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Process Units – Engineered Refractory Solutions for Thermal, Chemical & Mechanical Stress Zones

The petrochemical process industry involves units such as furnaces, reactors, reformers, crackers, fired heaters, and incinerators where refractories face extreme thermal gradients, chemical corrosion, erosion from gas flow, and cyclic thermal stress. Process conditions are highly variable, with exposure to alkalis, sulphur compounds, hydrocarbons, and soot, often in combination with mechanical vibrations and differential expansion.

Key parameters for refractory selection in petrochemical units:

  • Thermal Shock Resistance – withstands repeated start/stop cycles.
  • Chemical Corrosion Resistance – alkali, sulphur, hydrocarbon and CO attack.
  • Erosion / Abrasion Resistance – due to high velocity flue gases and particulate-laden streams.
  • Mechanical Strength – maintains lining integrity under high thermal and mechanical stress.
Steel Plants

Critical Equipment & Zone-Wise Failure Patterns

Equipment / Zone Dominant Failure Mechanism Thermlyte Refractory Approach
  • Fired Heaters / Reformers – Radiant Coil Zone
  • Convection / Flue Gas Section
  • Incinerators / Thermal Oxidizers
  • Reactor Tops / Cyclones
  • Crossovers / Ducts / Stack Linings
  • High flame impingement, thermal shock
  • Alkali-sulphate corrosion, dust abrasion
  • High temperature + chemical attack
  • Erosion due to gas velocity, particle impingement
  • Alkali / acid condensation + thermal cycling
  • As per EIL Recommendation



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