC wear-resistant castable with SiC≥50% aggregate offers extreme hardness and erosion resistance to 1600℃. High thermal conductivity promotes slag-coating self-protection. For CFB boiler cyclone barrels and cones, loop seals, copper flash furnace cones, launders and elbows under heavy wear.
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Wear-resistant castable with hard abrasion-resistant aggregate, Al₂O₃≥70%, 1500℃ max service and CCS≥90MPa. Dense matrix resists particulate erosion in gas-solid two-phase flow.
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Brown corundum castable based on dense fused alumina with Al₂O₃≥85%, 1750℃ max service and CCS≥90MPa. High hardness, refractoriness and excellent slag resistance. Used in steel ladle working linings and slag lines, main iron runners, converter mouth areas and CFB boiler cyclone wear zones.
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