Slep Furnace Overhaul for Shell-based Activated Carbon Plant
Activated Carbon ProductionProject Background
Two Slep activation furnaces had been operating for 5 years with severe refractory damage and gas leakage in the activation zone, causing reduced thermal efficiency and unstable product iodine values.
Diagnosis
| Issue | Finding |
|---|---|
| Outer wall temperature | 180℃ (normal <120℃) |
| Gas leakage rate | 8% (normal <2%) |
| Iodine value fluctuation | 850-1050 mg/g (normal range <50) |
| Thermal efficiency | Reduced ~25% |
| Minimum brick thickness | 80mm (original 230mm) |
Solution
Complete relining of activation zone with self-manufactured saddle-shaped refractory bricks, plus flue structure optimization and seal system repair.
Work scope:
- Demolition of old bricks (~12m³)
- New saddle-shaped brick installation (230mm thick, ~800 pieces)
- Replacement of activation channel partition bricks
- Steel structure and seal repair
- Furnace re-drying per heating curve (7 days)
Results
| Metric | Before | After | Improvement |
|---|---|---|---|
| Wall temperature | 180℃ | 95℃ | -47% |
| Leakage rate | 8% | 1.5% | -81% |
| Iodine fluctuation | ±100 mg/g | ±25 mg/g | -75% |
| Daily output | 3.2 t/d | 3.7 t/d | +15.6% |
| Energy consumption | 4.5 t steam/t | 3.6 t steam/t | -20% |