Careers Restoring Convection Section Efficiency at a US Methanol Plant (2006–2024)
Primary Reformer Efficiency Challenges at a Methanol Plant
A methanol plant in the US faced fouling issues in its primary reformer convection section. The shock tubes had moderate hydrocarbon buildup mixed with rust and plating, while the finned tubes suffered from extreme buildup of thick hydrocarbons between all finned areas. This fouling was impacting heat transfer efficiency and overall unit performance.
Solution Overview
IGS implemented a specialized convection section cleaning solution to restore the performance of the methanol unit. The cleaning approach involved:
- Utilizing twin lance technology for precision cleaning
- Ensuring 360-degree surface area coverage of each tube
- Methodically cleaning both shock tubes and finned tubes
- Addressing both front and back sides of all exchanger units
Project Execution
Timeline:
- Project Start: June 10, 2024
- Project Completion: June 14, 2024
Methodology: The team used TubeTech’s engineered cleaning lances starting from predetermined access points, systematically working through all tube lengths and depths to ensure complete cleaning coverage. This methodical approach was necessary given the different types of tubes and the varying degrees of fouling.
Project Outcome
The project was completed successfully and verified with a borescope inspection post-cleaning. Open communication throughout the project allowed effective navigation of challenges while delivering quality results.
Benefits:
- Restored convection section to original design efficiency
- Significantly reduced fuel firing requirements
- Decreased emissions output
- Extended tube life, postponing costly replacement
- Resolved critical operational issues including NOX emissions, ammonia oxidation problems, and scaling concerns within four months of service
- Increased steam production by approximately 20 tons
- Reduced critical temperatures by 5–10%
- Generated estimated annual savings of $250,000 to $500,000
Key Achievements from This Project Include:
The project was completed successfully and verified with a borescope inspection post-cleaning. Open communication throughout the project allowed effective navigation of challenges while delivering quality results.
- Complete removal of hydrocarbon deposits, rust, and plating from shock tubes
- Thorough cleaning of extreme buildup between finned areas, restoring proper heat exchange
- On-time project completion within the scheduled 5-day window
- Zero safety incidents throughout the entire operation
- Minimized downtime for the plant’s critical process equipment
The partnership between Tube Tech and the methanol plant has been strengthened through this successful collaboration, establishing a foundation for continued maintenance support to ensure the facility maintains optimal performance levels. This case study exemplifies Tube Tech’s commitment to delivering specialized industrial cleaning solutions that directly impact operational efficiency and equipment longevity for facilities in the refining sector.
Conclusion
The successful completion of this convection section cleaning project demonstrates the effectiveness of TubeTech’s technology in addressing complex fouling challenges. By restoring optimal heat transfer efficiency, the plant was able to resume normal operations with improved performance metrics and energy efficiency.
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