Cost Effective Improved Refractory Materials for Gasification Systems

72067S03-I High temperature, slagging gasifiers have refractory liners that deteriorate rapidly and have a relatively short life, requiring considerable, costly maintenance. Depending on operating temperature, unit size, and feedstock, refractory liners typically last 6-18 months and replacement costs exceed $1 million, including materials, manpower, and lost revenue due to downtime. Additionally, these refractories contain chrome oxide, which causes health and environmental concerns due to the potential of carcinogenic hexavalent chrome formation during use. This project will develop an advanced, improved refractory material for use in a coal-fed gasifier. This material will be free of chrome oxide, cost less than 50% of currently used chrome oxide-bearing refractories, and provide an estimated life expectancy of at least three years in a coal-fed gasifier application. In Phase I, ceramic materials will be formulated with properties targeted to meet the strength and high temperature slag corrosion resistance requirements of a coal-fed gasifier. Specimens will be fabricated and tests will be conducted, including strength, porosity, density, and static cup brick slag tests. A large chemical company, which owns and operates two coal-fed gasifiers, will participate in the project. Commercial Applications and Other Benefits as described by awardee: There should be many commercial applications for economical advanced refractory materials that contain no chrome oxide and provide excellent high temperature corrosion resistance. These include refractory lining applications in solid feed gasifiers, in molten metal (e.g., stainless steel) furnaces that yield slags, and in chemical reactors that produce corrosive chemicals. The benefits of such a refractory material would include excellent corrosion resistance, lower cost, longer life, and environmental safety.