M00044411
New product
API TR 979 Applications of Refractory Lining Materials, First Edition
standard by American Petroleum Institute, 10/01/2018
In stock
Warning: Last items in stock!
Availability date: 01/06/2022
Applications of Refractory Lining Materials
API TECHNICAL REPORT 979 FIRST EDITION, OCTOBER 2018
Special Notes
API publications necessarily address problems of a general nature. With respect to particular circumstances, local, state, and federal laws and regulations should be reviewed.
Neither API nor any of API's employees, subcontractors, consultants, committees, or other assignees make any warranty or representation, either express or implied, with respect to the accuracy, completeness, or usefulness of the information contained herein, or assume any liability or responsibility for any use, or the results of such use, of any information or process disclosed in this publication. Neither API nor any of API’s employees, subcontractors, consultants, or other assignees represent that use of this publication would not infringe upon privately owned rights.
API publications may be used by anyone desiring to do so. Every effort has been made by the Institute to assure the accuracy and reliability of the data contained in them; however, the Institute makes no representation, warranty, or guarantee in connection with this publication and hereby expressly disclaims any liability or responsibility for loss or damage resulting from its use or for the violation of any authorities having jurisdiction with which this publication may conflict.
API publications are published to facilitate the broad availability of proven, sound engineering and operating practices. These publications are not intended to obviate the need for applying sound engineering judgment regarding when and where these publications should be utilized. The formulation and publication of API publications is not intended in any way to inhibit anyone from using any other practices.
Any manufacturer marking equipment or materials in conformance with the marking requirements of an API standard is solely responsible for complying with all the applicable requirements of that standard. API does not represent, warrant, or guarantee that such products do in fact conform to the applicable API standard.
Classified areas may vary depending on the location, conditions, equipment, and substances involved in any given situation. Users of this technical report should consult with the appropriate authorities having jurisdiction.
Users of this technical report should not rely exclusively on the information contained in this document. Sound business, scientific, engineering, and safety judgment should be used in employing the information contained herein.
Where applicable, authorities having jurisdiction should be consulted.
Work sites and equipment operations may differ. Users are solely responsible for assessing their specific equipment and premises in determining the appropriateness of applying the instructions.
At all times users should employ sound business, scientific, engineering, and judgment safety when using this technical report.
API is not undertaking to meet the duties of employers, manufacturers, or suppliers to warn and properly train and equip their employees, and others exposed, concerning health and safety risks and precautions, nor undertaking their obligations to comply with authorities having jurisdiction.
All rights reserved. No part of this work may be reproduced, translated, stored in a retrieval system, or transmitted by any means, electronic, mechanical, photocopying, recording, or otherwise, without prior written permission from the publisher. Contact the Publisher, API Publishing Services, 1220 L Street, NW, Washington, DC 20005.
Copyright © 2018 American Petroleum Institute
Foreword
This report is the second in a series of three American Petroleum Institute (API) reports covering the use of refractory concrete (castables), plastics, and ramming mixes for applications for the hydrocarbon processing industry (HPI). Its content is complimented by the two other reports in this series:
API TR 978, Monolithic Refractories: Manufacture, Properties and Selection
API TR 980, Monolithic Refractories: Installation and Dryout
These API technical reports update and add to the original reports written by Committee 547 of the American Concrete Institute (ACI) in 1979 and 1989. The ACI reports are ACI 547.R-79, State-of-the Art Report: Refractory Concrete, and ACI 547.1R-89, State-of-the Art Report: Refractory Plastics and Ramming Mixes.
ACI Committee 547 was organized in 1969 to provide a reliable and comprehensive source of information on monolithic refractory technology. In subsequent years, participation in the ACI refractory technical community waned. At the same time, participation increased on the API committee that was drafting refractory content. The API committee currently runs a certification program for refractory practitioners based on API Standard 936, Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials. To facilitate use of the updated content in the API certification program, ACI allowed API to use the material from the two above- mentioned ACI publications, no longer maintained by ACI. This enabled API to create new technical reports by updating and adding to the material from the ACI reports.
API formed the Vessel Refractory Task Group in the late 1980s with the objective of providing a standard for the inspection and application of quality controls for monolithic refractories used in refining applications. In response to demands for greater reliability and cycle life objectives, refiners had already developed their own company specifications for refractory installations for the highest-value applications, where unit availability is critical. A cottage industry of supporting quality control experts and inspectors evolved has have helped owners reduce this gap in the last few decades. Up until that time, however, manufacturers and installers largely had little say in this development, and uniform industry standards were never developed or adopted.
To address this issue, a broad representation of all the stakeholders gathered as part of the API’s spring and fall Refining Equipment Standards Meetings. Addressing the standards gap and noting the many similarities in owner- and equipment manufacturer–developed specifications, the API task force undertook the task of identifying useful industry practices and/or negotiating to agreement best fits for standards application. API’s Refractory Installation Quality Control Guidelines—Inspection and Testing Monolithic Linings and Material was first issued in 1996 as a recommended practice. After a number of subsequent revisions, it was approved as API Standard 936 in 2006, with a certification program that began in 2004.
