ctive owners. names mentioned herein may be trademarks or trade names of their respec APPC PDH/PP PROJECT 8 CATOFIN REACTORS - JUBAIL SAUDI ARABIA ENGINEERING, DESIGN AND INSTALLATION OF REFRACTORY LINING Other pro oduct and company All rights pertaining to the reproduction, transformation and use of this document in any form or manner remain the exclusive property of CHIMNEY AND REFRACTORIES INTERNATIONAL SRL
SAMSUNG ENGINEERING CO. LTD. KOREA Awarded in October 2005 to CHIMNEY AND REFRACTORIES INTERNATIONAL SRL ITALY Purchase Order for ENGINEERING AND DESIGN MATERIALS SUPPLY SPECIAL SUPERVISORY SERVICES SITE INSTALLATION DRY OUT ASSISTANCE relevant to REFRACTORY LINING OF 8 NOS. CATOFIN REACTORS APPC PDH/PP PROJECT JUBAIL KINGDOM OF SAUDI ARABIA
ENGINEERING AND DESIGN Based on Licensor (ABB Lummus - USA) conceptual basic design, CHIMNEY AND REFRACTORIES INTERNATIONAL SRL s engineering and technical department was fully involved for the issue of GENERAL LAYOUT DRAWING DETAILS CONSTRUCTION DRAWINGS (cross sectional views, expansion joints, anchoring system, lining thickness) BILL OF QUANTITY LOADING DATA HEAT TRANSFER CALCULATIONS INSTALLATION PROCEDURES DRY OUT DIAGRAM
MATERIALS SUPPLY Based on Licensor (ABB Lummus - USA) technical specifications and approved vendor list and on SAMSUNG Requisition for Refractory Materials, CHIMNEY AND REFRACTORIES INTERNATIONAL SRL s project management and purchasing department decided, under single and full responsibility, to use: Sirma THERMAL CERAMICS SIRMA SPA CERAMICA INDUSTRIAL AVELLANEDA (ITALY FRANCE USA) (ITALY) (ARGENTINA) All insulating materials Super duty fireclay bricks and suspended shapes Super duty fireclay Perforated and T-support tiles
Sirma MATERIALS SUPPLY Super Duty Fireclay Bricks and Suspended Shapes Suspended Area Shapes Gravity Area Bricks Technical Specifications Minimum Requirements Min 40.0 % 1.5 % max 1.5 % max Min 42.0 % 1.4 % 0.9 % 2.4 g/cm^3 ± 10% 20 % max 40 MPa min -0.3 to +0.3 % >33 2.29 g/cm^3 12 % max 15.2 MPa 62.1 MPa 0.4 % 33~34 34
Sirma MATERIALS SUPPLY Super Duty Fireclay Bricks and Suspended Shapes Quality Control Inspection carried on all batched before the shipment PROPERTY TEST METHOD BULK DENSITY ASTM C-20 APPARENT POROSITY ASTM C-20 CHEMICAL ANALISYS ASTM C-573 COLD CRUSHING STRENGTH ASTM C-133 PERMANENT LINEAR CHANGE ASTM C-113 PRISM SPALLING TEST. ASTM C-38 MODULUS OF RUPTURE @ ROOM TEMP. ASTM C-133 MODULUS OF RUPTURE @ HIGH TEMP. ASTM C-583
MATERIALS SUPPLY Super Duty Fireclay Perforated and T-Support Tiles Technical Specifications Minimum Requirements Perforated Bricks and Support (Tiles) Bulk Density 2.4 g/cm^3 ± 10% Apparent Porosity 20 % Max. Pyrometric Cone Equivalent (PCE) >33 Reheat PLC @ 1600-0.3 to +0.3 % Cold crushing strength 40 Mpa min. MOR @ Room Temp. (Standard ASTM sample shape without slots) 12 Mpa min. 40 MPa min. Spalling Test @ 950, 45 mts, water 5 minutes Chemical Analysis-Calcined Basis > 30 cycles Silica (SiO2) Remainder ( 56.7) Alumina (Al203) Min 40.0 % Iron Oxide (Fe2O3) Lime (CaO) 1.5 % max. 0.3 % max. MgO - TiO2 - Soda (Na2O) + Potash (K2O) 1.5 % max.
MATERIALS SUPPLY Super Duty Fireclay Perforated and T-Support Tiles Quality Control Inspection carried on all batched before the shipment PROPERTY TEST METHOD BULK DENSITY ASTM C-20 APPARENT POROSITY ASTM C-20 CHEMICAL ANALISYS ASTM C-573 COLD CRUSHING STRENGTH ASTM C-133 PERMANENT LINEAR CHANGE ASTM C-113 PYROMETRIC CONE EQUIVALENT ASTM C-24 MODULUS OF RUPTURE @ ROOM TEMP. ASTM C-133 MODULUS OF RUPTURE @ HIGH TEMP. ASTM C-583 ROCKING TEST SIMULATED REACTOR LOADING TEST ABB specification ABB specification
PDH-PP CATOFIN REACTOR GENERAL LAYOUT
SITE INSTALLATION INLET NOZZLES A-B-C Nozzles Installation of internal steel liner Liner Application by trowel of plastic insulation
SITE INSTALLATION INLET NOZZLES A-B-C Nozzles Centering of steel liners Nozzles Final casting of insulation castable Nozzles Centering of steel liners
SITE INSTALLATION REACTOR BOTTOM PART Reactor Arches skew back detail Reactor Back lining Insulation board application Reactor Brick lining detail Reactor Refractory bricks installation
SITE INSTALLATION REACTOR BOTTOM PART (HEADS ARCHES) Reactor Arch type B design Reactor Arch type B Reactor Arch type B installation detail
SITE INSTALLATION REACTOR BOTTOM PART (GRID SUPPORT ARCHES) Reactor Arches type A installation Reactor Arches leveling Reactor Arches type A wedge & arch bricks details Reactor Arch type A design
SITE INSTALLATION REACTOR HEADS SUSPENDED TILES Reactor Heads design Reactor heads suspended tiles installation Reactor heads suspended tiles Reactor heads suspended tiles anchors system (hook + T bar)
SITE INSTALLATION REACTOR UPPER PART - SUSPENDED TILES Reactor suspended tiles anchor system Reactor suspended tiles installation
SITE INSTALLATION CATALYST SUPPORT GRID Reactor Catalyst Grid Support T-Tiles Reactor Catalyst Grid Support T-Tiles detail
SITE INSTALLATION CATALYST SUPPORT GRID AND VAPOR INLET BAFFLE Reactor Catalyst Grid Perforated Tiles installation Reactor Catalyst Grid Perforated Tiles Reactor Catalyst Grid Vapor Inlet Baffle
DRY-OUT ASSISTANCE 24 hours 7 days assistance and presence of CRInt supervisors during the dry-out period in order to monitor and to guarantee the respect of suggested heating-up and cooling-down curve. Visual inspection after the dry-out in order to check the status of refractory bricks walls and arches for any spalling, erosion, defects and loose. Visual inspection after the dry-out in order to check the status and the movement of expansion joints in nozzles liners and in reactors. 700 600 500 DRY-OUT DIAGRAM 25 C/h hold 36h 621 C 25 C/h 100% visual inspection after the dry-out of all T Support Tiles and Perforated Tiles in order to check any crack and break. TEMPERATURE (C) 400 300 200 15 C/h hold 24h 25 C/h hold 24h 25 C/h 177 C hold 48h 316 C 150 C 100 120 C After dry-out, installation of woven silica fabric and thermocouples sleeves. 30 C 0 0 6 30 33 57 63 111 123 159 178 TIME (HOURS)