Wear resistant linings are a cost-effective means of enhancing the overall efficiency in oil and petroleum refining as well as prolonging equipment lifetime and reaching maximum operation levels.
Wear resistant linings have extremely high wear, abrasion, and corrosion resistance, excellent thermal shock resistance, and minimal thermal expansion. They are extremely hard and can withstand harsh service environments such as those in the oil and petroleum refining industry.
Ceramic-based wear resistant liners are a cost-effective solution for oil and petroleum refining applications as they outperform standard refractory materials such as abrasion-resistant steels, plastics, and rubbers.
High-performance wear resistant linings serve a range of key functions in oil and petroleum refining, particularly in the catalytic cracking process. A few key aspects requiring enhanced abrasion resistance include:
• Regenerator nozzles
• Orifice chamber nozzles
• Critical flow nozzles
• Cyclone dust bowls and dip legs
• Reactor stand pipes
• Riser linings and wear pads
• Fractionator cones
• Reactor stripper nozzles
• Feed nozzle shrouds
• Buell under flow nozzles
Exploring each of these components in due depth in a short article would be improbable, so here is a brief exploration of two critical areas in which wear resistant linings dramatically enhance performance in refining applications.
Various forms of expansion joints are used for fluid catalytic cracking units (FCCU). Each of these must be protected from, not only the high pressures and temperatures of the process, but also the introduction of erosive media in the form of catalysts. Pre-cast/pre-assembly catalyst and regenerator expansion joints are used for both hot and cold wall joints, serving primarily to mitigate the abrasion of catalytic media flowing through the unit.
Wear resistant linings can strengthen pipes and help repair them when they are damaged. They encapsulate the pipe, preventing corrosion and sealing the pipework from the environment, and are suitable for a range of climates. Key examples of this include transfer piping tees, manifolds, and elbows. The benefits of these wear-resistant transfer piping components derive from their jointless construction; they are single piece casts used to encase pipe junctions and bends for maximum abrasion resistance at critical junctures.
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There is a broad range of wear resistant linings available in a variety of materials and configurations. They can be pre-engineered for significantly reducing wear in highly demanding applications.
Saint-Gobain Performance Ceramics & Refractories team of experts is committed to helping you understand which material is best for your application.
Whether resistance against fine particle abrasion, thermal shock resistance or high temperature is your priority, our team can help.
If you would like to find out more about wear-resistant films and their applications, take a look at our dedicated page for more information.
Abrasion Resistance: Ceramic linings exhibit exceptional resistance to abrasion, making them highly suitable for industries where materials face continuous wear.
Impact Resistance: These ceramics provide effective protection against impacts, maintaining structural integrity even in environments with occasional heavy impacts.
Chemical Resistance: Many wear-resistant ceramics are resistant to corrosive chemicals, enhancing their suitability for applications involving exposure to corrosive substances.
Smooth Surface Finish: The smooth surface of ceramics facilitates better material flow, reduces friction, and minimizes the likelihood of material buildup.
Long-Term Cost Savings: Despite the initial higher cost, the extended lifespan of ceramic linings translates to long-term cost savings due to reduced downtime, maintenance, and replacement expenses.
Improved Efficiency: The enhanced wear resistance and reduced friction contribute to improved operational efficiency and productivity.
Extended Equipment Lifespan: The wear-resistant properties of ceramics significantly extend the lifespan of equipment, reducing the frequency of replacements and associated costs.
Consistent Performance: Ceramic linings maintain their performance over an extended period, providing reliable protection against wear and abrasion.
Reliable Performance: The durability and consistent performance of wear-resistant ceramics contribute to a safer working environment by minimizing the risk of equipment failure.
Material Compatibility: Ceramic linings are often compatible with various materials, preventing contamination and ensuring product integrity.
Reduced Downtime: The durability of ceramics results in reduced maintenance downtime, allowing for continuous operation and increased overall productivity.
Lower Maintenance Costs: With fewer replacements and repairs needed, the overall maintenance costs associated with wear-resistant ceramics are lower compared to traditional materials.
Sustainability: The extended lifespan and reduced need for frequent replacements align with sustainability goals, minimizing material waste and resource consumption.
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