Live Heater Maintenance Saves Methanol Complex $30 Million

hot_refractory_repair
Problem

Hot spots on the outer casing of two furnaces (unit 3 and 5) due to refractory failure.

Solution

IGS (Integrated Global Services) applied a Hot-tek Hot Refractory Repair solution on live furnaces back-to-back with applications carried out without impacting production.

Outcome

Eliminating the need for shutdown and any loss of production has saved the complex $30 Million.

hot spot on furnace in methanol complex
Hot Spot Before: 688°C

 

hot spot furnace methanol complex repaired hot-tek
After Hot-tek Repair: 53°C

 

World Largest Methanol Complex

Located in the Kingdom of Saudi Arabia, the largest methanol producing complex in the world had hot spot issues in two separate furnaces.

Furnace Hot Spots

Localized refractory failure leads to hot spots. In this case some hot spots on the external shell reached temperatures of 915°C. These hot spots present a Health & Safety hazard, energy
wastage, poor performance and even complete fired heater shutdown.

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Solution | Hot Refractory Repair

HRR (Hot Refractory Repair) service Over 80 hot spots have been safely repaired on live heater units, 3 and 5, back-to-back, between September 1 and October 10 2022.

$30 Million in Savings

The only viable alternative to the Hot-tek solution would be to shut down the heaters and repair them offline.

Unit 5 produces $2.3 Million of methanol per day. Conventional repair would have taken 8 days to complete.

Unit 3 produces $1.2 Million of methanol per day. Conventional repair would have taken 10 days to complete.

Eliminating the need for shutdown and any loss of production has saved the complex $30 Million.

Hot-tek Services

North 3: Hot Spot Before 280°C
North 3: After Hot-tek Repair 70°C

Decades of experience, unparalleled customer support and commitment to excellence has solidifed Hot-Tek's position as a global leader in fired heater maintenance.

Over the last 10 years, over 60 refractories have been successfully repaired with no additional impact to production.

Contact an IGS subject matter expert today