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FCC Workgroup #4 – Refractory Dry-Outs & Techniques

Home Forums Conferences 2013 CatCracking Texas FCC Workgroup #4 – Refractory Dry-Outs & Techniques

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    SME facilitators -Damon McCrory, Harbison-Walker Refractories Co & Barry Robinson, Middough

    • One of the most important steps in a refractory installation
    • Proper curing & dry-out are required for monolithics to achieve maximum properties for best reliability
    • Monolithics have multiple dehydration points to get rid of free and chemically combined water
    • High pressure builds during dry-out and increases with steam which can overcome material strength
    • Dry-outs must be done in a controlled process following prescribed ramp rates and hold points to further allow proper development of designed properties

    Best Practices

    • Assure proper air cure times and temperatures (60*F to 90*F)
    • Assure proper air exchange during Dry-out for circulation and venting of gasses and steam
    • Use weep holes when possible
    • The conservative approach is always the best approach


    • Discuss Dry-Out of Phos Bonded Plastic Burner Throats of Furnace.  It was done electrically without proper air exchange.


    • Select the appropriate material for the job.  Consider installation technique and orientation of the equipment
    • Ensure material is within shelf life
    • Store materials properly
      • Maintain temperatures between 60*F and 90*F
      • Keep it DRY
    • Make sure proper equipment is used and it is in proper working order
    • When forming, make sure forms are water tight and sturdy enough to support the load of the material being installed
    • Assure proper accommodations for ambient temperatures.  Remember that Monolithics have to go through a chemical reaction which is exothermic and that reaction is affected by ambient conditions.
    • Get refractory contractor involved in T/A planning early, up to 1 year in advance
    • Owner – Operators: make sure refractory installers have clean potable water sources for compressed air, welding machines, and plot space in unit for material storage, mixing equipment, gumming rigs, etc.
    • Having a refractory coordinator to interface with installer works best
    • Inspect linings as a team, and color code markups so refractory marks are distinguishable from mechanical.
    • Refractory installers prefer to be responsible for anchor installations as well as for material installations.

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