CARBOWALL SYSTEM CASE STUDY AT PETROBRAS REFINING REPLAN IN 2010 AND RPBC IN 2023

This study presents the application and resulting performance data of an innovative insulation lining system, the Alkegen Carbowall Systemâ„¢. This system is an engineered solution utilizing vacuum formed ceramic fiber shapes installed in the convection zones of chemical and petrochemical furnaces. The solution is applicable to furnaces such as oil heater reformers and pyrolysis furnaces, whether new units or for repairs. The Alkegen Carbowall Systemâ„¢ can be installed at the end user location or at external sites.

Traditional project linings consist of refractory castable, Insulating Firebricks (IFB), or Refractory Ceramic Fiber Insulation anchored to the walls of the convection zone. The maintenance of these walls is extremely problematic. In many cases, it is necessary to remove the piping to allow free access to the lining. As well as potentially causing damage to the surrounding lining, this becomes a critical path in the downtime of the unit, costing excess money and time.

Designed and created to replace the conventional insulation lining of the sidewalls of the convection zones, the Alkegen Carbowall Systemâ„¢ consists of customized shapes made of high purity lightweight ceramic fiber and binders that are installed from the external side of the furnace. This eliminates the need to remove piping, dramatically reducing downtime, while improving energy savings.

Petrobras, one of the largest oil and gas producers in the world, operating primarily in exploration, production, refining, generation, and commercialization of energy in Brazil, have installed the Alkegen Carbowall Systemâ„¢ in a number of their facilities since 1998 without need for any maintenance. This study identifies specific results from the installations into the convection section of the Atmospheric Heater at the REPLAN facility in April 2010 as well as into the convection section of the Reformer Furnace at the RPBC facility in April of 2023.

The motivations for utilizing the Carbowall system for these Petrobras refinery projects will be explored, outlining the maintenance benefits of the lining system in addition to the construction options this system provided to Petrobras.