Refractory services for (petro-)chemical plants

Refractory services for (petro-)chemical plants

Ensuring reliability, efficiency, and extended lifetime of high-temperature process units – from engineering to maintenance, all from a single partner.

We gain momentum when it gets tricky.

High-temperature process units in the petrochemical and syngas industry operate under extreme thermal, chemical, and mechanical stress. Refractory linings are crucial to protecting equipment, maintaining efficiency, and ensuring safe and stable operation. When these linings degrade, unplanned downtime, energy losses, and safety risks can quickly follow.

At thyssenkrupp Uhde Engineering Services, we provide a 360° refractory service that covers the entire lifecycle of your refractory-lined equipment. As an experienced EPC partner, we combine engineering know-how, high-quality materials, and efficient on-site execution to extend service life, optimize thermal performance, and reduce operational risks.

Technology & Services Overview

We offer a comprehensive portfolio of refractory services for primary reformers, secondary reformers, gasifiers, waste heat boilers, methanol converters and more.

Petrochemical & Syngas Plants – Refractory EPC Expertise

High-temperature petrochemical process units operate under extreme mechanical, thermal and chemical stress. In methanol, ammonia, hydrogen and syngas production, refractory linings are critical to ensure efficiency, protect process equipment, and guarantee plant safety.

Click on the icons below to explore what our Refractory EPC scope includes.


  1. Engineering & Design
  2. Material Supply
  3. Construction & Installation
  4. Repairs & Revamps
  5. Inspection & Maintenance

Engineering & Design

  • Thermal process analysis and heat transfer calculations

  • Selection of refractory materials tailored to process conditions

  • Design of anchoring, multiple layer linings combined with detailed expansion systems analysis to minimize stress and energy loss

  • FEM analysis of existing structures incl. improvements and failure RCA's

Material Supply

  • High-alumina bricks, silicon carbide, dense castables, insulating castables and ceramic fibers tailored to each process zone

  • Anti-chemical attack linings for radiant and reaction zones

  • Pre-cast shapes, bricks and burner blocks incl. workshop dry fit tests to accelerate installation and ensure a smooth construction phase

Construction & Installation

  • From consulting to full turnkey refractory lining installation for primary reformers, secondary reformers, waste heat boilers, methanol converters, CO2 removal units and gasifiers

  • Qualified on-site supervision and quality inspection

  • Precision assembly of burner throats, dome linings, transition areas and convection sections

Repairs & Revamps

  • Hot repair techniques to minimize downtime in critical production units

  • Re-lining or partial repair of reformer tubesheet areas, dome sections and waste heat boiler and full equipment linings

  • Replacement of damaged linings and arches under high stress TA conditions

  • Integration of upgraded refractory systems to increase plant efficiency and lifetime

Inspection & Maintenance

  • Regular hot- and cold-condition inspections using endoscopic and thermographic surveys

  • Remaining lining life assessments and predictive maintenance strategies

  • Recommendations for upgrade paths, including energy-efficient insulation concepts and advanced anti-spall coatings

Our refractory services span the entire lifecycle of your petrochemical and syngas process units – from new plant installation and component upgrades to inspection, repair and long-term maintenance. By combining advanced thermal and process engineering with decades of refractory expertise, we help ensure safe, reliable and energy-efficient operation under demanding high-temperature conditions. Whether you require targeted support for a specific unit or a fully integrated turnkey solution, we tailor our approach to your plant’s operating profile and performance objectives.

Partnering with thyssenkrupp Uhde Engineering Services means measurable benefits:

Extended service life of critical petrochemical process equipment

Minimized unplanned outages through predictive maintenance and hot repair options

Optimized thermal efficiency and reduced heat losses for lower operating costs

Full EPC capability – from design to commissioning – from a single partner

Our expertise - Your one-stop partner for refractory issues

Our expertise - Your one-stop partner for refractory issues

At thyssenkrupp Uhde Engineering Services, we bring decades of hands-on experience in refractory engineering, turnaround services, hot repairs, and field inspections to industrial plants worldwide. From the petrochemical to the hydrogen and gasification sectors – our agile team delivers proven solutions when precision, speed, and reliability matter most.

We’re not just contractors – we’re your technical partners for energy-efficient, long-lasting, and operationally proven refractory systems.

What sets thyssenkrupp Uhde Engineering Services apart?

  • Deep knowledge & operational experience – We’ve successfully tackled the most complex refractory challenges across global projects in ammonia, methanol, hydrogen and petrochemical plants.

  • Flexible & agile team – Our experts react quickly, adapt on-site and offer creative, practical solutions – especially under tight turnaround schedules.

  • Long-standing industry reputation – Trusted for decades, our name stands for quality, integrity, and technical excellence in the field.

We work closely with your operations and maintenance teams to ensure reliable, long-term performance of your refractory systems – from strategy to commissioning and beyond.

Applications

Our refractory solutions are applied across the petrochemical and chemical industries, supporting high-temperature units in:

Ammonia

Ammonia

Hydrogen

Hydrogen

Methanol

Methanol

Gasification (POX)

Gasification (POX)

Petroleum & refining plants

Petroleum & refining plants

and many more.

and many more.

Our company culture

At thyssenkrupp Uhde Engineering Services, we foster an open-minded, hands-on approach across all generations. We believe engineering excellence comes from technical curiosity, real-world experience, and teamwork. Whether in the office or on-site, we’re always ready to solve problems others shy away from.

We gain momentum when it gets tricky.

360° service – from design to lifetime extension

360° service – from design to lifetime extension

Our integrated refractory service portfolio supports maximum operational efficiency, resource conservation and reduced emissions across high-temperature units such as primary and secondary reformers, gasifiers, waste heat boilers and related equipment.

Our service offering

  • Repairs, inspections and maintenance of refractory linings and structural components

  • Optimization and performance upgrades to improve thermal efficiency and reduce energy losses

  • Proven lifetime extension strategies to enhance equipment durability and minimize downtime

With more than 150 years of high-temperature plant engineering, thyssenkrupp Uhde unites trusted expertise, continuous innovation and a global service network. The result: safe, efficient and sustainable operation throughout your plant’s lifecycle.

Contact us

Innovative chemical engineering starts with one conversation.

Get in direct contact with our technical experts!

Get in direct contact with our technical experts!

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Take a look at our FAQs!

FAQs

Yes – our team has delivered numerous successful refractory projects globally. References are available upon request.

Our engineers bring in-depth knowledge of all major reactor and reformer designs – with practical solutions backed by data and operational experience and operational experience.

We operate with short reaction times and hands-on decision-making. Our agility is your advantage.