The cracking furnace is a key piece of equipment in ethylene production, operating at temperatures as high as one thousand two hundred sixty degrees Celsius. It must withstand frequent startups and shutdowns, exposure to acidic gases, and mechanical vibrations. To reduce energy consumption and extend equipment lifespan, the furnace lining material must possess excellent high-temperature resistance, thermal shock resistance, and low thermal conductivity.
CCEWOOL® Ceramic Fiber Blocks, featuring high-temperature stability, low thermal conductivity, and strong thermal shock resistance, are the ideal lining material for the walls and roof of cracking furnaces.
Furnace Lining Structure Design
(1) Furnace Wall Structure Design
The walls of cracking furnaces typically use a composite structure, including:
Bottom section (0-4m): 330mm lightweight brick lining to enhance impact resistance.
Upper section (above 4m): 305mm CCEWOOL® Ceramic Fiber Insulation Block lining, consisting of:
Working face layer (hot face layer): Zirconia-containing ceramic fiber blocks to enhance resistance to thermal corrosion.
Backing layer: High-alumina or high-purity ceramic fiber blankets to further reduce thermal conductivity and improve insulation efficiency.
(2) Furnace Roof Structure Design
Two layers of 30mm high-alumina (high-purity) ceramic fiber blankets.
255mm central-hole hanging ceramic insulation blocks, minimizing heat loss and enhancing thermal expansion resistance.
Installation Methods of CCEWOOL® Ceramic Fiber Insulation Block
The installation method of CCEWOOL® Ceramic Fiber Insulation Block directly affects the thermal insulation performance and service life of the furnace lining. In cracking furnace walls and roofs, the following methods are commonly used:
(1) Furnace Wall Installation Methods
The furnace walls adopt either angle iron or insert-type fiber modules, with the following features:
Angle iron fixation: Ceramic Fiber Insulation Block are anchored to the furnace shell with angle steel, enhancing stability and preventing loosening.
Insert-type fixation: Ceramic Fiber Insulation Block are inserted into pre-designed slots for self-locking fixation, ensuring a tight fit.
Installation sequence: Blocks are arranged sequentially along the folding direction to compensate for thermal shrinkage and prevent gaps from enlarging.
(2) Furnace Roof Installation Methods
The furnace roof adopts a "central-hole hanging fiber module" installation method:
Stainless steel hanging fixtures are welded to the furnace roof structure to support the fiber modules.
A tiled (interlocking) arrangement is used to reduce thermal bridging, enhance furnace lining sealing, and improve overall stability.
Performance Benefits of CCEWOOL® Ceramic Fiber Insulation Block
Reduced energy consumption: Lowers furnace wall temperature by one hundred fifty to two hundred degrees Celsius, cutting fuel consumption by eighteen to twenty-five percent, and significantly reducing operational costs.
Extended equipment lifespan: Two to three times longer service life compared to refractory bricks, withstanding dozens of rapid cooling and heating cycles while minimizing thermal shock damage.
Lower maintenance costs: Highly resistant to spalling, ensuring superior structural integrity and simplifying maintenance and replacement.
Lightweight design: With a density of one hundred twenty-eight to three hundred twenty kilograms per cubic meter, CCEWOOL® Ceramic Fiber Insulation Block reduce steel structure loads by seventy percent compared to traditional refractory materials, enhancing structural safety.
With high-temperature resistance, low thermal conductivity, and excellent thermal shock resistance, CCEWOOL® Ceramic Fiber Insulation Block have become the preferred lining material for cracking furnaces. Their secure installation methods (angle iron fixation, insert-type fixation, and central-hole hanging system) ensure long-term stable furnace operation. The use of CCEWOOL® Ceramic Fiber Insulation Block enhances energy efficiency, extends equipment lifespan, and lowers maintenance costs, providing a safe, efficient, and energy-saving solution for the petrochemical industry.
Post time: Mar-17-2025
