Careers Delayed Coker Unit (DCU) Heater Applications
Restoring Heater Performance & Extending Run Lengths in Coking Operations
Delayed Coker Units (DCU) are among the most challenging refinery assets to operate efficiently. High coking rates, severe fouling, and thermal stresses create persistent threats to run length, energy efficiency, and reliability.
IGS provides proven solutions engineered to address the unique challenges of DCU fired heaters, convection sections, and transfer lines – helping refiners increase throughput and reduce unplanned outages.
Common DCU Challenges
-
Severe fouling and coke deposition reducing heater efficiency and throughput
-
High radiant and convection tube metal temperatures leading to reliability issues
-
Accelerated tube wall loss and corrosion in transfer lines and heater sections
-
Shortened run lengths driving frequent decoking and costly downtime
IGS Solutions for DCU Heaters
We combine proprietary technologies and decades of refinery experience to restore and protect DCU performance.
TubeTech™ Robotic Convection Section Cleaning
Efficiently cleaning convection section tubes to bare metal and restoring process efficiency to like-new condition.
- Robotic fired heater convection sections cleaning
- Removes tenacious fouling, and debris inaccessible by traditional methods
- Proven to recover lost efficiency and improve heat transfer
- No-man-entry, intrinsically safe XXI-century technology
TubeTech™ Twisted Tube Fouling
Tube Tech™ has developed an advanced cleaning technology, specifically engineered for Twisted Tube™ heat exchangers. Traditional methods cannot effectively reach the complex geometry, but Tube Tech™’s solution restores performance without damage.
-
Safely removes fouling from intricate Twisted Tube™ designs
-
Restores heat transfer efficiency and throughput
-
Reduces downtime compared to conventional cleaning methods
Cetek®
Cetek® engineered coatings control heat flux inside DCU heaters, reducing coke formation, optimizing tube metal temperatures, and extending run lengths. By applying engineered combinations of high- and low-emissivity coatings on tubes and refractories, heat absorption is optimized to minimize oxidation and improve reliability.
- Lower tube metal temperatures, balance radiant heat flux, and extend heater run lengths
- Reduce emissions
- Extend tube life
Cetek® delivers DCU heater optimisation worldwide.
HVTS™
-
On-site, large-scale alloy cladding for DCU transfer lines and heater components
-
Provides corrosion-resistant protection without replacing original equipment
-
Extends asset life and reduces risk of failures
Other Maintenance Services
Online Hot-tek Maintenance
Hot Refractory Repair (HRR)
- Avoid forced shutdown by repairing hot spots online
- 40 years global experience: hundreds of heaters fixed with zero incidents
- Case study: Overcoming Severe Refractory Failure
Hot Inspection Service (HIS)
- Allows thorough assessment of damage and repair condition
- Referenced in this case study
Hot Convection Cleaning
- Removes convection section tube fouling & scale during furnace operation.
- Increased heat transfer efficiency, steam production & process pre-heat.
Welding Services
Extend asset life and safeguard critical infrastructure with IGS’s industry-proven automated welding services
Benefits of IGS DCU Solutions
-
Increase heater efficiency and throughput
-
Extend run lengths by minimizing fouling and coke build-up
-
Lower tube metal temperatures to reduce overheating risk
-
Protect transfer lines and heater tubes against corrosion and erosion
-
Reduce unplanned shutdowns and enhance DCU reliability
Proven Global Partner for DCU Performance
With more than 40 years of experience across global refineries, IGS has become the trusted partner for extending the life and performance of Delayed Coker Units. Our combination of Cetek®, Tube Tech™, and HVTS™ provides an unmatched, turnkey solution to address fouling, reliability, and corrosion challenges in DCU operations.
Restore DCU performance and protect your assets.
Free consultation with an IGS Subject Matter Expert