Careers Restoring Over $2.5M in Annual Feed Value Through Precision Cleaning
Located within a major olefins production facility, a critical steam cracker furnace had been experiencing significant fouling in its convection section. Dust and dirt accumulation on finned tubes impaired heat transfer efficiency, causing a decline in feed throughput and overall furnace performance.
As part of a broader operational goal to enhance plant reliability and recover lost capacity, the client sought a solution to restore the performance of this key asset without major disruption to ongoing operations.
Evaluating Alternatives to Optimize Throughput
The plant had previously used jetting methods on other furnaces with varying results and was evaluating whether to continue with internal cleaning programs or invest in more specialized cleaning solutions.
IGS was selected based on:
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Proven performance of the TubeTech ROV system
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Ability to access tight tube sections with precision
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Track record for safe and rapid deployment
The decision favored IGS due to speed, cleanliness, and minimal risk to furnace internals and fiber insulation.
Quantifiable Impact and Proven Results
The most compelling outcome of this project was the recovery of significant feed throughput. Internal engineering estimates confirmed:
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3,000 PPH feed rate recovery yields approximately $1.51M per year
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5,000 PPH feed rate recovery yields up to $2.52M per year
These values reflect partial-year operational time (50% utilization across 7.5 furnaces), making them conservative estimates. The TubeTech solution restored lost feed capacity and delivered immediate financial impact through increased production and avoided purchase of supplemental feedstock.
Beyond improving heat transfer and restoring efficiency, we helped this plant reclaim capacity they didn’t even know they had lost. This project proves that asset vitality is about seeing the full picture: performance, profitability, and peace of mind.
– James Turner, Business Development Manager, IGS
Solution Delivery
IGS deployed its TubeTech cleaning solution to access the convection section of the furnace through two specific access points. The project was completed over three shifts with minimal disruption to plant operations.
Cleaning was performed on both upper and lower tube banks, restoring cleanliness across the tube surface area. Two tubes were intentionally left untouched due to proximity to fragile fiber lining.
Despite a one-day delay caused by an unrelated air leak during pressure testing, the work was completed safely and efficiently. All confined space and safety protocols were followed, with zero reported incidents.
Future Recommendations and Next Steps
Following the success of this cleaning, the plant initiated discussions for similar applications across other furnace units at the site. The rapid turnaround and measurable results reinforced the value of proactive ROV-based cleaning programs and positioned IGS as a long-term reliability partner.
Recovered over $2.5M per year in feed value through precision convection cleaning.
That’s Asset Vitality.
WATCH: TubeTech Robotic Convection Section Cleaning System
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