Oil & Gas

Customer Success Story

Commonly used across a variety of industries, carbon reactors serve to convert industrial emissions – most commonly carbon dioxide – into other chemical compositions that can be used as alternative fuels or other chemical forms.

This evolving and growing technology plays an important role as industries strive to find an economical route to make their production processes greener. Certain types of carbon reactors require high temperature processing to complete the desired reaction of industrial by-products. As a result, a refractory insulating system is necessary that can withstand the temperature of the application and be very reliable while in service.

Location

Midwest United States

Operating Temperature

2,000°F (1,090°C)

Application

Carbon Reactor

NUTEC Products

MaxBlock® 2600 Modules, MaxWool® 2600 Blankets

Anchoring Method

Prewelded Stud-Tite Studs

Installation Technique

Unidirectional Construction with Single Batten Strips

1/24/2023
2 Minutes
Carbon_Reactor

The Challenge

NUTEC was contacted by an industry-leading OEM that manufactures carbon reactors. Traditionally, refractory systems for these units consisted of hard refractories such as castables or bricks with the heat source commonly being an electric element system. Typical issues with this type of design are:

Thermal Efficiency

The dense refractory system materials have a very high heat storage capacity. This means that considerable heat energy, and more importantly time, is necessary to bring the carbon reactor up to process temperature.

Operating Cost

Electrical heating is very expensive relative to using a natural gas-fired burner. Also, with a hard refractory system, the additional time necessary to reach the required reaction temperature is a sunk cost that is not offset by producing a usable product form. Conversion to a gas burner system also provides more uniform heating for the application.

System Weight

Carbon Reactors are often mounted at elevation within the industrial facility. Therefore, the weight of the assembly must be carefully considered for structural support and safety requirements.

Fig. 1 NUTEC's Stud-Tite system was selected as the anchoring method

Solution & Product Selection

NUTEC’s Application Engineering Group thoroughly reviewed the application and customer requirements.

Given the need for improved thermal efficiency, reducedoperating costs and a reduction in overall assembly weight; a MaxBlock 2600 Module system was recommended. These modules are rated for intermittent service up to 2600°F (1425°C) and continuous use up to 2450°F (1345°C). Relative to hard refractories, these modules are completely immune to thermal shock and provide significantly reduced heat loss and heat storage. Also, the weight of the refractory package is reduced by up to 90%.

For security and assurances that the modules would remain attached to the external reactor stainless steel casing plate, NUTEC’s Stud-Tite attachment system was selected.

The Stud-Tite system incorporates a stainless steel anchoring stud that is prewelded to the casing plate. If necessary, the quality and strength of each weld stud may be inspected and/or tested.

The Stud-Tite modules were then installed on to the prewelded studs and secured into place with a stainless steel anchoring nut. The modules were installed in a unidirectional pattern and a strip of MaxBlock 2600 blanket 1" thick and 8pcf density was compressed between each row.

For this project, the reactor chamber was constructed in sections. At the OEM’s facility, the Stud-Tite studs were welded in place and the reactor panels were then shipped to the customer’s location. The Stud-Tite modules were then installed on site, and the panel sections hoisted into place for final reaction chamber assembly.

To meet these specific requirements, NUTEC’s Application Engineering Group provided detailed installation drawings and a customized bill of materials to match the recommended design. Considerations were made for field joints and the necessary assembly sequence for the reactor sections.

Fig. 2 For each section of the Reactor, NUTEC Application Engineering provided complete and detailed installation drawings

NUTEC fulfilled all customer and end user requirements for this project. The detailed application engineering provided and the utilization of Stud-Tite prewelded stud anchoring ensured that the fiber lining system would be installed to specification. Due to the properties of no thermal shock, reduced weight and low heat loss/heat storage, which are inherent to NUTEC’s fiber materials, the end user is realizing excellent results in terms of thermal efficiency and operating cost.

Results & Benefits

NUTEC fulfilled all customer and end user requirements for this project. The detailed application engineering provided and the utilization of Stud-Tite prewelded stud anchoring ensured that the fiber lining system would be installed to specification.

Due to the properties of no thermal shock, reduced weight and low heat loss/heat storage, which are inherent to NUTEC’s fiber materials, the end user is realizing excellent results in terms of thermal efficiency and operating cost.

The Takeaway

Not every application or customer requirement is the same. NUTEC’s Application Engineering Group fully understood the customer’s requirements and provided a thermal management solution to best meet their needs.

Apart from detailed application support, NUTEC is able to offer a full range of fiber-based products that can be used across a variety of industries and temperature ranges in order to provide the best and most economical solutions to meet customers’ requirements.

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