| Zone |
Service Conditions |
Type of Refractory |
OCL Product |
| Fluidised catalytic cracking unit |
A.i. Reactor 450°c-550°c
ii. Regenerator 700°-900°c
B. Thermal stress & strain
C. Abrasion
D. Chemical reaction
E. Graphitisation |
High purity Alumina Castable with Fe < 0.5 %
backed up by 35-40% AL2O3 insulating castable |
Occast -95
Occast- 97
Insulcast 11/13 |
| Cyclone , Catalyst
transfer line, Slide valves(fccu) |
310-850°c thermal shock and
high erosion & severe abrasion. |
High strength low porosity castable backed up by med.
wt insulating castables |
Excel cast - 60
with ss fibre.
Insulcast 11 |
| Naptha reformers |
500-600°c hot hydrogen atm.,
high pressure up to 20 kg/ cm²
moderate erosion. |
Composite lining:
dense castable backed up by bubble alumina based
insulating castables |
Occast -95
With ss fibre.
Insulcast ba 97 |
| Process furnaces,
Heaters, Boilers,
Crude stills etc. |
1000-1300°c oxidising atm.
mechanical abuse, abrasion
due to charge fuel gases,
liquid like acidic sludge to tar. |
Side walls and roof: medium purity light wt. castables
flame impingement area & floor: high purity castables |
Excelcast-45
Occast -95 |
| Incinerators,
Air / vacuum heaters. Hoods feedlines |
1100°-1500°c. thermal and
mechanical spalling. Highly
Corrosive materials like alkalis severe mechanical and chemica abuse. Continuous long service period spalling. |
Silicon carbide based low cement castable
medium purity ultra low cement castable purity backed by medium purity insulating castable |
Excelcast bs-75
Ultracast-70 |
| Coal gasifiers |
1000-1600°c. reducing H2, Co & CH4 high pressure flame erosion and spalling. |
High purity high alumina bricks & castable |
Occast-95 / 97
Excelcast bs-75 |
| Ammonia units secondary reformers |
1000-1600°c. hot H2, Co & CH4
high pressure flame erosion and spalling. |
High purity high alumina castable / silicon carbide based low cement castable |
Occast-95 /
Excelcast bs-75 |
| Fractionator towers & columns |
Spalling and erosion in the temp range of 650-850°c |
Spalling and erosion in the temp range of 650-850°c |
Occast-60 |
| Sulphur recovery units |
High temp operation at 1650°c, erosion and abrasion |
High alumina high purity bricks for reactor and gunning mix for downstream |
95-97 % Al2O3
Bricks
Occast-95 g |
