High-performance Nano-bonded Castables for Petrochemical Applications

J. Medeiros1, E. Prestes2, J.L.B.C. Veiga Petrobras3, V.C. Pandolfelli4, D.T. Gomes5

1 CENPES/EB-AB-G-E/EEQ Rio de Janeiro – RJ/Brazil
2 Federal University of São Carlos, Materials Engineering Department, 13565-905 São Carlos – SP/Brazil
3 CENPES/EB-AB-G-E/EEQ Rio de Janeiro – RJ/Brazil
4 Federal University of São Carlos, Materials Engineering Department, 13565-905 São Carlos – SP/Brazil
5 CENPES/EB-AB-G-E/EEQ Rio de Janeiro – RJ/Brazil

Revision 05.03.2012, 13.06.2012

Volume 4, Issue 3, Pages 111 - 116


Nowadays, in the refractory market, castables specially designed for fluid catalytic cracking (FCC) units are not common. One aspect that induces this scenario is the difficulty to attain optimized properties in the temperature range compatible with the process conditions. The development of suitable refractory compositions can be achieved by adding nanoscaled particles, which increases the system reactivity, resulting in high mechanical strength values with the temperature increase. Additionally, the use of sintering additives helps the densification at lower temperatures. In this context, colloidal silica bonded castables containing tabular alumina, fused silica or mullite grog and specific sintering additives were designed for riser application. The erosion loss of the developed castables was significantly reduced. Compared with the commercial reference products currently used by the Brazilian petrochemical industry, the nano-bonded material performed better for the main usual properties. Based on this novel technology, a self-flow castable with suitable apparent density and thermal conductivity, high thermal shock resistance and reduced erosion loss was developed for riser application.


nano-bonded castables, colloidal silica, sintering additives


[1] Motoki, E.; Yoshimizu, Y.: Refractory lining technology for fluid catalytic cracking units. Taikabutsu Overseas 19 (1999) [3] 69–74


[2] Motoki, E.; Yoshimizu, Y.: Damage of petrochemical plant refractory linings. J. of the Japan Tech. Ass. of Refractories 21 (2001) [4] 293–298


[3] O´Driscoll, M.: Refractories in petroleum refining. Industrial Minerals, 403 (2001) 29–33


[4] Bugajski, M.; et al.: New multifunctional refractory concretes for fluid catalytic cracking units in refineries. Unitecr‘05 (2005) 921–925


[5] Ismael, M.R.; et al.: Colloidal silica as a nanostructured binder for refractory castables. Refractories Applications and News 11 (2006) [4] 16–20


[6] Ismael, M.R.; et al.: Thermo-mechanical prop-erties of colloidal silica-containing castable. Cerâmica 53 (2007) [327] 314–31


[7] Oliveira, I.R.; et al.: Dispersão e empacotamento de partículas – princípios e aplicações em processamento cerâmico (Dispersion and pack-ing of particles – basic principles and applications to ceramic processing). São Paulo, Brasil 2000


[8] Ismael, M.R.; Ramal jr., F.T.; Pandolfelli, V.C.: Silica sol as a binder agent for refractory castables. Cerâmica 52 (2006) [321] 82–87


[9] Pileggi, R.G.; et al.: Novel rheometer for refractory castables. Amer. Ceram. Soc. Bull. 79 (2000)  [1] 54–58


[10] Ismael, M.R.; Salomão, R.; Pandolfelli, V.C.: Optimization of silica sol application as a binder for refractory castables. Cerâmica 52 (2006) [321] 92–97


[11] Iler, R.K.: The chemistry of silica: solubility, polymerization, colloid and surface properties, and biochemistry. New York 1979, 312


[12] Lee, W.E.; et al.: Castable refractory concretes. Inter. Mat. Ver. 46 (2001) [3]  


Göller Verlag GmbH