Hi All

We are using Z-Bloks as primary reformer radiant section roof refractory. We are currently facing hot spots problem in this zone due to the falling of hot spots. We are using anchors of SS-309 to hold Z-Bloks.

Could anyone please tell me that what really is the problem? Have anyone faced this problem before?

Regards
Afaq Aslam

How old is the refractory?

When was it constructed?

Is it a newly discovered problem?

Is it a top-fired reformer?

Have you used thermography to monitor the hotspots? What is the highest temperature of the hotspots and the operating temeperature of the reformer?

How extensive is the falling of the refractory blocks?

What refractory material is it? Alumina or fire insulating brick?

hot spot are typical occurence in a firebox. we got an ABB Lummus SRT 1 and 3 cracking heaters that uses the Z-block modules. Its over 20 years old but the ceramics modules are still OK. We got several hot spots and when we commission an inspection company to conduct an IR survey - man it glows. The skin heaters are still structurally sound and the we're still converting ethane to ethylene at record capacity.

Unless there is a signicant impact in production or safety - hot spots are not a big threat to the heater performance. Check for gaps and then fill it with ceramic blankets.