Hot-erosion of nano-bonded refractory castables for petrochemical industries

Cold-erosion tests are usually applied for refractory castable evaluation in petrochemical industries, mainly for materials used in cyclones and risers of fluidized catalytic cracking units (FCCU). Due to the fact that in the operation, the refractory material is subjected to high temperature, at first, hot-erosion tests could be more representative. Erosion wear has a great influence on the FCCU refractory working life and the lost income associated with a production halt can reach values close to US$500,000 per day. These aspects are strong enough to justify hot-erosion resistance characterization. The test viability, which could result in selecting better material for the application, was evaluated using commercial products and nano-bonded castables from 200 up to 815 °C. At this temperature range, a significant difference between the cold and hot-erosion loss was not observed. Therefore, it indicates that the cold-erosion test is suitable and sufficient for selecting refractory castables for FCCU applications. The cold-erosion test also presented a higher data correlation with the splitting tensile strength and the hot modulus of rupture. Regarding the different evaluated materials, the nano-bonded castables showed a higher erosion resistance and were less susceptible to the temperature effect than the calcium aluminate cement bonded commercial products.