Careers Atmospheric Crude Distillation Troubleshooting and Optimisation
Maximise reliability, efficiency, and run length of your CDU heaters.
Atmospheric Crude Distillation Units (CDUs) are key in refinery operations, but the heaters are often the bottleneck. Fouling, uneven heat transfer, and corrosion can lead to higher stack temperatures, poor energy efficiency, and costly shutdowns.
IGS provides proven solutions to troubleshoot and optimise CDU heaters, ensuring peak performance and extended run lengths. Backed by decades of experience and field-proven technologies, we help refiners reduce fuel consumption, cut emissions, and protect assets.
Our Asset Integrity Services
High Velocity Thermal Spray (HVTS) Cladding
– Protect Against Corrosion & Extend Heater Life
CDU heaters operate in harsh conditions where corrosion and metal wastage can compromise safety and efficiency. High Velocity Thermal Spray (HVTS) Cladding provides a proven CRA barrier.
Advanced Alloy Cladding – dense, impermeable NiCrMo-based cladding applied at high velocity.
Superior Protection – Resistant to sulfidation, naphthenic acid attack, and salt-induced corrosion.
Rapid Application – No impact to the existing shell and no post-weld heat treatment required.
Extended run lengths, reduced risk of tube failure, and long-term protection in the most aggressive CDU environments.
Free whitepaper
Crude Distillation Unit Column Overhead Corrosion Protection
Our Energy Efficiency Services
TubeTech™ ROV Cleaning
– Reduce High Stack Temperature & Optimise Process Preheat
Deposits inside convection sections restrict heat transfer, forcing higher firing rates and increasing stack temperatures.
- In-situ, no-man entry furnace convection section cleaning with robotic technology, no need for tube replacement.
- Restores heat transfer efficiency and lowers fuel demand.
- Reduced stack temperature, improved process preheat, and immediate energy savings.
Cetek® High Emissivity Refractory Coatings
– Increase Radiant Section Efficiency
Refractory emissivity is key to the performance of your radiant section. Cetek’s high-emissivity ceramic coatings provide heaters with a measurable boost and improve refractory heat transfer.
- High emissivity coatings applied directly to refractory.
- More heat absorbed into the process, less wasted energy.
- Lower firing rates, increased throughput, and reduced CO₂ footprint.
Tube Shielding
– Avoid Fluid Separation & Protect Tube Integrity
Hot spots and metal loss can significantly shorten tube life. IGS shielding is applied to the 180° circumferential surface of the roof tubes and protects against failure in high-risk areas.
- Installed to prevent fluid separation and reduce localized overheating.
- Shields tubes from corrosive environments and erosion.
- Safer operations, fewer leaks, and extended tube life.
Hot-tek® Services
– Prevent Shutdowns with Online Solutions
Unplanned shutdowns can cost millions. Hot-tek provides live maintenance solutions to fix issues before they become failures and to keep production running.
- Hot Spot Repair / Hot Refractory Repair
- Hot Tube Descaling
- Hot Tube Stabilization
- Hot Convection Cleaning
- Hot Inspection Service
Continuous operation, reduced downtime, and maximum uptime.
IGS Energy Efficiency Solutions Benefits
| Heater Type | Fuel Saving / Increased Capacity | CO₂ Reduction | NOₓ Reduction |
|---|---|---|---|
| Ammonia SMR | 2–5% | 2–5% | 12–25% |
| Crude / Topping / DCU | 2–5% | 2–5% | 5–15% |
| CRU | 5–15% | 5–15% | 10–20% |
| Ethylene | 2–5% | 2–5% | 15–30% |
| Hydrogen SMR | 2–5% | 2–5% | 12–25% |
| Other | 2–5% | 2–5% | 5–15% |
| Vacuum | 2–5% | 2–5% | 5–15% |
Why Choose IGS?
Proven Expertise
Over 35 years of global heater optimisation and asset protection.
Trusted by Industry Leaders
Supporting refiners and petrochemical plants worldwide.
Comprehensive Solutions
Cleaning, cladding, coatings, shielding, and online repair. Our solutions are invented by us, installed by us, and proven by us. We own every step of the solution for maximum reliability and quality.
Safety & Quality First
Zero-incident safety philosophy and industry-leading standards
Ready to optimise your CDU heater performance?
Get in touch today to talk with one of our specialists about how IGS can help you maximise reliability, efficiency, and run length of your CDU heaters.
Free consultation with an IGS Subject Matter Expert
IGS is here to provide information, answer questions and create an effective solution for your needs.