Hello everyone, we rely on Z-Bloks as the main refractory for our reformer's radiant section roof. Currently, we are experiencing issues with hot spots in this area stemming from the dislodgement of the Z-Bloks. We are utilizing SS-309 anchors to secure the Z-Bloks in place. Can anyone provide insight into the root cause of this problem? Has anyone encountered a similar issue in the past? Thank you, Afaq Aslam.
What is the age of the refractory lining? When was it installed? Is this a recent issue? Is the reformer top-fired? Have thermal imaging techniques been utilized to detect hotspots? What are the peak temperatures at the hotspots and the operating temperature of the reformer? How severe is the deterioration of the refractory blocks? What type of refractory material is being used - alumina or fire-insulating bricks?
Hot spots are a common occurrence in fireboxes, especially in older heaters like our ABB Lummus SRT 1 and 3 cracking heaters utilizing Z-block modules. Despite being over 20 years old, the ceramic modules are still in good condition. After noticing several hot spots, we enlisted an inspection company to perform an IR survey, and the results were illuminating. The skin heaters remain structurally sound, allowing us to continue converting ethane to ethylene at maximum capacity. As long as production and safety are not compromised, hot spots do not pose a major threat to heater performance. To address any gaps, we recommend filling them with ceramic blankets to maintain optimal operation.
Hi Afaq, this issue might stem from a combination of thermal cycling and mechanical stresses which could be causing dislodgement of the Z-Bloks. Even minor design misalignments may exacerbate these stress factors over time. While SS-309 anchors generally do a decent job, they could start yielding under long-term high heat flux and/or mechanical loads that exceed their endurance limit. It might help to reassess the installation methodology and design, the overall operating conditions, and the quality and dimensions of the Z-Bloks and the anchors. Has regular preventive maintenance been adhered to? That's another crucial element that comes into play here. Looking forward to hearing an update on this!
Hi Afaq Aslam, I've encountered a similar issue previously. The root cause of the problem may be the thermal expansion of the Z-Bloks, which can cause them to dislodge over time. Since you are using SS-309 anchors, I'd also check the tensile strength of these anchors at operating temperatures. If it's not up to par, it could be contributing to the Z-Bloks shifting. Another point to consider could be the installation procedure of the Z-Bloks and anchors - if not done correctly, it could lead to issues down the line. Hope this helps!
Hi Afaq, it sounds like a frustrating situation. I’ve encountered similar issues before, and it could be related to the thermal expansion mismatches between the Z-Bloks and the anchors, especially if the temperatures are fluctuating significantly. You might want to check if the SS-309 anchors are suitable for the specific thermal cycling in your application; sometimes, using anchors made from a different material or adjusting the anchoring technique can help reduce dislodgement. Additionally, ensuring that the installation was done with proper alignment and spacing can make a big difference. Good luck, and I hope you find a solution soon!
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Answer: 1. What could be causing the dislodgement of Z-Bloks in the reformer's radiant section roof? - The dislodgement of Z-Bloks in the reformer's radiant section roof could be caused by factors such as thermal cycling, mechanical stress, improper installation techniques, or low-quality refractory material.
Answer: - SS-309 anchors are commonly used to secure Z-Bloks in place due to their high-temperature resistance and strength. However, if not installed correctly or if subjected to extreme conditions, they may not prevent dislodgement effectively.
Answer: - Potential solutions could include reinforcing the anchoring system, improving the installation process of Z-Bloks, using higher quality refractory material, or implementing maintenance procedures to monitor and address dislodged Z-Bloks promptly.
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