Careers Efficiency Recovered in Ethylene Furnace with Robotic Convection Cleaning
At a key olefins production facility in Europe, one of the site’s most critical assets, a large-scale ethylene furnace, was suffering from performance inefficiencies traced back to years of unaddressed convection section fouling. This was causing thermal inefficiencies, elevated stack temperatures, and growing pressure to boost output without increasing fuel usage or emissions.
With visibility of a successful cleaning campaign at their sister plant in the U.S., the European site reached out to IGS through an internal referral. Initial engagement was led by Business Development Manager, Guillaume Champion, who worked closely with the reliability and operations team to assess fouling severity and prioritize quick, safe deployment.
Their goals were to reduce stack temperature, improve heat recovery, and identify fuel savings, without compromising schedule or safety.
Evaluating Available Options
The site evaluated several options, including leaving the fouling in place and adjusting operational parameters, attempting conventional water jetting methods, or deploying a proven high-performance cleaning solution. Ultimately, the client selected IGS for:
- Demonstrated success at a similar plant within the same company
- Safe, non-invasive deployment method using Remote Operated Vehicles (ROVs)
- Ability to remove 90%+ fouling from all seven convection section banks with minimal access modifications
- Rapid mobilization and a reputation for delivering quantifiable results under tight timelines
The technical team was especially drawn to IGS’s ability to demonstrate clear ROI through data and modeling.
IGS Solution Delivery
IGS TubeTech™ deployed its remote-operated fouling removal system across the convection section, cleaning over 90% of the surface area across all accessible banks. The system was adapted to work around limited access points without compromising the schedule or quality.
The cleaning was completed on time and without incident. Post-job photos and inspection documentation verified complete fouling removal, even in areas with calcium and refractory dust buildup.
Partnership Evolution
The trust built through this project, combined with the demonstrated ROI and emissions reduction, has opened the door to further collaboration with the client, including extending the same solution to another unit.
“Our goal wasn’t just to clean tubes, it was to help our client unlock performance gains. By applying learnings from their US site and adapting to local constraints, we enabled them to achieve higher output, lower stack temps, and confidence in their equipment again.”
– Guillaume Champion, Business Development Manager, IGS
Quantifiable Impact and Proven Results
The results of the cleaning were confirmed by a post-job performance evaluation conducted under stable operating conditions (3.3% O₂). The improvements were significant and directly tied to measurable efficiency gains:
- 40.5°C reduction in stack temperature
- 5.41 GJ/hr fuel savings, equating to a 3.0% reduction in fuel usage
- 2.2 percentage point gain in overall fuel efficiency
- Annual savings of €564,800, with >€2.0M in projected benefits over 8 years (fuel price at 40 €/Gcal and CO2 price at 90 €/tonne)
- 1,680 tonnes of CO₂ reduction annually – a significant environmental benefit
This cleaning brought stack temperature closer to design specifications and restored optimal performance of the convection section. In short, the asset now runs hotter (in the right places) and cooler (where it counts), with less fuel and fewer emissions.
€564,800 saved annually. 1,680 tonnes of CO2 avoided. All in 10 days.
That’s Asset Vitality.
WATCH: Why Our Customers Choose TubeTech, an IGS Solution, to Clean Their Mission Critical Equipment
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