Refractory lining performance plays a critical role in the safe and efficient operation of Hydrocarbon Process Industries (HPI). Equipment such as fired heaters, reformers, sulphur recovery units (SRU), reactors, and thermal oxidisers operate under extreme temperatures and aggressive chemical environments. When refractory linings fail, the result is often unplanned shutdowns, safety risks, and costly repairs.
Understanding the root causes of refractory failure is the first step toward improving plant reliability.
One of the most common causes of lining damage is selecting refractory materials that are not suited to actual service conditions. Hydrocarbon units experience combinations of high temperature, thermal cycling, sulphur compounds, hydrogen attack, and mechanical stress.
Using generic refractory materials without a proper service-condition study often leads to:
Material selection must consider temperature profiles, process chemistry, heat flux, and mechanical loading to ensure long-term performance.
Even the best refractory materials can fail prematurely if installation quality is compromised. Common installation-related issues include:
These issues are frequently observed during shutdowns when schedules are tight and supervision is limited. API-936 certified inspection during installation significantly reduces these risks.
Hydrocarbon units are especially sensitive to improper heat-up procedures. Rapid temperature increases can create thermal gradients within the lining, leading to cracking and delamination.
Controlled dry-out and heat-up procedures, monitored by experienced refractory inspectors, are essential to prevent early-life failures.
Unexpected process excursions such as flame impingement, temperature spikes, or abnormal chemical exposure can severely damage refractory linings. Designing refractory systems with operational flexibility and conducting periodic inspections helps mitigate these risks.
Many refractory failures occur because early warning signs—such as hot spots, hairline cracks, or anchor corrosion—go unnoticed. Regular condition assessments and third-party inspections allow corrective action before failures escalate.
Refractory failures in hydrocarbon plants are rarely caused by a single factor. They result from a combination of material selection, installation quality, operational control, and inspection discipline. A structured refractory management approach—supported by certified expertise—significantly improves plant safety, availability, and lifecycle cost.
