Optimizing Refinery Equipment Performance with Kennametal® FCC Wear Resistant Component Solutions

In the FCC process, catalyst withdrawal spools are responsible for continuously moving catalyst particles and gases through the system. The spools handle the flow of residual feedstocks and flue gases, which are critical for the cracking reaction. However, these spools are exposed to some of the most extreme conditions found in refineries, including: 

• High temperatures reaching up to 1400 °F. 
• High-velocity gas flow reaching up to 40 m/s.  
• Abrasion from catalyst particles. 

The combination of these factors leads to extensive internal erosion, which, over time, compromises the integrity of the spools. This erosion reduces the lifespan of the equipment, leading to costly repairs and unplanned downtime. 

Stellite is a cobalt-based alloy known for its ability to withstand high temperatures, corrosion, and erosion. When applied to refinery components, Stellite creates a protective barrier that extends the lifespan of the equipment. 

UltraFlex™ Stellite™ 720 is part of the Kennametal Conforma Clad™ portfolio and is specifically designed to meet the demanding conditions of refinery applications. This advanced alloy is ideal for protecting equipment from the combined effects of high temperatures and abrasive wear in the FCC process. 

UltraFlex Stellite 720 offers exceptional protection for refinery applications with its high hardness (55-60 HRC), superior erosion resistance, and corrosion resistance. It effectively shields catalyst withdrawal spools from wear caused by high-velocity gas flows and abrasive catalyst particles, extending their lifespan. Additionally, Stellite 720 resists corrosion from chlorine, sulfur, and other refinery chemicals, ensuring durability in harsh environments all while withstanding extreme temperatures. 

By extending equipment life, Stellite™ 720 reduces maintenance needs and downtime, leading to more efficient operations and higher production rates. This makes it a valuable investment for ensuring durability, reliability, and efficiency in challenging refinery conditions. 

UltraFlex Stellite 720 is applied internally to catalyst withdrawal spools using Kennametal Conforma Clad’s Slurry Cladding Method, a proprietary process developed by Kennametal that is designed to apply Stellite™ materials to complex geometries and non-line-of-sight areas. 

The process begins with slurry preparation, where powders and binders are mixed to create a slurry, which is then applied to the surface of the spool using flow coating methods. After the slurry is applied, the coating is fused to the substrate in a vacuum furnace, forming a metallurgical bond that ensures the coating remains intact even in demanding environments. This results in a fully dense, uniform, and metallurgically bonded coating that provides consistent protection across the entire surface. The coating typically ranges from 0.020” to 0.030” in thickness but can be adjusted to meet specific requirements. 

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