High-temperature process unit lining assessment
Lining condition review of a high-temperature process unit, linking operating history and wear mechanisms to a repair and monitoring plan.
Assessment objective
Condition review of the refractory lining of a high-temperature process unit, connecting operating history, observed wear mechanisms, and process constraints to a repair-ready lining plan.
Review methodology
Operating history was reviewed with the plant team before shutdown: recurring hot-spot locations, thermal cycling frequency, and process changes. During the outage, wear was mapped systematically — residual thickness readings, crack patterns, and zones of chemical attack — against a single layout to identify the dominant wear mechanism per zone (thermal cycling, mechanical abrasion, or process chemistry).
Recommendations
The work package defined, per zone:
- material family and installed thickness
- access requirements and lead time
- installation and quality-control method
- curing and dry-out requirements in the restart plan
A monitoring list was issued for the interval until the next outage, specifying the indicators to track between campaigns.
Outcome
The assessment links field observations to defined actions, providing a documented baseline for subsequent lining decisions.
Photographic documentation
Customer details are withheld. This record is published as an illustrative MSI project example.
Related references
- RUSAL aluminium furnace refractory reference — Kerui manufacturer reference for anode-baking furnace lining
- Steel industry refractory supply references — Kerui manufacturer reference for steel-plant lining
- Monolithic refractory: castables and ramming materials
- All projects and references