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Petroleum refineries need refractory solutions that provide insulation and abrasion resistance for Fluid Catalytic Cracking Units to improve the efficiency and reliability of producing gasoline and diesel for the demanding transportation fuels industry. 

Fluid Catalytic Cracking Units Refractory Solutions

HarbisonWalker International addresses the increasing demand for transportation fuel with advanced refractory solutions that increase production efficiency, improve total performance, and expand unit reliability in the harsh conditions of an oil refinery.

Fluid catalytic cracking is an important step in producing gasoline in the refining process. The process converts thick, long-chain hydrocarbons distilled from crude oil into more profitable, shorter-chain hydrocarbons like gasoline. This is accomplished using catalyst particles. The catalyst and long-chain hydrocarbons are fed into the bottom of the riser line, fluidized, and blown upward at a high velocity, reacting as they rise. The now coke-coated catalyst is separated from the short-chain hydrocarbon gas products by two sets of cyclones in the reactor. The catalyst is fed into the regenerator section, fluidized by an air grid, and the coke is burned off the catalyst particles. The catalyst absorbs this heat, is separated by another two sets of cyclones, and is eventually fed back into the riser. The process repeats in the riser, using the absorbed heat to fuel the cracking reaction.

We provide several products to meet your fluidized catalytic cracking unit refractory lining needs, including our popular GREENLITE®-45-L and HPV® 110 families of products that provide great insulating value in addition to excellent abrasion resistance.

Fluid Catalytic Cracking Units Refractory Linings: Key Benefits

  • Exceptional thermal insulation
  • Consistent thermal reliability at high temperatures
  • Increased thermal shock resistance
  • High abrasion resistance
  • Resistance to acid corrosion
  • Extended service life of units
  • Increased production efficiency
  • Reduced energy consumption
  • Reduced maintenance costs and downtime


Did You Know?

HWI’s GREENLITE®-45-L family of light and strong insulating refractories is one of the most-widely used monolithics for refineries across North America.

Fluid Catalytic Cracking Units (FCCU)

Product SDS
CLIPPER® DP A super duty fireclay brick
CORAL® PLASTIC 28-82 ADTECH® An 82% alumina, phosphate bonded refractory plastic
EXCELERATE ABR PLUS A high alumina, phosphate bonded ramming mix with excellent abrasion resistance
GREENCAST®-94 F PLUS A 94% alumina, low silica castable
GREENCAST®-94 GR PLUS A 94% alumina, low silica gunning mix
GREENCAST®-94 PLUS A 94% alumina, low silica castable
GREENLITE®-45-L GR ON-LINE® A 2500°F rated lightweight gunning mix
GREENLITE®-45-L PLUS A 2500°F rated lightweight castable
GREENLITE®-45-L PUMP A 2500°F rated lightweight pumping mix
GREENTHERM 23 LI A 2300°F rated insulating firebrick
GREENTHERM 26 LI A 2600°F rated insulating firebrick
GREENTHERM 28 LI A 2800°F rated insulating firebrick
GREENTHERM 30 LI A 3000°F rated insulating firebrick
H-W CORUNDUM A high purity, 99% alumina brick English
HPV® 110 CASTABLE A 110lb/ft3, abrasion resistant castable
HPV® 110 GUN MIX A 110lb/ft3, abrasion resistant gunning castable
HT MASTIC 500-NF® Asphalt based water emulsion coating used behind refractory English
HT MASTIC 500® A solvent based asphaltic mastic coating used behind refractory English
INSWOOL® CSW HP MODULE A folded, pre-weld, 2300°F rated ceramic fiber module English
INSWOOL® CSW HTZ MODULE A folded, pre-weld, 2600°F rated ceramic fiber module English
INSWOOL® MOLDABLE 2300°F Ceramic Fiber Moldable Material - troweled or hand packed into place.
INSWOOL® PUMPABLE 2300°F Ceramic Fiber Pumpable Material - formulated for pumping with special equipment.
INSWOOL®-HP BLANKET A 2300°F rated, alumina silica ceramic fiber blanket
INSWOOL®-HTZ BLANKET A 2600°F rated, alumina silica zirconia ceramic fiber blanket
INSWOOL®-S BLANKET 8# A Low Biopersistent / Soluble Fiber blanket made from Silica-Calcia-Magnesia chemistry. English
KALA® A 50% alumina brick
KALA® HPC CHECKERS A 50% alumina brick
KAST-O-LITE 23 LI PLUS A 2300°F rated lightweight gunning mix
KAST-O-LITE® 20-45 G PLUS A 2000°F rated lightweight gunning mix
KAST-O-LITE® 23 LI PLUS A 2300°F rated lightweight gunning mix
KAST-O-LITE® 26 LI PLUS A 2600°F rated lightweight castable
KAST-O-LITE® 30 LI G PLUS A 3000°F rated lightweight gunning mix
KAST-O-LITE® 90-28 HP (E) 2800F Insulating Castable EU English
KAST-O-LITE® 97 L PLUS A 3300°F rated lightweight castable
KORUNDAL XD® A 90% alumina, mullite bonded brick with low porosity
KORUNDAL XD®/C High Alumina (90%), mullite bonded brick shape with low porosity English
LO-ABRADE® HPI GR PLUS An abrasion resistant gunning mix English
LO-ABRADE® HPI PLUS An abrasion resistant castable
TUFLINE® 90 DM A 90% alumina brick designed for thermal shock resistance
UFALA® A 60% alumina brick shape
UFALA® A 60% alumina brick shape
UFALA® MCR A 60% Alumina - Andalusite Brick Shape English
UFALA® MCR A 60% Alumina - Andalusite Brick Shape English
VERSAGUN® ABR PLUS A 60% alumina, low-cement gunning mix designed for abrasion resistance

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