A fluidized bed system having a containment vessel, a precast and predried monolithic refractory floor module positioned in the vessel, and a plurality of precast and predried monolithic refractory wall modules stacked within the vessel. The plurality of wall modules includes a first wall module is
A fluidized bed system having a containment vessel, a precast and predried monolithic refractory floor module positioned in the vessel, and a plurality of precast and predried monolithic refractory wall modules stacked within the vessel. The plurality of wall modules includes a first wall module is positioned on the floor module, wherein the floor module and the first wall module have interlocking surfaces, and wall modules adjacent to one another have interlocking surfaces. A method for assembling a fluidized bed reactor is also provided.
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1. A fluidized bed system comprising: (a) a containment vessel;(b) a precast and predried monolithic refractory floor module positioned in said vessel;(c) a plurality of precast and predried monolithic refractory wall modules stacked within said vessel, wherein said wall modules are ring-shaped and
1. A fluidized bed system comprising: (a) a containment vessel;(b) a precast and predried monolithic refractory floor module positioned in said vessel;(c) a plurality of precast and predried monolithic refractory wall modules stacked within said vessel, wherein said wall modules are ring-shaped and have inner and outer circumferences, and further wherein said plurality of wall modules includes a first wall module in the form of a unitary ring positioned on said floor module;(d) a plurality of precast and predried monolithic refractory insulating modules stacked within said vessel and positioned about the outer circumference of said wall modules;(e) a dry vibratable refractory material located between the outer circumference of said wall modules and said insulating modules; and(f) a dry vibratable refractory material located between the outer circumference of said insulating modules and said containment vessel; wherein the floor module and said first wall module have interlocking surfaces, and wall modules adjacent to one another have interlocking surfaces. 2. The fluidized bed system of claim 1, wherein at least one of said wall modules is configured to provide an input port for reactants or an output port for product. 3. The fluidized bed system of claim 1, wherein an input port for reactants is provided on at least one of said wall modules and an output port for product is provided on at least one of said wall modules. 4. The fluidized bed system of claim 1, wherein the modules are formed of a refractory material comprising low cement, ultra low cement or cement-free monolithic castable. 5. The fluidized bed system of claim 1, wherein said floor module includes a circular central raised portion having an outer circumference which is less than the inner circumference of the first wall module such that said central raised portion facilitates alignment of the first wall module on the floor module. 6. The fluidized bed system of claim 1, wherein at least one of said wall modules comprises two or more monolithic ring segments joined along interlocking sidewalls. 7. The fluidized bed system of claim 6, wherein at least one of said wall modules has a tapered inner circumference. 8. The fluidized bed system of claim 1, wherein a circumferential groove is provided on one endwall of two or more of said modules, and a mating circumferential ridge is provided on the opposite endwall of said two or more of said modules. 9. The fluidized bed system of claim 1, wherein each of said wall modules comprises either (a) a unitary ring, or (b) two to five monolithic ring segments joined to one another along interlocking sidewalls. 10. The fluidized bed system of claim 9, wherein said insulating modules are ring-shaped and insulating modules adjacent to one another have interlocking surfaces. 11. The fluidized bed system of claim 10, wherein the interface between adjacent insulating modules is vertically offset from the interface between adjacent wall modules. 12. The fluidized bed system of claim 9, wherein said plurality of insulating modules includes a first insulating module positioned on said floor module, and further wherein the floor module and said first insulating module have interlocking surfaces. 13. The fluidized bed system of claim 9, wherein said plurality of wall modules includes a lower section of wall modules in the form of unitary rings stacked upon said first wall module, and at least one additional wall module located above said lower section, said at least one additional wall module comprising two to five monolithic ring segments joined to one another along interlocking sidewalls. 14. The fluidized bed system of claim 13, wherein said at least one additional wall module is stacked atop both the upper-most wall module of said lower section and the upper-most one of said insulation modules. 15. A method for assembling a fluidized bed reactor comprising: (a) providing a containment vessel,(b) installing a precast and predried monolithic refractory floor module in said vessel;(c) stacking a plurality of ring-shaped, precast and predried monolithic refractory wall modules and insulation modules in said vessel, wherein said insulation modules are positioned about and spaced away from the outer circumference of said wall modules, and further wherein said plurality of wall modules includes a first wall module in the form of a unitary ring that is positioned on said floor module; and(d) installing dry vibratable refractory material in the space between the wall modules and the insulation modules; wherein the floor module and said first wall module have interlocking surfaces, wall modules adjacent to one another have interlocking surfaces, and insulation modules adjacent to one another have interlocking surfaces. 16. The method of claim 15, further comprising the step of installing a dry vibratable refractory material on which the floor module is installed. 17. The method of claim 15, further comprising the step of installing dry vibratable refractory material between the insulation modules and the interior of the containment vessel. 18. The method of claim 17, further comprising the step of installing a microporous, mica-covered insulating layer adjacent to the interior of the containment vessel, wherein dry vibratable refractory material is installed between the insulation modules and the microporous, mica covered insulating layer. 19. A fluidized bed reactor comprising: (a) a containment vessel;(b) a precast and predried monolithic refractory floor module positioned in the bottom of said vessel; and(c) a plurality of ring-shaped, precast and predried monolithic refractory wall modules stacked within said vessel, wherein said plurality of wall modules includes a first wall module positioned on said floor module;(d) a plurality of ring-shaped precast and predried monolithic insulating modules stacked within said vessel and positioned about the outer circumference of said plurality of wall modules such that an annular space is provided between the plurality of insulating modules and the plurality of wall modules; and(e) a dry vibratable refractory material that fills said annular space between the plurality of insulating modules and the plurality of wall modules; wherein the floor module and said first wall module have interlocking surfaces such that an interlocking joint is provided between the floor module and the first wall module, and wall modules adjacent to one another have interlocking surfaces such that an interlocking joint is provided between adjacent wall modules; and further wherein each of said wall and insulation modules comprises either (a) a unitary ring, or (b) two to five monolithic ring segments joined to one another along interlocking sidewalls, with said first wall module comprising a unitary ring.
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