Research Projects

The present available castable refractory application in petrochemical industries at fluid catalytic cracking units facing so many demerits during in the various processing steps. The gasoline and LPG were produced in the petrochemical industry at FCC units the erosion and cracking are occur contacting by petroleum oil with fluidized very fine particles of catalyst . The different process parameters are strongly related to a nos of FCC maintenance halts. The aim of the present proposal to develop of alternative refractory castable(alumina-magnesium borate) with nano bonding (SiO2, Cr2O3, ZnO and TiO2) by using one of the cheaper route that is sol-gel route and investigate its physical, thermo-mechanical, erosion, wear and microstructural analysis of developed casteble for Indian petrochemical industry application at FCC units. The comparative analysis will be done between present CAC bonded castble with developed nano bonded casable .The present use castable not suitable for application in petrochemical industries at FCC units due to excessive wear, low thermo mechanical properties and erosion loss at different temp. range . An alternative development of nano bonded metal oxides into alumina magnesium borate castable enhanced the properties at low to high operation temperatures. This will be replacing the calcium aluminate cement (CAC) bonded castable currently used in petrochemical industries by nano bonded metal oxides (SiO2, Cr2O3, ZnO and TiO2) alumina magnesium borate castables. This nano bonded aqueous suspension that will be easily mixed to castables . due to high surface area the nano bonded material will be increase the system reactivity, enhance the mechanical properties of the newly developed castable .Another possibility after use of sintering additives(magnesium borate) increase density at low temperature range . The combination between nano bonded particles and sintering additives allows to development of better performance nano-bonded anti erosive castables for petrochemical applications. The high th. shock resistance other enhanced properties of newly developed castable will be make better choice and demand at the FCC units and will be reduced maintenance costs and increase lining life also. The erosion loss will be reduced the main importance of newly developed castable refractory at FCC units. Already some preliminary works has been done and it shows that the properties are increases compare to CAC bonded castable currently used in petrochemical industries.

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