In addition to maintaining API 936 and overseeing the certification program, the task force reorganized in 2014 under the API Committee on Refinery Equipment (CRE) and became the Refractory Project Group. As a project group, work expanded to writing ceramic fiber and brick quality control standards and unit-specific applications, such as sulfur recovery units and hydrogen furnaces, as well as drafting technical reports (such as this report). In response to this broadening recognition of the need to advance this technology for HPI applications, the API CRE reclassified the group as a full subcommittee in 2016, and it now works under the title of Subcommittee on Refractory Materials (SCRM).
iii
Contents
Page
Scope 1
Referenced Documents 1
Terms and Definitions 1
Hydrocarbon Processing Applications 4
Fluid Catalytic Cracking Units 4
CO Furnaces 22
Applications Outside of Hydrocarbon Processing 26
Iron and Steel 26
Nonferrous Metal Production 38
The Ceramic Industry 39
Glass Production 42
Mineral Processing 42
Power Generation and Incineration 44
Aerospace Technology Applications 45
Nuclear Applications 46
Miscellaneous Applications 46
References 48
Figures
Example of a Fluid Catalytic Cracking Unit Showing Key Components 5
Cyclone Dipleg Trickle Valve with Hexmetal Retained Refractory Lining
to Prevent Erosion Damage to Steel 6
Example of FCCU Showing Types of Refractory Lining Materials Used
by Component Location 8
Standard Lance Grid Hexmetal Used in Cyclones Applications 9
A Typical Two Stage Cycles in Regenerator Showing Primary (Green) and
Secondary (Yellow) Stages for Each of 9 Pairs in the Vessel 10
Typical Cold Wall Slide Valve 11
Cold Wall Refractory Lined Expansion Joint with Bellows Protected
and With Erosion-resistant Refractory and Hexmetal on Steel Sleeves 11
A Typical Third Stage Separator 12
The Revised ASTM C704 Test Replaces the Old Style Aluminum Body
Sand Blasting Nozzle Using a Taped Open Trigger with a Precisely Dimensioned
Stainless Steel Nozzle Machined Specifically for Testing 13
A Typical Sulfur Recovery Unit 15
A Vendor System of Interlocking Shapes 17
Hexhead Ferrules Installed on a Thermal Reactor Tubesheet 18
Example of a Continuous, Infrared Temperature-measuring Device for Fired Heaters 19
A Typical Oil Refinery Fired Heater 20
A Typical Delayed Coker 23
A Typical Gas Fired Rotary Kiln Used for Calcining or Complete Combustion
of Coke From Delayed Coker of Fluid Coker Operation 24
Typical Blast Furnace Showing Some of the Possible Application Areas for Refractory Concretes 28
Typical Basic Open Hearth Furnace for Producing Steel from
Blast Furnace Iron and Scrap Steel 30
A Typical Electric Arc Melting Furnace 31
v
Contents
Page
Cross Section of a Direct Arc Furnace 35
Channel Induction Furnace 36
Coreless Induction Furnace 37
A Typical Reverberatory Aluminum Melting Furnace 41
A Nose Ring of a Rotary Cement Kiln 43
Tables
Characteristics of Different Types of Gasification Processes 25
Typical Operating Temperatures for Iron and Steel Plant Furnaces 33
vi
Application of Refractory Lining Materials
This technical report focuses specifically on the information on the applications of refractories contained in two American Concrete Institute (ACI) refractories documents:
ACI 547.R-79, State-of-the-Art Report: Refractory Concrete;
ACI 547.1R-89, State-of-the-Art Report: Refractory Plastics and Ramming Mixes.
The original content of these ACI reports was focused primarily on steel- and glass-making applications, which represent the largest refractory markets. API, in tailoring the revision of this content to the hydrocarbon processing industry (HPI), has greatly expanded the text pertaining to the specialized oil refining and petrochemical processing applications. At the same time, API has retained and updated the information covering applications outside of the HPI (see Section 5) because of the similarities and applicability that this information has for refractory professionals in these other industries.
API Standard 560, Fired Heaters for General Refinery Service
API Standard 936, Refractory Installation Quality Control—Inspection and Testing Monolithic Refractory Linings and Materials
API Technical Report 978, Monolithic Refractories: Manufacture, Properties, and Selection 1
API Technical Report 980, Monolithic Refractories: Installation and Dryout 1
ACI SP-34, Handbook on Concrete Reinforcement and Detailing
ASTM C71, Standard Terminology Relating to Refractories
ASTM C638, Standard Descriptive Nomenclature of Constituents of Aggregates for Radiation-Shielding Concrete
ASTM C704, Standard Test Method for Abrasion Resistance of Refractory Materials at Room Temperature
NOTE See ASTM C71 and API 936 for additional information on definitions.
The ability to withstand the effects of eroding particles for an extended period without significant loss of material or other damage.
NOTE 1 Often referred to as “erosion in fluid solids units,” such as FCC units, which is technically incorrect, but commonly understood in refining jargon.
NOTE 2 For refractory materials, abrasion resistance is measured in the form of eroded volume loss in accordance with ASTM C704/C704M.
EXAMPLE A vapor stream containing solid particles.