This petrochemical facility stands out as Malaysia’s first and largest integrated producer of olefins and polyolefins, and ranks as the second-largest polyolefins producer in Southeast Asia. Its reputation for scale, innovation, and strategic importance makes it a cornerstone of the region’s industrial landscape.
While most of our work is collaborative, we occasionally take on solo projects that demonstrate our adaptability and technical depth. These rare instances are a testament to our ability to deliver high-quality results independently, and they form a valuable part of our project portfolio.
The project was both urgent and technically demanding, as immediate intervention was required to address the detachment of hex metal, an issue that was actively contributing to Metal Catalyzed Coking (MCC).
The scope of work involved a solo effort of RAW Project Manager. One of the heaviest metal catalytic cracking experienced so far was handled, showcasing that even though the base metal was very uneven, the welds were totally fine. The SILICON Project Manager’s experience with complex inlet designs enabled smooth transitions between round, rectangular, and sharp-edged shapes, despite the challenging geometry of the shared inlets.
This type of work was possible with concurrent efforts, where one shift could weld while the other shift could grind in the area. The experience of working alone in a quiet and peaceful environment was quite different, especially since no other work was taking place once the grinding was completed. Carrying out the setup alone required considerable physical effort, adding to the complexity of the task and highlighting the dedication involved in completing the work independently.
The SpeedSerie® Anchors, including SpeedHex® 6, SpeedHex® 3, SpeedHex® Mini, and SpeedTab® were chosen to tackle the MCC issue. The combinations of refractory anchors represent SILICON’s most advanced solutions for refractory linings in petrochemical environments.
Engineered for high-performance and rapid installation, these anchors are designed to withstand extreme abrasion, thermal cycling, and mechanical stress. Each model serves a specific purpose: SpeedHex® 3 offers a robust honeycomb fit and single-shot installation for high-abrasion zones; SpeedHex® Mini is ideal for tighter spaces and lighter applications; SpeedHex® 6 is designed to cover large surface areas with maximum efficiency, enabling faster installation without compromising durability; and SpeedTab® provides versatile corner and edge solutions where traditional anchors fail.
These anchors are fully compatible with Rapid Arc Welding (RAW) technology, ensuring seamless integration and superior weld quality. Their proven reliability has made them the go-to choice for major turnaround projects. Whether used individually or in combination, SpeedSerie® Anchors deliver unmatched performance, helping refineries reduce downtime and improve long-term lining durability.
The work environment was calm and culturally rich, with diverse traditions shaping a unique schedule and offering memorable meals. While there were moments of heightened attention, such as occasional flare-ups from nearby units, the overall atmosphere remained focused. The installation itself marked a clear improvement, especially considering that hex metal had failed within months. Once the main tasks were completed, grinders and refractory personnel took over to finalize the process.
