Common Causes of Lining Failure in Chemical Reactors and Warnings about Material Selection Mistakes: Avoid Shortening Equipment Lifespan Due to Misselection

Common Causes of Lining Failure in Chemical Reactors and Warnings about Material Selection Mistakes

In the chemical industry, the lining of high - temperature furnaces plays a crucial role in ensuring the normal operation of equipment, extending its service life, and improving energy efficiency. This article delves into the selection principles of lining materials for chemical reactors, with a focus on the key performance indicators of refractory insulation bricks below 1350°C and their impact on the operating life and energy efficiency of high - temperature furnaces in the chemical industry.

Basic Performance Parameters of Refractory Insulation Bricks

To understand the performance of refractory insulation bricks, we first need to establish evaluation criteria. The main performance parameters include thermal conductivity, thermal shock resistance, mechanical strength, and linear change rate.

• Thermal Conductivity: It reflects the ability of a material to conduct heat. A lower thermal conductivity means better insulation performance. For example, the thermal conductivity of high - strength refractory clay insulation bricks at 1000°C is about 0.2 - 0.3 W/(m·K), while that of some high - alumina bricks may be around 0.3 - 0.5 W/(m·K).
• Thermal Shock Resistance: In the chemical furnace environment with frequent start - stop and large temperature differences, materials need to have good thermal shock resistance to avoid cracking and damage. High - strength refractory clay insulation bricks can withstand about 10 - 15 thermal shock cycles from room temperature to 1000°C, which is better than some common materials.
• Mechanical Strength: Sufficient mechanical strength ensures that the lining can withstand the impact and pressure during the operation of the furnace. The compressive strength of high - strength refractory clay insulation bricks can reach 15 - 20 MPa.
• Linear Change Rate: A low linear change rate indicates that the material has good dimensional stability during heating and cooling processes. The linear change rate of high - strength refractory clay insulation bricks is generally controlled within ±0.5% at 1300°C for 2 hours.

Performance Comparison of Different Materials

By comparing the performance of various materials such as high - alumina, clay, and hollow spheres through tables and diagrams, we can clearly see the comprehensive advantages of high - strength refractory clay insulation bricks.

Applicability in Typical Chemical Reactor Conditions

In typical chemical reactor conditions, especially in scenarios with frequent start - stop and large temperature differences, high - strength refractory clay insulation bricks show excellent adaptability. For example, in a chemical plant's reactor that needs to be started and stopped frequently, the original lining material was a common clay brick, which cracked and peeled off after only 3 - 5 months of use. After replacing it with high - strength refractory clay insulation bricks, the lining has been in normal operation for more than 1 year, which greatly improves the reliability of the equipment and reduces maintenance costs.

Common Material Selection Mistakes and Avoidance Suggestions

In the process of material selection, there are often some common mistakes, which can lead to equipment failure and reduced service life. The following are some common mistakes and corresponding avoidance suggestions:

• Ignoring Thermal Shock Resistance: Some engineers only focus on the mechanical strength and thermal conductivity of materials, ignoring the importance of thermal shock resistance. When selecting materials, it is necessary to consider the actual operating conditions of the furnace and choose materials with good thermal shock resistance.
• Blindly Pursuing High - Grade Materials: High - grade materials do not necessarily mean the best choice. Sometimes, high - strength refractory clay insulation bricks can meet the requirements at a lower cost. Therefore, it is necessary to select materials according to the actual needs of the project.
• Neglecting Material Compatibility: Different materials may have different expansion coefficients and chemical properties. When using multiple materials in combination, it is necessary to ensure their compatibility to avoid damage caused by expansion and contraction differences.

In conclusion, high - strength refractory clay insulation bricks have significant advantages in the lining of chemical reactors, especially in terms of energy - saving and reliability improvement. If you want to learn more about the technical parameters of these materials and obtain a professional material selection manual, please click here.