Careers 13-Year CCR Enhancement Success in Australia
This case study examines a long-term success story where targeted thermal efficiency services — Hot Access Creation (HAC) and Hot Convection Cleaning (HCC) — have delivered consistent results over a 13-year period at a major Australian petrochemical facility. The case demonstrates the value of these services as part of a long-term live CCR fired heater maintenance strategy, ensuring sustained performance, efficiency, and reliability.
Problem
The facility operates a Continuous Catalytic Reforming (CCR) unit, which, like many similar units, experiences challenges with thermal efficiency and steam production. The root cause of these inefficiencies was convection section fouling caused by friable refractory and other debris buildup.
Solution
In 2011, Integrated Global Services (IGS) was engaged to resolve these issues using their Hot-tek™ live fired heater services. IGS performs Hot-tek services while the fired heater or furnace remains in normal operation, making it ideal when the next turnaround is still years away and inefficiencies are causing major throughput, fuel consumption, or emissions problems.
Implementation Timeline
1. Initial Intervention (2011)
- Full implementation of both Hot Access Creation (HAC) and Hot Convection Cleaning (HCC) services
- Established baseline access points for future maintenance
2. First Follow-up (2016)
- HCC service performed using the original HAC access points
- Demonstrated sustained effectiveness of the initial installation
3. Recent Service (2024)
- Latest HCC maintenance executed using the original 2011 access points
- Validated the long-term viability and durability of the implemented solution
Success Factors
1. Durability of Initial Installation
- 2011 HAC access ports have remained effective for over 13 years
- Enables efficient and repeatable cleaning operations
2. Consistent Performance
- Repeatable results across multiple cleaning cycles
- Predictable return on investment
3. Strategic Maintenance Planning
- Integration into regular maintenance schedule in between turnarounds
- Proactive approach to efficiency management
Sustained Performance Gains With Measurable Financial Return
By restoring heat transfer efficiency without disrupting operations, the Hot-tek™ solution delivered both operational and financial impact. Plants achieved consistent reliability improvements alongside predictable and repeatable returns.
- Sustained improvement in unit efficiency
- Consistent reduction in stack temperatures
- Measurable increase in steam production
- Predictable maintenance costs across cycles
- Payback period of less than 3 months for each intervention
- ROI maintained across multiple cleaning cycles
- Reliable performance enhancement with each application
Key Takeaways
- Regular furnace convection section maintenance yields consistent performance improvements
- Quick payback periods make HCC a financially attractive solution
- Carrying out HCC on a live fired heater prevents the need for a costly shutdown
- Long-term relationships built on proven results drive continued success
- Well-executed HAC access point installations can provide value for over a decade
This case study demonstrates how the strategic implementation of IGS Hot-tek™ services can deliver sustained value over an extended period.
Future Outlook
The facility has committed to continuing this maintenance strategy, recognizing the consistent benefits and reliable returns it provides. This approach has become an integral part of their long-term operational planning.
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